Electrical Manual 50K

NAPS TRAINING MANUAL ON ELECTRICAL SYSTEMS NAPS/STC/TM/50000-05
Chapter-1
Introduction
1.0 The major objective of an electrical power distribution system in a power plant is to
obtain the best possible reliability compatible with economic consideration. In a
Nuclear Power Plant, because of the implications of failure of certain section of the
system, the requirement of reliability is considerably greater.
Due to inherent feature of the reactor and its protective system, complete loss of all
power supplies within the station could result in extensive damage to the reactor and
hence the cost of the extra built in reliability can be fully justified from an economic
point of view.
A further factor which has influenced the distribution system for this station is the fact
that there is a very high ratio of capital cost which makes downtime due to failures of
equipment very costly and higher degree of reliability must be built into the system
than would normally be the case with the conventional generating station or
industrial plants.
The factors, which influence the electrical distribution system configuration and the
reason for the selection of the equipment and equipment ratings. As the feature of
the reactors follows very closely the feature of the reactors situated at Rawatbhata
(Kota) and Kalpakam (Madras), the basic philosophy of the electrical distribution
system used for this plant except that seismic consideration has been included in its
feature.
1.1 GENERAL DESCRIPTION
CLASS OF POWER
Each load within the station has been classified according to the degree of reliability
required for its supply. There are four classes of power within the station.
CLASS I POWER
The class I power system supplies all loads that require a 250 V.D.C. voltage, which
should be uninterruptible.
CLASS II POWER
The class II power system supplies all loads, which must be fed from an A. C.
source, which should be uninterruptible.
CLASS III POWER
The class III system covers all loads, which may be interrupted for a short period (1-
2 minutes) during an outage or disturbance on the system.
CLASS IV POWER
The class IV power station service system covers all other loads, which may be
interrupted during an outage or disturbance without endangering the plant.
1.2 ELECTRICAL OUTPUT SYSTEM
The electrical output system delivers the output of the generator transformer through
transmission lines to the 220 KV grid.
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Next Rev Due on Oct.- 2013 Page 1 of 403
1.3 CLASS -IV SUPPLY SYSTEM

Power for the class IV station service is normally available from two sources. These
are the unit transformer, which are directly connected to the generator output
terminals, and the start up transformer, which is connected to the 220 KV bus
system of the station.
Class IV supply is arranged in two voltages viz. 6.6 KV and 415 volts. Motors loads
above 200 KW are fed at 6.6 KV voltage as is the standard practice in this country
for 200 MW units. This choice is based on the economics of supplying large capacity
motors considering the cost of motors, cables and switchgears motors below 200
KW rating are fed at the medium voltage of 415 volts which is the standard medium
voltage for distribution in our country
The 6.6 KV class IV system consists of two main bus bars 5241-BU-D & E and 5241-
BU-F & G. These can be further split up into four bus sections BU-D, BU-E, BU-F
and SU-G split up into four bus sections BU-D, BU-E, BU-F and SU-G by means of
links provided. The main bus 5241-BU-D & E is fed from the unit transformer through
5241-CB-16 and main bus 5241-BU-F & G is fed from start up transformer through
5241-CB-33. There is a bus section breaker 5241-CB-17 connecting both the main
buses for effecting transfer of all 6.6 KV loads to any one of the transformers (UT or
SUT). There is also provision for availing start up power from the other unit (NAPP-2)
for any of the 6.6 KV buses, for which purpose tie breaker 5241-CB-1, IS-1 5241-CB-
34 are provided.
The 415 volts class IV system consists of four class IV buses, 5242-BU-K, 5242-BU-
L, 5242-BU-M, 5242-BU-K1. Each of these bus bars are fed from 6.6 KV class IV
supply through 2000 KVA aux, transformer. Bus K1 and bus K are fed from 6.6 KV
(UT side) BU-L and BU-M are fed from 6.6 KV (SUT side). There is also a provision
of standby 415 volts bus BU-J (fed from UT side via a standby 2000 KVA
transformer). This bus can be connected to any of the three class IV buses BU-K,
BU-L, BU-M and class III buses BU-P and BU-Q (which will figure in class III
description) in case of no availability of the transformer associated with these buses.
This facility is not available for BU-K1 (C.W.P.H. supply bus) in view of its
remoteness from the turbine bldg. , where all the auxiliary power supplies are
located. Motors rated for 90 KW and above are fed directly from these class IV
buses and lower capacity motors are fed from MCCs, which in turn are fed from
these buses.
1.4 CLASS III SUPPLY SYSTEM: -

The class III supply system consists of two main buses 5231-BU-P and 5231_BU-Q.
Bus BU-P is fed from 6.6 KV switchgear ( UT side) through a 2000 KVA transformer
and BU-Q is fed from 6.6KV switchgear (UT side) through another 2000 KVA
transformer. Emergency diesel generators, one each, are connected to these class
III buses to restore supply in 30 to 60 sec. on loss of class IV station supply.
Provision is also available for the substitution of any one of the class III transformers
by the class IV reserve transformer connected to the CL-IV BU-J. Smaller capacity
loads are fed from class III MCCs which in turn are fed from class III buses BU-P and
BU-Q. Class III loads of C.W.P.H. system, which is located far away from turbine
Rev. No. : 02, Oct. 2008
bldg., are grouped into two section BU-P1 and BU-Q1 and these in turn are fed from
BU-P and BU-Q from turbine bldg There are a tie between two main buses BU-P and
BU-Q. This tie is effected via two breakers in series to take care of the eventually of
failure class III supply to affected Bus.
1.5 CLASS II SUPPLY SYSTEM

The class II power supply system consists of two main buses 5231-BU-S and 5231-
BU-T. Each of these is fed from motor generator set of 325 KVA capacity. The DC
motor of these motor generator sets are fed from separate 250 volts DC buses 5232-
BU-U1 and 5232-BU-V1 sets which in turn gets supply from class III system
through ACVRs. Buses 5232-BU-U-2 and 5232-BU-V2 feed DC supply to MG set
motors when class III power is lost. The batteries can feed class II loads for about 30
minutes mean while class III power supply must be restore.
1.6 CLASS I SUPPLY SYSTEM
The class I power supply system consists of two main buses 5232-BU-U and 5232-
BU-V each is fed from 500 KW ACVR, which is fed from class III buses BU-P, and
BU-Q respectively. Each bus has a 2200 AH battery bank connected to it. The
normal supply is from class III system through ACVRs and the battery bank. Battery
bank has 2250 AH, discharge capacity for 30 minutes with the end of discharge
voltage of 204 volts.
The bus BU-U and BU-V are further sectionalized into three sections i.e. BU-U1, BU-
U2 and BU-U3 (BU-VI, BU-V2 and BU-V3) with tiebreaker in between. The ACVR
and MG set are connected to section BU-U1 (BU-V1), the battery, standby charger
(RC-3, RC-6) are connected to section BU-U2 (BU-V2), and the DC motor loads on
section BU-U3 (BU-V3). With this arrangement following facilities are available.
(A) Bus section BU-U1 and BU-U1 (BU-V1 and BU-V3) can be isolated from
section BU-U2 (BU-V2) when the battery bank has to be boost charged by
standby charger.
(B) The DC motor loads can be fed from any of the buses BU-U3 / BU-V3.
1.7 CLASS II CONTROL SUPPLY SYSTEM

Separate 415 volts AC, 50 Hz, supply has been provided for class II supply to
control systems. The supply consists of three buses 5233-BU-A, 5233-BU-B, and
5233-BU-C. These are fed from individual inverters of 60 KVA capacities. There are
four inverters , three working in and one standby. These inverters are fed from class
I station 250 volts DC power and control buses.
1.8 CLASS I CONTROL SUPPLY SYSTEM
Separate 250 volts DC supply has been envisaged for controls. The supply system
consists of two buses 5232-BU-W and 5232-BU-X. These buses are normally fed
from RC-4 (RC-5) which gets supply from CL-III MCC’s. Standby charger (RC-3),
RC-6) are also provided for feeding BU-W(X) in case of failure for RC-4(RC-5) and
also for boost charging of batteries.
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1.9 MOTOR CONTROL CENTERS SYSTEM

Motors below 90 KW capacity are fed from the MCC of the associated class of the
systems (Class IV, III or II ).The following motor control centers are provided
1.9.1 CLASS IV SYSTEMS
MCC A and MCC Service bldg. auxiliaries
H
MCC B, D and J Turbine bldg. Auxiliaries
MCC C and E Reactor bldg. auxiliaries
MCC F Water treatment plant
MCC G1 (G2) Cooling water pump house auxiliaries
MCC R & S Raw water pump house
MCC 1,2,3,4 & 5 Upgrade plant
MCC 1,2,3 & 4 Waste Management plant
1.9.2 CLASS III SYSTEMS
MCC K1, K2 & L1 Turbine bldg. and reactor bldg. auxiliaries
MCC L2 Class III safety related system
1.9.3 CLASS II SYSTEMS

MCC M and N Turbine and reactor bldg, auxiliaries
MCC Q Class II safety related system
1.10 SELECTION OF VOLTAGE LEVEL
The selection of the voltage levels for the station distribution system was primary
influenced by the requirement to use voltages, which conformed to Indian Standards.
This decision was made to enable maximum utilization of Indian manufacture
equipment.
1.11 VOLTAGE REGULATION ON CLASS IV 6.6 KVBUSES & 415 BUSES
The transient voltage dips are calculated for the following conditions
a) Starting of primary coolant pump.
b) Fast transfer of UT buses to SUT buses.
c) On starting 150 KW pump on class III bus.
CONDITION VOLTAGE DIP ON
6.6.KV BUS 415V BUS
1. Starting of PHT pump 6.5% 7.47% at -1.5% tap
6.0% at -3.0% tap
2. Starting of 150 KW motor 7.23% at -1.5% tap
on class III Bus. 5.50% at-3.0% tap
3. Fast transfer 18.6% 19.6% at-1.5% tap
18.1% at-3.0% tap
1.12 PROTECTIVE RELAYING

The protective relaying system provided on the main generator GT, UT, SUT,Aux.
Transformer, motors are similar to the relay protection on a large conventional power
plant.
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Chapter - 2
GENERATOR AND STATIC EXCITATION SYSTEM

(41000)
3.1 GENERATOR
3.1.1 GENERAL DESCRIPTION
The generator is two-pole type with cylindrical rotor using direct water-cooling of
stator winding including phase connecting bus bar, terminal bushing and direct
hydrogen cooling of rotor winding. Using gap pick up method. The losses in other
parts of generator such as stator iron losses, Friction & Wind age losses are
removed by hydrogen circulating in casing.
The generator stator frame is of pressure-resistant and gas tight construction with 4
horizontal cooling in the frame itself forming part of ventilation and close cooling
circuit.
The generator consists of the following components shown.
STATOR
Stator body
Stator Core
Stator winding
Gas coolers
ROTOR
Rotor shaft
Rotor winding
Rotor Retaining Rings and other fittings.
Field connections
BEARING & BRUSH GEAR
SHAFT SEALS
For the operation of generator the following auxiliary system are required :
Seal oil supply system
Gas system
Stator water-cooling system
Excitation system.
The cooling of generator parts is described in cooling system.
3.1.2 COOLING ARRANGEMENT.
The generator is Hydrogen gas cooled at 3.5 Kg/cm², the temperature of which is
controlled by 4 Nos. longitudinally mounted gas coolers. In addition to this the
generator stator windings are cooled by de-mineralized water passing through the
hollow conductor.The reasons for selection of Hydrogen cooling along with stator
conductor cooling by DM water are enumerated below.
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The output of an electric generator is a function of the volume of the machine,

expressed in terms of length and diameter at the air gap, speed and the electrical
and magnetic loadings. When output per unit volume is more, the quantity of heat,
which must be dissipated per unit available area, is also more.
The dissipation of this heat can be achieved in two ways.
i) Increasing the heat dissipation area, which amounts to increasing the size of the
machine. Proportional increase in size of machine for increase in output is not
practicable due to
a) Problem of transport & lifting difficulties
b) Increase in the depth of copper is limited because of eddy current losses.
ii) The second way is by using a cooling medium, which has got better thermal
capacity, with lesser density for minimizing the wind age loss. Hydrogen is
preferred over air for cooling because of its superior cooling and corona discharge
inhibiting properties and much lower density minimizing wind age losses.
(Hydrogen has a density of 0.0898 Kg/m³ at 0°c and at 760mm Hg compared to
1.293 Kg/m³ for air under same condition, which shows H2 possesses only 7% of
the density of air, which is the predominating factor for minimizing the wind age
losses)
Table – 1
S No. Properties Air H2
1. Thermal conductivity 1 6.69
2. Sp. Gravity 1 0.0696
3. Sp. Heat at constant 1 14.35
pressure
4. Heat transfer coefficient 1 1.51
5. Heat capacity 1 0.0996
An examination of the properties shown in table-1 indicates the following advantages
of H2 for cooling over air.
i) Increased efficiency due to decrease in wind age loss about 7 times.
ii) Increased output per unit volume of material, which reduces the size of
machine.
iii) Reduced cost of maintenance and increased life of insulation. The deterioration
of insulation associated with corona discharge in atmosphere, containing oxygen
is eliminated which increases the insulation life.
iv) No fire risk. H2 will not explode in presence of air when H2 purity is above 74%.
v) Being less denser H2 can penetrate through small holes thus giving effective
cooling especially for rotor and stator iron packages.
vi) Increased current densities (15 - 25)%, which means, with increased H2 pressure
the conductor max. rating can be increased by some 10 to 30% according to
pressure.
However H2 system requires gastight explosion-proof shell and means for sealing
shaft glands. Also H2 will, when mixed with air, likely to explode “between” 4% to
74% H2 by volume.
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However, since the stator conductors are only indirectly cooled by hydrogen, the
thermal gradient across the high voltage winding insulation becomes the major factor
in the temperature rise and state of diminishing return with increased H2 pressure is
reached.
Direct water-cooling aims to reduce the copper winding cross section to remove the
heat losses. The reason for going to D.M water is because of its high thermal
capacity, low electrical conductivity, low viscosity, freedom from fire or toxic risk and
the simple requirements it places on external heat exchangers.
While the stator winding is direct water-cooled, the stator core and rotor are cooled
by Hydrogen at 3.5 Kg/ cm². The gap pick up method is adopted for the cooling of
rotor wherein the gas is sucked from the air gap between stator and rotor and routed
through holes and ducts provided in the rotor to effectively cool the rotor winding and
the core.
3.1.3 CONSTRUCTIONAL FEATURE:
3.1.3.1 STATOR FRAME
The stator body with core and stator winding form the heaviest component of the
entire Turbo Generator system. The active parts to be accommodated and the forces
and torques arising during operation call for a rigid and strong stator shell. Moreover,
it is featured to withstand high internal pressure, which may arise due to unlikely
event of explosion of hydrogen air mixture without any residual deformations.
Stator body is a totally enclosed gas tight fabricated structure made up of high
quality mild steel and austenitic steel. It is suitably ribbed to ensure high rigidity and
strength. The cooling circuit for the flow of gas and the required mechanical strength
and stiffness determines the arrangement location and shape of inner walls. The
water connection to gas coolers is done by external pipe brought at the level of
coolers at turbine end. For filling the generator with H2, a perforated manifold is
Provided at the top inside the stator body. The feed and vent terminate flanges for
Hydrogen, carbon dioxide and air provided at the bottom of stator body.
Manhole is provided at the bottom to inspect inside of the generator if required.
On completion of manufacture of stator body, it is subjected to a hydraulic pressure
of 8Kg/cm 2 for 30 minutes for ensuring that it will be capable of withstanding all
explosion pressures, which might arise on account of hydrogen air mixture
explosion. At the stage leakage in weld seam, if any, is detected rectified
immediately.
Complete stator body is then subjected to gas tightness test by filling in compressed
air.
3.1.3.2 CORE
A rotating magnetic flux threads with the core. In order to minimize magnetizing and
eddy current losses in this active portion of the stator the entire core is built up of thin
laminations. For reasons of manufacture, each lamination layer is made up of a
number of individual segments.
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The segments are stamped out with accurately finished die forms sheets of cold
rolled high quality silicon steel. Before insulating with varnish each segment is
carefully debarred. The stator body is turned on end while the core is stacked with
lamination segment in individual layers.
3.1.3.3 STATOR WINDING:
i) GENERAL
The stator has a three phase, double layer, short pitched and bar type of windings
having two parallel paths. Each slot accommodated two bars. The slot lowers bars
and the slot upper bars are displaced from each other by one winding pitch and
connected at their ends so as to from coil groups. The coil groups are connected
together by bus bars inside the stator frame in conformity with the connection
diagram.
ii) CONDUCTOR CONSTRUCTION:
Each bar consists of solid as well as hollow conductors with cooling water passing
through the latter. Alternate arrangements of hollow and solid conductors ensure an
optimum solution for increasing current and to reduce losses.
The conductor of small rectangular cross-section is provided with glass lapped
strand insulation. These are arranged side by side in two layers and insulated form
each other by a. separator. In the straight slot portion the strands are transposed by
360° to reduce the eddy losses.
The transposition provided for a mutual neutralization of voltages induced in the
individual strands due to the slot cross- field and end-winding field and ensures that
no circulating currents will arise.
The current flowing through the conductor is thus uniformly distributed over the entire
bar cross section so that the current dependent losses are reduced.
At the Rojabel Crossover points putting insulating strips of thermosetting tape
reinforces the insulation.
To ensure that strands are firmly bonded together and to give dimensional stability in
slot portion, a layer or glass tape is wrapped over the complete stack. After that the
stack is pressed and cured in steam-heated hydraulic press.
Bar insulation is done with epoxy mica thermosetting insulation. This insulation is
void free and possesses better mechanical properties.
3.1.3.4 DISTILLATE HEADER:

Ring type water headers, made of copper are provided separately for distillate inlet
and outlet in the stator on turbine side. The headers are supported on insulators and
isolated from stator body. The end connection of top and bottom bar is done by
putting copper ferrule over the two coil lugs and then soldered to have solid joint.
The water connection is done by connecting a copper tube to the two opening of lugs
at exciter ends. At turbine side, each individual bar is connected with inlet/outlet
headers by P.T.F.E hoses. The bar heads are insulated fiber molded covers.
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The vent pipe connections are provided at the top of both inlet and outlet header to
expel air during filling these headers with distillate. This vent pipe can be connected
to gas trap device if provided, to measure the extent of hydrogen leaking into water
circuit.
3.1.3.5 TERMINAL BUSHING:
Three phases and six neutral terminals are brought out from the stator frame through
bushings which are capable of withstanding high voltage and provided with gas tight
joints for this purpose, the bushings are bolted to the bottom plate of the terminal box
which is welded underneath the stator frame at exciter and is made of non magnetic
steel to avoid eddy current losses and thus any inadmissible temperature rise.
Provision is made for fixing the external bus ducts with terminal plate.
The conductor of the bushing is made of high conductivity copper tube on which
silver-plated terminal plates are brazed at both ends. A copper pipe is connected to
circulate water for cooling. The terminal bar conductor is housed in porcelain
insulator which can be mounted on the terminal box by means of ring.
The bushing is assembled and tested for flow, by means of flexible copper leads for
making the electrical connections conveniently.
3.1.3.6 ROTOR:
The rotor comprises of following components.
1. Rotor shaft
2. Rotor winding
3. Rotor wedges & other locating parts for winding
4. Retaining ring.
5. Fans.
6. Field lead connections.
The rotor shaft is a long forming measuring more than 9 meters in length and slightly
more than one meter in diameter. The high mechanical stresses resulting from the
centrifugal forces due to rotation and short circuit torques call for a high quality, heat-
treated steel. The main constituents of the steel are chromium, molybdenum, nickel
and vanadium. The shaft and body are forged integral to each other by drop forging
process. Comprehensive tests conducted ensures adherence to the specified
mechanical and magnetic properties as well as a homogenous forging.
Rotor conductors are made of hard drawn silver bearing copper. Apart from low
electrical resistance this grade exhibits high creep resistance so that coil deformation
due to thermal cycling due to start and stop operation are minimum.
The rectangular cross-section copper conductor has ventilating ducts on the two
sides thus providing channel for hydrogen flow. Two individual conductors placed
one over the other are bent to obtain half turns and are brazed in series to form coil
on the rotor. After insertion into the rotor slot all these coils are connected in series
by brazing.
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Layer of glass laminates insulates the individual rotor turns from each other. Glass-
prepped strips build this laminate on the turn of copper and baked under pressure
and temperatures to give monolithic inter turn insulation. The coils are insulated from
rotor body by U-shaped glass laminate. Molded slot troughs made from glass cloth
impregnated with epoxy varnish. At the bottom of slot D-shaped liners are put to
provide a plane-seating surface for conductors and to facilitate easy flows of gas
from one side to another. These liners are made from molding material having
sufficiently high compressive strength. To increase the creep age distance between
coils and rotor body very thick top packing are put at the top slot. Glass laminate
blocks called liners separate the overhang winding. These liners also confine the
movement of copper conductors due to thermal expansion and centrifugal forces.
The overhang windings are insulated from retaining ring by two layers of retaining
ring segments having L-shape and made of glass cloth impregnated by epoxy resin.
The rotor winding are cooled by means of direct cooling method of gap pickup
method. Hydrogen gas is sucked through the elliptical holes serving as scoop on the
rotor wedges and is directed to flow a long lateral vent ducts on rotor copper coil to
bottom of the coil. The gas picked up by the wedge scoop in the inlet zones due to
the pressure created under the scoop by rotation corresponding ducts on the other
side and flows outwards thrown into the gap in the out let zones. In this machine
these are zones, which result in multi jet flow of hydrogen exposing large amount of
rotor winding copper to the cooling medium thus creating very low ratio of maximum
to average copper temperature. In this cooling the temperature rise becomes
independent of length of rotor. The overhang portion of the winding is cooled by axial
two-flow system and sectionalized into small parallel paths to minimize the
temperature rise.
3.1.3.7 SHAFT SEAL:
The locations where the rotor shaft passes through the stator casing are provided
with radial seal rings. The seal ring is guided in the seal body, which is bolted on to
the end shield and insulted to prevent the flow of shaft currents. The seal ring is lined
with Babbitt on the shaft journal side. The gap between the seal ring and the shaft is
sealed with seal oil. The seal oil is applied to the sealing gap from the seal body via
radial holes and an annular groove in the seal ring.
To ensure effective sealing, the seal oil pressure in the annular gap is maintained at
a higher level then the gap pressure within the generator casing. The oil drained on
the hydrogen and airsides of the seal rings is returned to the seal oil system through
drains in the seal body and seal cover respectively. In the seal oil system,
the oil is regenerated by a vacuum treatment and then returned to the shaft seals.
On the airside, pressure oil also called ring relief oil is supplied laterally to the seal
ring via an annular groove. This ensures free movement of the seal ring in radial
direction
3.1.3.8 BRUSH GEAR:
The rotor winding is solidly connected to the slip rings by means of field lead bars,
current carrying bolts field lead core bar and flexible leads. The field current to the
rotor winding is provided through the Brush gear. The current carrying brush gear
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assembly is rigidly supported on an independent pedestal on the exciter side. There

are two brush gear stands; each is fabricated from silicon brass sheet. Brush holders
are fitted in rows of four brushes to the ribs of brush gear strand. These are
staggered in such a way that slip ring wear is uniform throughout the width. Provision
is also made for radial adjustment of brush holders so that required radial clearance
may be maintained after machining of slip. Brushes are spring loaded to 1Kg.
Brushes can be replaced during operation of machine. Brushes have a low co-
efficient of friction and are self-lubricating. The brushes are provided with double
flexible copper leads. A helical spring is mounted radially (as a part of brush holder)
over each brush, so that the required pressure can be applied normally on the brush.
Before fitting, the brushes are rubbed with medium or fine sand paper in the direction
of rotation. This is to obtain the most favorable condition for equal current
distribution. The brush pressure is adjusted by moving the spring fulcrum either up or
down on the brush holder. Excessive pressure tends to induce chattering or
bouncing of the brushes; insufficient pressure tends to cause sparking.
3.1.3.9 BEARING:
The rotor shaft is supported on pedestal type of bearings, which have spherical
seating to allow self-alignment. The turbine side bearing is accommodated in LP
casing of turbine. The bearing pedestal is a massive steel casing providing high
rigidity. Bearing pedestal houses bearing liner also made of cast steel whose
spherical surface is scarped for proper seating. The top cover is provided to facilitate
removal of top to approach the bearing liner. On the top of bearing pedestal vent
pipe emerges connecting bearing chamber to the atmosphere for venting out oil
vapour or traces of hydrogen. A current collector located just above the rotor shaft
and touching it is also mounted on the bearing body to give shaft voltage for rotor
earth fault protection. To prevent the flow of shaft currents slip ring and bearing and
connecting pipes are insulated from earth. The inner surfaces of bearing liners are
provided with dovetail grooves, which solidly clamp the Babbitt to the liner body. The
upper half liner is secured to the bearing body by means of a pin. The bearing liner is
split in two halves to facilitate removal without disturbing the rotor. The upper and
lower half liners are tied together by means of bolts. The lower half of the Babbitt is
equipped with two resistance temperature detectors for measurement of the
temperature of Babbitt and the terminals are brought out on the bearing body. For
visual checking of oil flow check windows are provided in the drain oil pipe, which is
connected to the common drainage of the turbine and generator. The oil is supplied
through inlet pipe and flow is adjusted by means of proper selection of diaphragm
orifice. A set of orifice is supplied with each machine.
The generator bearings are provided with a hydraulic shaft-lifting device to reduce
bearing friction during start up the barring gear operation of the turbo set for this
purpose. Oil at high pressure is forced between the bearing surface and the shaft
journal lifting the rotor shaft to allow the formation of a lubricating oil film.
3.1.3.10 GAS COOLER:
Four gas coolers mounted longitudinally inside the generator stator body cool hot
hydrogen. Gas coolers consist of cooling tubes made out of cupronickel with coiled
copper wire wound on them to increase the surface area of cooling. Cooling water
flows through the tubes while hydrogen flowing across the cooler comes into
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contacts with the external surface of the cooling tubes. The tubes are arranged in a
staggered form so as to expose maximum surface area to Hydrogen. The ends of
tubes are expanded into tube plates so as to provide watertight joints. Water
chamber are bolted to the tube plates on either end through rubber gaskets. The
outside flange of water chamber on slip ring side is elastically fixed to the stator body
with the help of molded rubber gasket to allow free expansion of cooler where as on
the turbine side it is fixed rigidly to the stator. Flexible rubber sheets are provided at
all four corners of the gas cooler, which are pressed against the enclosure in starter
frame flowing past the cooler. End covers water chambers are movable without
purging the hydrogen from the generator. This enables cleaning of the tubes of
coolers while the generator is running at partial load. In order too remove air from
gas coolers while filling them with water, vent pipes are provided on slip ring side.
For alignment of the coolers the stator while insertion, the bolts are provided at each
end. The rollers in gas cooler facilitate easy insertion of cooler into the stator frame.
3.1.3.11 ROTOR VENTILATION
Two axial fans mounted on the rotor on both sides circulate the gas in two
independent and symmetrical closed circuits with respect to centerline of the
generator. The scheme of stator core cooling is as shown. The cold gas divided itself
into paths.
FLOW PATH –1
The cold gas after gas cooler enters chamber at the back of core and enters radically
the ventilation ducts and flows to air gap after removing heat of the core. To remove
higher looses in the end part, some of the cold gas is diverted towards press ring
and press fingers.
FLOW PATH – 2
Gap Pick accomplishes the direct cooling of rotor winding. The barrel portion is
divided into a number of inlet and outlet zones. The slot wedges have special profile
with holes milled into them, which are in line with the lateral ducts cut in the copper
winding. The gas picked up by the wedge scopes in the inlet zones due to the
pressure created under the scoops by rotation, passes inwards, past the lateral
ducts on one side of the rotor coil stack and joins the corresponding duct on the
other side and flows outwards and thrown into the gap in the out let zones. Such a
multi jet flow of hydrogen exposes large amount of rotor winding cooper to the
cooling medium thus creating very effective cooling and enabling a very low ratio of
maximum to average copper temperature.
FLOW PATH – 3
The overhang portion of the winding is cooled by axial flow system and sectionalized
into small parallel paths to minimize the temperature rise. Cold gas enters the
overhang from under the retaining rings, thorough special chamber in the stator end
shields and ducts under the fan hub and gets released into the air gap at the rotor
barrel ends.
Rev. No. : 02, Oct. 2008

3.1.4 GASES REQUIRED FOR FILLING GENERATOR:

The amount of gas are required to fill the generator are specified herein. An example
related to 210MW generator is given here to illustrate the calculation for determining
the amounts of CO2, H2 and air required for filling in the machine.
1.0 Example
P = Operating Pressure = 3.5 bar
V = Generator volume = 56m 3 (cubic meter)
V1 = Amount of gas required to fill the generator.
V2 = Hydrogen cylinder volume = 5 m 3 at NTP
V3 = CO 2 cylinder volume = 12M 3 at NTP
Z = No. Of cylinder required
1.1 Filling
Amount of CO2 required for removing air from generator (2 generator volumes)
V1 = 2xV = 2x56 = 112 M 3
Z = V1 = 112 ~ 10 CO2 cylinder

V3 12
Amount of H 2 required for removing air from generator (2.5 generator volume)
V1 = 2.5 x V = 2.5 x 56 = 140M 3.
Z = V1 = 140 ~ 28 H2 cylinders
V3 5
Amount of H2 required filling the generator to operating pressure

(operating pressure in bars x generator volume)
V1 = pxv = 3.5 x 56 = 206 M3
Z= V1 = 206 = 42 cylinders of Hydrogen

V2 5
1.1.1 Purging
Amount of CO2 for removing H2 (2 generator volumes)
V = 2 x V1 = 2x56 = 112M 3
Z = V1 = 112 ~ 10 CO2 cylinder

V3 12
Amount of compressed air required for removing CO2 (3 generator volumes)
V1 = 3xV = 3 x 56 = 168 M 3 of air at NTP
Rev. No. : 02, Oct. 2008

The amount of gas calculated refers to the condition when generator rotor is at
standstill. With the unit on turning gear, more gas will be requited for replacing air,
CO2, and H2, respectively since there will a mixing of the gases due to the fanning
effect of the specified purities.
3.1.5 TECHNICAL DETAILS:
3.1.5.1 RATED ELECTRICAL PARAMETERS
At rated hydrogen pressure and cooling water temperature are…
i) Maximum continuous kVA rating. 264MVA

ii) Maximum continuous kW rating. 237.7MW
ii) Rated terminal voltage. 16.5KV
iv) Rated stator current. 9240 A.
v) Rated power factor. 0.9 Lag
vi) Excitation current at full load 2755 A
condition
vii) Excitation voltage at full load 326 V
condition.
viii) Rated speed. 3000 RPM
i) Rated frequency. 50 Hz
x) Efficiency at full load conditions. 98.6%
ii) Short circuit ratio. 0.58
xii) Negative sequence current I² t <= 7
capability.
iii) Direction of rotation when viewed Anti clock wise slip ring end.
from
xiv) Phase connection. Double star
xv) No. of terminals brought out. 9 (6 Neutral, 3 Phase)
xvi) Frequency variation. ± 5% (subject to turbine
limitation)
xvii) Voltage variation. ± 5%
iv) EFFICIENCIES
At Maximum capability & 0.9 p.f 98.6%

At 75% MCR & 0.9 p.f 98.6%
At 50% MCR & 0.9 p.f 98.44%
At 40% MCR & 0.9 p.f 98.25%
At 20 % MCR & 0.9 p.f 97.13%
3.1.5.2 MECHANICAL DATA
A) TORQUES, CRITICAL SPEEDS, ETC,
i) Torque under normal working conditions. 76.40 Tones.
ii) Ratio of short circuit torque to full load torque. 8.6
iii) Fly wheel moment of rotor. 20.5 T.M²
iii) 1 st critical speed of rotor. 1283 RPM
iv) 2 nd critical speed of rotor (calculated). 3600 RPM
Rev. No. : 02, Oct. 2008
B) GENERATOR VOLUME AND FILLING QUANTITIES:
i) Total gas volume of the generator. 56 M3

iii) CO2 for expelling hydrogen with unit at 120 M3
standstill.
iii) CO2 for expelling hydrogen with unit under 168 M3
rolling
iv) H2 filling quantity with unit at standstill. 300 M3
v) H2 filling quantity with unit under rolling. 336 M3
vi) Stator winding distillate-filling quantity. 0.35 M3
C) HYDROGEN IN STATOR CASING:
i) Nominal pressure of hydrogen. 3.5 Kg/cm 2 (G)

ii) Permissible variations. ± 0.2 Kg/cm2 (G)
iii) Maximum temperature of cold gas. 40°c
iv) Purity of hydrogen (minimum). 97%
v) Oxygen content. 1.2%
v) Relative humidity of hydrogen at normal > 30%
pressure
vi) Moisture content in generator casing (Max.). 15 gm/M3 of H2
D) DISTILLATE OR D.M. WATER TO STATOR WINDING:

i) Nominal gauge pressure at inlet to winding. 3.2 Kg/M3 (G) Sept. ’01
ii) Flow of distillate through stator winding. 30 M3 / hr
iii) Permissible variation. ± 3 M3/hr.
iv) Nominal temperature of distillate at inlet to - 45°c
winding.
3.1.5.3 HYDROGEN COOLER DATA:

a) PERFOMANCE PARAMETER
SL. Particulars Operating hydrogen pressure Units
No. 3.5 K/g/cm 2 (g) Feature
values
1. Gas flow per cooler. 7.5 M3/Sec.
2. Heat Load. 582.5 KW
3. Cold gas temperature (Max.). 44 °C
4. Hot gas temperature (Max.). 60 °C
5. Cooling water flow per 87.5 M3/hr.
cooler.
6. Max. Water inlet 37 °C
temperature.
7. Pressure drop through 17.5 MWC
cooler.
8. No. of coolers/generator 4
Rev. No. : 02, Oct. 2008

b) MATERIALS
i) Fins Copper
ii) Tubes Cupro Nickel
ii) Water boxes Carbon steel
iv) Tube sheets Carbon steel
c) PRESSURES
i) Feature pressure (water side of cooler) 6 Kg/cm 2 (g)
ii) Max. Permissible operating pressure (Waterside 3.0 Kg/cm 2 (g)
of cooler)
iii) No. of passes of water in gas cooler 2
3.1.5.4 SEAL OIL COOLER DATA:

A) PERFORMANCE PARAMETER
Sl. No. Particulars Feature Units

value.
1. Oil flow. 6.0 M 3 /hr.
2. Heat dissipating capacity. 70 kW
3. Oil inlet temperature 65 °C (40°cold oil)
4. Pressure drop of oil. 11 MWC
5. Cooling water flow. 72 M 3 /hr.
6. Max. Cooling water inlet temperature 37 °C
7. Max. Cooling water outlet temperature 37.84 °C
8. Pressure drop of cooling water. 1.8 MWC
9. No. of cooler per system 2 nos
B) MATERIALS
i) Tubes Cupro Nickel

ii) Tube sheets Carbon steel
ii) Water boxes. Carbon steel.
C) PRESSURES
i) Feature pressure, waterside. 12 K/g/cm 2 (g)

ii) Test pressure, waterside. 18 K/g/cm 2 (g)
iii) Feature pressure, waterside. 12 K/g/cm 2 (g)
iv) Test pressure, oil side 18 K/g/cm 2 (g)
3.1.5.5 STATION WATER COOLER DATA:

A) PERFORMANCE PARAMETER
S.No Particulars Feature Units
value.
1. Primary flow (including polishing unit by 32 M3/hr.
pass)
Rev. No. : 02, Oct. 2008
2. Heat Load 751 KW

3. Primary water inlet temperature 75 °C
4. Primary water out let temperature 44 °C
5. Pressure drop in primary water 7.5 MWC
6. Cooling water flow 150 M3/hr.
7. Max. Cooling water inlet temperature 37 °C
8. Max. Cooling water outlet temperature 41.3 °C
9. Pressure drop of cooling water. 12 MWC
10. No. of cooler per system 2
B) MATERIALS
i) Shell. Stainless steel

ii) Tubes. Cupro Nickel.
ii) Tube Sheets. Brass
iv) Water boxes. Carbon steel
C) PRESSURES
i) Feature pressure, (primary water) 8 Kg/cm 2

ii) Test pressure, (Primary) 12 Kg/cm 2
iii) Feature pressure and full. 5.0 Kg/cm 2 (g)
iv) Hydraulic test pressure (Cooling) Vacuum
3.2 GENERATOR EXCITATION SYSTEM:
3.2.1 GENERAL DESCRIPTION
In order to maintain system stability it is necessary to have fast Excitation System for
large Synchronous Machines which means the Field Current must be adjusted
extremely fast to changing operational conditions, besides maintaining the Field
Current and steady state stability limits. It is because of this reasons the “Static
Excitation System” is preferred to conventional Excitation Systems.
In this system, the required AC excitation power is taken from the Generator
Terminals itself, supplied to fully controlled Thyristor Bridge converter via excitation
transformer and from there it is delivered to the generator field through the field
breaker, thereby controlling the generator output voltage. This, so called shunt circuit
requires a separate circuit for excitation build-up initially, since the residual voltage of
the generator is too low. Station auxiliary field flashing supply provides excitation
build-up upto 30% of generator voltage. After 30% voltage both auxiliary and self-
excitation comes into picture. After 70% of generator voltage Self-excitation only
remains in picture.
The redundancy is of eminent importance for the operational reliability. It is achieved
by splitting the converter into independent converter group/blocks. Each of the
blocks comprises it’s own pulse output stage, cooling fan and monitoring system,
failures of one block results in an alarm; uninterrupted operation can be further
maintained. The second block failure leads to limitation on output according to the
control scheme.
Rev. No. : 02, Oct. 2008
Besides these reliability measures taken in the converter section corresponding

measures are also taken for the voltage regulator since two completely independent
channels are provided. The automatic channel, which is normally in operation,
comprises the voltage regulator. Here the actual value is processed and
subsequently compared with the reference value. The PID amplifiers in the AVR with
adjustable gain and time constant permits to stabilize the control circuit easily.
Output signal limiter (In N-1 only) controls control voltage output before it is fed to the
unit. Four limiters operate in parallel to the voltage regulator.
Rotor current limiter prevents thermal overloading of the rotor by lowering the output
value of the voltage regulator with a delay and thus the field current, in case the
permissible current is exceeded.
The effect of the load angle limiter (measuring transducer and under excitation
regulator X2 9302 wherever provided works for load angle) is reverse since it
increases the field voltage instantaneously for increased excitation and thus stops
the generator from falling out of step.
The stator current limiter is provided to increase or reduce the field voltage
depending on under-excited or over-excited operation and limits the stator current
when the change in the stator current exceeds the relevant permissible limits.
Supplementary signal acting on the regulator is supplied from the stabilizer

equipment. The latter serves to damper active power oscillations and comprises of a
measure and converter, Active power signal converter and summing and monitoring
module.
The gate control set with subsequent line driver and intermediate pulse-stage is
duplicate (for both the channels). In the automatic channel the voltage regulator
already mentioned controls it and in the manual channel it is directly controlled from
a digital reference value unit as open loop control. The manual channel should only
used on failure of the automatic channel or under emergency conditions.
The gate control set converts the analog input signal into a sequence of triggering
pulses of the right phase position. The synchronizing voltage for the gate control set
is taken through the filter. The pulses supplied by control sets are amplified and
delivered over by two line driver modules to an intermediate pulse stage, where the
pulses are amplified further. The output pulses of both the pulse intermediate stages
(Auto & Manual) are connected to the common pulses bus. The two channels are
changed over electronically by blocking or releasing the corresponding intermediate
pulse stages.
The incorporated redundancy is effective, only if suitably monitored. A pulse
supervision unit is connected to the output of gate control set in both the channels, to
monitor the pulses at the common pulse bus bar connected through a potential
separating unit. If the pulse failure is detected by auto channel, automatic transfer
from the auto to manual channel takes place is initiated in the control room.
In order to avoid any surge on change over between the automatic and manual
channel, the pulse position of both channels is compared in the pulse comparing
stage for manual channel follow-up. Matching is effected with a follow-up control
Rev. No. : 02, Oct. 2008
device directly acting on the manual reference value unit. Each converter block has
its own pulse final output stage. They are further amplified for firing the thyristors. On
failure of one converter block, e.g. caused by a fan etc., the pulses are blocked in the
corresponding final stage.
The power supply for the electronics is derived from the generator supply in case of
AC/DC converters and from station battery in case of DC/DC converter supply. For
testing, with the generator at standstill, a switch (Test/service) permits supply from
the auxiliary mains of the station.
In the automatic channel there are two power supplies, supply A&A1 each of these
power supplies comprises one required DC voltage. Manual channel is also provided
with a power supply. Besides this, each pulse final output stage is provided with it’s
own power pack.
3.2.2 AUTOMATIC CONTROL:

The control amplifier first generates a DC signal proportional to the generator voltage
after rectification of the PT voltage, the so-called actual value. A voltage, dependent
on the generator current, vector ally to be added in order to attain the so-called
droop, normally to compensate the voltage drop of the unit transformer.
In case of under frequency the actual value is further increased which means a lower
voltage will be regulated in the field winding, thus avoiding saturation effects in the
transformer and instrument transformers connected to the generator terminals.
In order to ensure fast and well-damped setting, the voltage regulator amplifier is
provided with a PID filter adjustable over wide ranges. The reference value for the
generator voltage is applied to the mixing point and supplied from the reference
value generator. The reference value can be adjusted by commands from the control
room or from the local panel.
The rotor current limiter is provided to protect the generator against excessively
long duration of ceiling excitation current i.e., beyond safe limits. Currents up-to
ceiling excitation are permitted for more or less time according to the magnitude of
currant and the reduced to the thermally allowed maximum continuous current. While
the limiter is in operation, if a voltage dip occurs in the network, (short circuit on HV
side) then once again the limiter is reset-allowing ceiling current and will then limit
the current again to the safe value.
The manual limiter is provided to set a lower reference value for the rotor current
limiter in the event of failure of 2 thyristor bridges in order the reduce the rotor
current to lower level of operation. This point is actuated from the control logic in
which failure of (N-2) bridges is sensed. In case of this limit no overloads in the rotor
current is allowed.
In the load angle limiter protects the generator from stator over current and voltage
as a DC voltage signal and monitored, using simple generator model. If the set angle
limit is exceeded, the unit will step up excitation and thus avoids the machine from
falling out of step.
Rev. No. : 02, Oct. 2008

The stator current limiter protects the generator from stator over currents, such as,
for example, can arise in case of sudden network voltage changes or due to an
operational error. If the limiter is in action it is released to the over excited range in
case of network voltage drops (ex. Short circuits on HV side etc.) and will take over
its limiting function after a set time of 2 to 10 sec. Again.
The unit is split up into two limiting circuits, which separately process the capacitive
(under excited range) and inductive (over excited range) generator currents,
respectively.
The priority structure of the regulators used in the system can be illustrates as
follows.
Rotor Limiter Stator Limiter
1 st Priority Rotor Current limiter Stator Current inductive limiter
2 nd Priority Load angle limiter Stator Current limiter
Capacitive
3 rd Voltage regulator
Appropriate placing of wire bridges permits to match the regulators to the prevailing
conditions and requirements.
The power system stabilizer serves damper rotor swings and its duties are as
follows:
- The measured transducer measures generator current and voltage and converts
them into proportional DC voltage.
- The stabilizing signal transducer converts current and voltage singles into a DC
voltage proportional to the active power and frequency as well as into a DC. Signal
proportional to the change in active power and frequency. The power signal is
monitored. In the case it falls below a minimum value (0…100% PN) the stabilizing
equipment is switched off.
- The summing and monitoring module adds the two DC signals (active power and
frequency variation signal) supplied signal transducer and amplifies them to a level
suitable for the gate control unit. Power system stabilizer settings should be
reviewed depending on the RSEB/NREB grid conditions, as system impedance act
major roll on setting.
3.2.3 MANUAL CONTROL
In case of faults in the automatic channel, there is a possibility to use the manual
channel. It is also comprises of the gate control set and the intermediated pulse
stage. However, the analog input signal for the gate control set in not supplied from
the voltage regulator but the desired field voltage is directly adjustable by a digital
reference value unit. Thus there is no closed loop control. Therefore the manual
channel should only be used if the automatic channel failed or for emergency.
Rev. No. : 02, Oct. 2008

3.2.4 AUTO/MANUAL CHANGEOVER

The Auto to manual channel change over can be done manually from the control
room or automatically incase of faults in the automatic channel. Basically, the
channels can be changed over at any time; however, the firing angles of the two
channels should first be matched in order to avoid voltage or reactive power surges.
Auto to manual channel change over occurs on the following parameters :-
(i) AVR PT supply fail.

(ii) Auto pulse failure.
(iii) High auto reference.
(iv) Ext. xmer over current delayed (140% for 4 sec).
(v) Auto supply failure
(vi) Limiter supply failure.
(vii) Regulation supply fail.
To ensure surge free transfer at any time, follow-up control is provided. The pulse
comparing stage delivers a DC voltage proportional to the firing angle difference.
After the impedance matching stage the differential voltage is supplied to a Balance
voltmeter in the local panel as well as control room and at the same time to the
follow-up device, which supplies matching signals to the manual reference value
unit. Thus the manual channel will always follow the automatic channel. Therefore
surge free changeover is ensured at any time.
For changing over from manual to automatic channel, matching must be OV, which
is achieved by corresponding matching, orders given to the automatic reference
value unit. After this the changeover can be carried out. Without special equipment
this matching procedure would be difficult due to the high gain of the open voltage
control loop. Therefore the gain is reduced by a feedback loop from the impedance
matching unit to the summing point of the control amplifier.
The changeover itself is carried out by electronic blocking of the pulses in the
intermediate pulse stage of the channel not in use.
If during steady operation with the automatic channel there is a difference reading on
the matching voltmeter without the manual reference value unit being in its final
position, there is a fault in the follow-up control.
Under such circumstances the faulty circuit must be attended to either for
replacement of modules or attending loose connections. However following are the
auto to manual change over parameters.
3.2.5 POWER SUPPLY UNITS:
Thyristor Bridge and its electronic modules are directly supplied from the generator
terminals over the excitation transformer. The regulation transformer delivers the
required three phase voltage of 380V, 220V, 1Ф supply is derived from 380V, 3Ф
and supplied through independent transformer to power packs.
Rev. No. : 02, Oct. 2008

A separate transformer supplies the synchronous voltage 3X380V for the filters for
both auto and manual channels and the voltage relay.
The voltage for each thyristor bridge-cooling fan is taken from an independent or
common transformer depending on scheme, which gets its input supply from the
secondary of the excitation transformer.
Due to this supply concept the excitation system is fully independent from the supply
problems during operation. For the test purposes at standstill or for static checks a
rotary switch permits changeover to the auxiliary mains, which provided 3X380V
through an auxiliary transformer in Reg. Cubicle. Cubicle heaters and illuminations
as well as some measuring circuits are supplied from the auxiliary supply
transformer.
3.2.6 SUPPLY A & M
For the supply of automatic (A) as well as the manual (M) channel power supply
modules
UN 0900 and UN 901 are used in parallel, which supply the stabilized DC voltage ±
24V, ± 15V and monitors these on their own.
Supply A-1
Two power packs UN 0900 & UN 0901 operating in parallel supply the stabilized
voltages ±24V, and ± 15V and monitors these on their own. Miniature circuit breaker
is provided at the input of each power supply for over load and short circuit
protection. Supply distribution of each supply is given in the table (Ref diagram
No.2).
The final stages are featured in such a way that they operate independent from one
another i.e. each final pulse amplifier UN 0097 has its own power supply module
UN 0098 which supply ± 15V and ± 10V and is protected with an external MCB at the
input.
6.0 PROTECTIONS
The following protections are provided for the excitation system.
i) Transformer over current instantaneous & time delayed.

ii) Transformer over temperature instantaneous & time delayed.
iii) Rotor over voltage.
iv) Failure of 3 or more thyristor bridge.
v) Field flashing disturbed.
vi) Regulator supply fuses failures.
Protection (i), (iii) and (iv) trip the turbine, generator breaker and field breaker
simultaneously (class A tripping), while (ii) & (vi) trip the turbine first (through class
B trip). Protection (v) trips the field breaker directly(Before synchronizing the
generator).
Rev. No. : 02, Oct. 2008
7.0 ALARM AND ANNUNCIATIONS
7.1 The following annunciations are provided in control room.
- General excitation control supply fails ANN 4335

- Excitation system trouble ANN 4334
- AVR trouble-automatically change over the manual control ANN 4402
- Generator excitation trip ANN 2346
- Rotor winding temperature high ANN 4336
7.2 The following lamp indications are provided on the excitation system panel, in
addition to various LED displays for each control function.
- Supply for limiter circuit failed.

- Supply for auto channel failed.
- Supply for manual channel failed.
- Protective change over to manual.
- Excitation transformer over current.
- 48 volts DC failed.
- 24 volts supply failed.
- Earth fault relay supply failed.
- Rotor earth fault.
- Slip stabilization failed.
- Excitation transformer over temperature (stage I and stage II)
- Field flashing disturbed.
- Excitation transformer over current (stage I and II)
- Rotor over voltage.
- Thyristor tier fan supply failed (for each bridge).
- Regulator supply fuse failed.
- Pulse final stage fail (for each bridge).
- Field breaker trip relay operated.
- Control supply switch (SWI) in test position.
- Thyristor fuse fail (for each bridge).
8.0 METERING
8.1 The following meters are provided on the excitation panel.
- Generator voltage
- Generator current
- Field current
- Auto-manual balance voltmeter
8.2 The following meters are provided on the control room panel
6610-PL-2
- Generator field voltmeter 6412-G1 (2)-VM-11
- Generator field ammeter 6412-G1 (2)-VM-15
- Balance voltmeter 6412-G1 (2)-VM-12
- Slip stabilization voltmeter 6412-G1 (2)-VM-13
Rev. No. : 02, Oct. 2008

9.0 TECHNICAL DATA

It should be as per attached sheet.
9.1 Excitation transformer
NAPS-2 NAPS-1
Rating 833 KVA.1 phase 3150 KVA- 3phase
Make M/s. May & Christe of BHEL Jhansi
West Germany
Cooling Air natural Air natural
Rated voltage 16.5 KV+- 10% / 332 126.5KV/575V
volts
Class of insulation H H
Applicable standard IEC 76/BS 171 Same
Short time rating for HV 200 / 1A, 10VA, (one
buses 100 KA for one per phase)
second HV side CT rating
Accuracy class 5P10 5P10
Insulation class 22 KV 50KV
LV side CT rating 2500/5A, class 5P10, 2500/5A
60 VA (on R & B phase
only)
No load losses 1500 watts 6KW
Load losses (at 75 7500 watts 22KW
degree Celsius)
Insulation withstand HV 125 KV/power freq. 125KV
36 KV
9.2 Field breaker
-Rating 3500A, double pole, 3000A three pole
1100V KV 1000V DC
-Make M/s. GEC, England BBC
-Type OB4N AMFCC-NOR 30-31
-Number of auxiliary 12 NO + 12 NC 3NO + 2NC
contacts
-DC Ct rating 1500/2A
DC PT rating 600 V/20 V
9.3 Rectifiers
Make/type BHT R 66-166/146
Rating 800A
Peak inverse voltage 2500 V
Fuse rating 2 numbers 450A in parallel Siemens make
Series inductance 10 micro henry. +2.5%, 700A
9.4 Field flashing contactor
Rating 400A, 500V (Unilec, France)
Non linear discharge resistor 2400A I max. 900V max 20 KWS
Field flashing transformer 8KVA, 415/35. 45, 55, 70V
Rev. No. : 02, Oct. 2008
Chapter 3
22 KV ISOLATED PHASE BUS DUCT
(51130)
1.0 SCOPE
This chapter covers the description and feature particulars of the 22 KV isolated
phase bus duct including generator CT's. Generator PT and surge protection
cubicles and Generator neutral grounding cubicles.
2.0 Feature Criterion
The bus duct interconnects the 235 MW generator to the generator transformer, unit
transformer, generator PT and surge protection cubicles, static excitation cubicles
and neutral grounding cubicles.
The rating of the generator is given below
Power output 237,700 KW

Max continuous 264,400 KVA
Rating
Stator voltage 16,500 V
Stator Current 9,240 A
Power factor 0.9
Frequency 50 Hz
Based on the generator rating, the current rating of the bus duct is chosen as
10,000 A and the voltage rating as 22 KV (being the next higher standard class of
voltage).
Isolated phase bus duct is recommended as per practice adopted for systems 11 KV
and higher especially for generator leads with current ratings over 4000A. This also
conforms to the practice adopted in our country for 200 MW units.
Continuous type of isolated phase bus ducts have been recommended to minimize
inductive heating of supporting structures and associated losses.
Based on the three-phase fault level in 16.5 KV system. short time rating of 100KA
for one second has been adopted for the bus duct. Consequently the momentary
peak current of 255 KA has been specified.
The neutral grounding resistor value has been chosen on the well-known basis of
restricting the ground fault current to a value such that the power loss in the resistor
(for the fault current) is equal to the charging KVAR of the ungrounded system/ The
transformer and the resistor have a continuous rating to cater to requirement.
Rev. No. : 02, Oct. 2008

All terminations of equipment connected to bus duct terminals are by braided flexible
joints for bus bars and through rubber bellows for enclosures to allow for vibrations
and thermal expansion without imposing extra stress on the terminals/bushings.
3.0 GENERAL FEATURES

3.1 The output terminals of the turbo generator are connected to the generator
transformer by 22 KV, 10000 A rated tap-off connections are provided on the bus
duct run one each for static excitation equipment, PT and surge protection cubicles
and unit auxiliary transformer primary.
The bus ducts are made of Aluminum, a non-magnetic material, to reduce short
circuit forces. The bus bars are made of 500 mm A/C, 16 mm thick octagonal
Aluminum section for main bus duct and of 152.66 x 51.66 x 8.10 mm A1 channel for
tap-off bus ducts. The enclosure is 1000 mm thick for tap-off bus ducts. The bus bar
is supported on the enclosures by a set of 3 insulators for main bus duct and one
insulator for the tap off bus duct at regular intervals.
The main enclosure is continuously bonded, and is in two sections (viz one from
generator up to tap-off to static excitation cubicles and the other form this tap-off to
the generator transformer) joined by rubber bellows for the enclosures ends of each
section are shorted and connected to ground by 4/0 AWG copper conductor.
The shipping sections of bus duct are joined by Aluminum split cover assemblies for
the enclosure and by welding for the bus bars. At each the run split cover assemblies
and at other low points along the run of the bus duct, drain plugs are provided to
drain condensed moisture within the enclosures.
Provision is made in the run of the bus duct to disconnect Generator and unit
transformer from the generator transformer by means of accessible flexible joints.
The bus duct is natural air-cooled. The inside of the enclosure is painted matt black
to enhance heat dissipation.
Wall frame assembly with seal-off bushings is provided where bus duct is crossing
the turbine-building wall to provide a seal between the wall and bus duct to prevent
leakage of rainwater into the building. The seal of bushing prevents exchange of air
between the indoor and outdoor sections. On either side of the seal-off bushing silica
gel breathers are provided. The wall frame assembly is grounded for safety.
3.2 POTENTIAL TRANSFORMERS AND SURGE PROTECTION CUBICLES

The generator PT's and surge protection equipment is housed in a cubicle. The
cubicle is of three-tier construction. The bottom two tiers contain two sets of three
single-phase potential transformers. These are used for AVR control (the PT's in the
bottom tier) and for generator protection and metering purposes (the PT's in the
middle tier). The rating of the potential transformers are given below
Rev. No. : 02, Oct. 2008

Rating Use Location

PT-1 16500 110 V, 100 VA Cl. 3.0 AVR Control Bottom tier
3 3
PT-2 16500 110 V, 400 VA Cl 1.3.0/0.5 Protection and Middle tier
3 3 metering
The PT has on the primary side 24 KV, 1A, HRC glass fuses with current limiting
resistors. The surge protection tier contains per phase one 18 KV lighting arrestor
and a surge protection capacitor of 0.25 MFD, 24 KV.
These cubicles are located at EL-100Metre between grids D and E inside the turbine
building.
3.3 TERMINATIONS AND CT ENCLOSURES ON THE GENERATOR SIDE
3.3.1 PHASE SIDE
The isolated phase bus duct is joined to the generator phase side terminals by
matching flanges through an enclosure of segregated phase construction. This
enclosure is insulated from the bus duct thermally to avoid heating due to enclosure
longitudinal current otherwise flowing through generator frames. A 3 mm thick, 220 x
170 mm A1 perforated sheet is provided on a 150 x 200 cut out on the enclosure for
escape of hydrogen leaking from the generator. This perforated sheet is provided
with a cover plate. The enclosure is sealed from the isolated phase bus duct by seal
off bushings to prevent leakage of hydrogen into the isolated phase bus duct portion.
The enclosure is earthed. The isolated phase bus ducts near the generator phase
side enclosure house the following CTs for generator protection and metering.
CT PARTICULARS PURPOSE
1. 10000/5 A, C P S, KPV>400V, I exc = 80 mA, Generator differential
RTC<1.5 ohms protection
2. 10000/5A, 50/75 VA, C1.0.2/1 Under & Reverse power
protection
3. -do- Metering
4. 10000/5A, 150 VA, C1.13, SF 10 A.V.R.
3.3.2 NEUTRAL SIDE
All the 6 terminals on the neutral side (Two per phase) of the generator winding are
brought out of the generator. These are taken out through a segregated phase
enclosure, which houses CT's for interterm protection. This enclosure is connected
to an isolated phase bus duct through matching flanges and is thermally insulated as
in the case of phase side enclosure. Perforated sheet for hydrogen escape is
provided on neutral enclosure as in the case of phase side enclosure.
The isolated phase bus duct on the neutral side houses the other generation CT's.
The neutral side CT particulars are given below
Rev. No. : 02, Oct. 2008

CT Particulars Purposes
1. 500/5A C1, PS, KVP > 300 V I exc = Interturn Protection
210 MA and RCT < 1 ohm (located in
the neutral enclosure)
2. 10000/5A C1. PS, KPV > 400 VI exc = Generator differential, Generator
80 mA, and RCT < 1.5 ohms (3 nos on transformer, Differential and
each phase in the IP Bus duct) other Protections.
The neutral is formed after the CT's and the neutral is taken in an enclosure to the
Neutral Grounding cubicles.
3.4 NEUTRAL GROUNDING CUBICLES
A separate cubicle is provided for housing the grounding transformer and the
grounding resistor. The grounding transformer and the grounding resistor. The
generator neutral is brought in an enclosure to connect to this cubicle. This cubicle is
located below the generator at EL 100Metre between columns IV and IV A in the
turbine building.
The neutral grounding transformer is rated 50 KVA, 16.5 KV/250 V
( Dry type in unit-1 & oil follow in unit-2 ) and the resistor of 0.467 ohm, 306 A, 1.1
KV is connected on secondary side of transformer.
3.5 CT's IN TAP-OFF BUSDUCTS
The following CT's are provided in the tap-off to unit transformer and static excitation
cubicles
CT PARTICULARS PURPOSE LOCATION

(TAP OFF AT)
a) 200/1A, 15VA 5P20 Static excitation Static excitation
cubicles
b) 1200/5A, C1 PS, KPV > UT Diff. Protection Unit Transformer
260 V I exc=600 mA,
TCT < 0.60 ohms
c) 1200/5A, 30VA, 5P20 UT Backup and o/c Unit Transformer
Protection
d) 10000/5A, c1 PS, KPV > Gen. Trans. Diff. Unit Transformer
400I exc=80 mA, RCT<1.5 Protection
ohms
3.6 SUPPORT STRUCTURES
The supporting structures of this bus duct are featured considering the short-circuit
forces and the seismic requirement of Narora.
3.7 INSPECTION OPENING

Inspection openings are provided on the bus duct at all equipment terminations, bus
bar joints and CT locations for easy access.
Rev. No. : 02, Oct. 2008

4.0 TECHNICAL PARTICUALS

4.1 BUS DUCT
Manufacturer's Name BEST & CROMPTON ENGG.
LTD, MADRAS
Main Tap-off
Rated/Maximum working voltage (KV) 22/24 22/24
Basic impulse level (1.2/50 microsecond.) KV Peak 125 125
One minute power frequency (KV rms) with stand1 55 55

sec. short circuit
current (KA) RMS Symm 100 100
Asymm 180 180
Momentary short circuit current (peak) KA 255 255
Continuous current rating (Amps) 10000 10000
Temp. rise over 500C Ambient for bus bar. 35/15 35/15
enclosure (00C)
Bus bar Material (Grade as per 155082) 91 E 91 E
Bus bar Shape Octagonal Channel
Bus bar Cross-section (sq. mm) 20372.48 1993.54
Enclosure Material Aluminum Alloy '25'

Enclosure Shape Circular Circular
Enclosure Size 1000 mm ID6.35 600 mm ID

mm thick 6.35 mm
thick
Phase spacing (mm) 1250 / 1200 1250
Type of Bus duct
a) Resistance (micro ohm/m) at 200C 1.5379 15.7112
b) Inductive reactance (Micro ohm/m) at 200C 68.8 111.73
c) Capacitive reactance (Micro/m) at 200C 48.2 87.39
Heat loss (Watt/m) per phase 38.4 23.56
Rev. No. : 02, Oct. 2008

4.2 INSULATORS
Manufacturer M/s W. S. Insulator Ltd. Madras
Standard applicable IS 2544
Rated voltage 24 KV
Impulse (KV peak)/One min. power frequency 125/55 KV
(withstand)
Min. creep age distance 360 mm
Cantilever strength 2000 Kgs.
Weight per insulator 12 Kgs.
4.3 SEAL OFF BUSHINGS
Manufacturer A Bond Strand, Madras
Rated voltage 24 KV
Impulse (KV peak ) / one min. power frequency 125/55 KV
withstand
Min. creep age distance 384 mm
Weight per bushing 35 Kgs.
4.4 CURRENT TRANSFORMERS
Manufacturer M/s Prayag Electricals, Bombay
Technical particular Refer Para 3.3 to 3.5
Applicable standard IS-3156
4.5 VOLTAGE TRANSFORMER & SURGE PROTECTION CUBICLE
Primary voltage 16500/3V
Secondary voltage 110/3 V
PT connection Star/Star
HV winding impulse/one min power frequency 125/50 KV
withstand
Rated burden 400 VA for protection & Metering
100 VA for AVR PT
Accuracy class 0.5/3 for prot. & Met. PT
3.0 for AVR PT
4.5.2 SURGE PROTECTION EQUIPMENT
4.5.2.1 LIGHTING ARRESTORS
May & Type M/s W.S. Insulators, Madras CPL
RM Type
Rated Voltage 18 KV
Nominal discharge current 10 KA
Residual voltage at the nominal discharge current 42 KV
Impulse/one min. power freq withstand 47/70 KV

Power freq. spark-over voltage 1.5 times the rating
4.5.2.2 CAPACITORS
Make M/s Madhav Capacitors, Poona
Voltage rating 24 KV
Capacitance 0.25 MFD
Rev. No. : 02, Oct. 2008

4.6 GROUNDING TRANFORMER

4.6.1 (NEUTRAL GROUNDING TRANSFORMER FOR UNIT-1)
Manufacturer M/s Prayag Electricals Ltd
Madras
Type Dry Type
Applicable standard Is-2026
Primary/secondary rated voltage 16.5 KV / 250 V
Insulation class Class F
Rated output 50 KVA
Basic insulation level 125 KV( peak)
Type of cooling Air Natural
Rated primary/secondary Current 3.03 A / 200 A
4.6.2 (NEUTRAL GROUNDING TRANSFORMER FOR UNIT-2)

Manufacturer M/s Electrical Transformer
Equipment Co, Hyderabad.
Type Non-inflammable synthetic
liquid filled
Applicable standard IS-2026
Primary/secondary rated voltage 16.5 KV/250 V
Insulation class Class-B
Rated output 50 KVA
BIL 125 KV (Peak)
Type of cooling Oil Natural Air Natural
Rated primary/secondary Current 3.03 A/200 A
4.7 GROUNDING RESISTOR
Manufacturer M/s Paranjepe Engg. &
Foundry Co Pvt. Ltd., Nagpur.
Type Cast Iron Grid
Applicable standard BS-587
Rated Voltage 1.1 KV
Continuous current rating 306 A
Resistance value (ohms) 0.45 (Measured value 0.467
for NAPS-1 & 0.47 for
NAPS -2)
Temp. rise at continuous rating over 50 C Ambient 3750C
0
Construction Sheet-steel fabricated

Type of Enclosure 14 SWG Sheet Steel
Type of cooling Natural Air
Continuous rating 42 KW
Rev. No. : 02, Oct. 2008

CHAPTER 4
260 MVA GENERATOR TRANSFORMERS
(51210)
1.0 This chapter covers the description of generator transformer, its cooling system and
its protections, indications and controls. The details given fro GT-1 is equally
applicable for GT-2.
2.0 The generator for Narora is rated for 265 MVA, 0.9 pf. The load on UT on full load
conditions is of the order of 14 MVA. Therefore the net power flowing into the grid is
250 MVA. A rating of 260 MVA with a margin of 10 MVA is selected for generator
transformer. For generator transformer of this order of power rating the percentage
impedance of about 14% is usual, while CBIP specification for percentage
impedance for distribution transformer is 14% impedance.
It is usual to specify the voltage ratio of the generator transformers in a way as to

allow for the full load voltage drop in the transformer to be partially compensated a
voltage ratio of 1`5.75 KV/235 KV generator transformers.
In case of Narora the generating voltage is 16.5 KV, for this generating voltage
16.5/235 KV generator transformer is chosen. The HV voltage of 235 KV is about 6.8
% above 220 KV (the nominal system voltage). The 14% impedance specified will
result in a voltage drop of about 7% at full load and 0.9 pf. Thus the full load voltage
drop in the transformer is almost neutralized by the higher ratio specified.
Off load tap chargers are provided for Narora GTS as the plant is to work normally
as a base load station in the grid. A range of +10% in steps of 2.5% has been
providing for varying the output voltage of transformer.
Though the BIL of the 220 KV system is 1050 (Peak), for economical reasons the
transformer is specified with a BIL level of 950 KV (Peak). However they are
protected by dedicated lightning arrestors (LA's) located near the transformer HV
terminals. The impulse spark over voltage of the LAS is 950 KV (Peak) and hence
the transformer is adequately protected Graded insulation for the HV winding is
adopted for reasons of economy.
A vector group of Yd11 is specified for the generator transformer so that graded
insulation in HV side can be chosen that as well as on 6.6 KV side of UT and SUT is
achieved. Vector groups of Yd11 for GT, DY1 for UT, Yd1YO for SUT ensure this, at
the same time ensuring star connection (for graded insulation on the HV side of GT
and SUT.) Oil forced air forced (OFAF) and oil forced water-cooled (OFWF) type of
cooling were considered for the transformer and from economic considerations
OFWF cooling was adopted.
3.0 The generator transformer is featured to withstand an earthquake of 0.5g

acceleration.
Rev. No. : 02, Oct. 2008

4.0 The GT is installed outdoors on the west side of the turbine bldg. between columns 9
and 11 for unit-I and 23 & 25 for unit-II. The transformers are installed on rails on a
pile based on RCC foundations and are provided with bi-directional rollers for
movement on rails. A rail track with necessary turning points is provided for moving
the transformer to the loading bay in the turbine bldg. The HV bushing of the GT are
to be removed for movement.
A soak pit is provided around the GT foundation for collecting oil emerging from GT
incase of fire/rupture of main tank. A common under ground burnt-oil tank is provided
for GT and UT. The soak pit has a capacity of about 1/3 rd oil content of the
transformer and the burnt oil tank has 100% capacity for both transformers.
A barrier wall is provided between the GT and UT, which is located between the
turbine bldg. wall and GT.
5.0 The LV terminals of the GT are connected to the generator by means of 10,000
amps isolated phase bus duct. There is a tap off connection in this bus duct for the
UT. Bolted links are provided in the bus duct to facilitate isolation of generator
transformer from generator as well as isolation of generator and UT as a group from
the generator.
The HV terminals of the GT are connected by 'MOOSE' ACSR conductors to support

insulators, for line anchoring strain insulators on the turbine bldg. wall and then to the
220 KV switchyard through an intermediate tower and are terminated in bay-2 (bay-
9 for GT-2). The associated GT breaker in switchyard is 513-CB-2 (513-CB-9 for GT-
2). Two earth wires are provided for shielding the 220 KV leads from lightning.
6.0 SALIENT FEATURES

6.1 CORE
The core is made of cold rolled grain oriented silicon steel of low loss grade. The
core is provided with number of oil ducts both in the plane of the core and in
perpendicular plane to facilitate rapid cooling. The lamination joints are mitered and
inter leaved to avoid after annealing. The assembly of the core is having boltless
construction.
6.2 WINDING
The HV winding is star connected and solidly earthed. It is provided with graded
insulation. Each phase winding is provided with five taps near the star-point. This
tapped portion of the winding adds or subtracts with the main winding to provide a
range of +10% taps in steps of 2.5%. Disc coils are provided for HV winding there is
also a surge shield winding to distribute the impulse voltage uniformly along the
winding height. The LV winding is delta connected and is uniformly insulated.
6.3 BUSHINGS
6.3.1 HV BUSHING
245 KV, 800 Amps., outdoor, oil immersed self-contained bushings are provided for
the HV side. The active part of the bushing consists of a condenser body, made from
Rev. No. : 02, Oct. 2008
high quality insulating paper. The paper strips are wound over the central tube with
aluminum foils inserted at suitable locations. The central steam and condenser body
is housed in a porcelain housing, consisting of a tap expansion chamber, an upper
porcelain, a welded flange ground sleeve assembly, a lower porcelain and bottom
cap. A compression spring assembly located in the top housing holds oil synthetic
gaskets and 0 rings between porcelain and metal parts under controlled pressure
completely sealing the bushing.
The annular space between the condenser body and porcelain is filled with
transformer oil up to the expansion space in the top housing. the gas space above
expansion chamber is filled with dry nitrogen. A stress-relieving shield is provided on
the bottom cap. The shield consists of an aluminum shroud insulated with oil-
impregnated paper. The bushing has impulse strength of 1050 KV, total creep age of
6100 mm and protected creep age of 2900 mm.
6.3.2 HV NEUTRAL BUSHING
One 1000 Amps. 36 KV, weather proof, cover mounted, shaded porcelain bushing is
provided for the HV neutral. Bushing has an impulse strength of 75KV/170 KV and a
total creep age of 580 mm and protected creep age of 170 mm.
Two numbers 75 x 6 copper strips that are supported from the tank by support
insulators connect the neutral bushing to the station ground. This enables 'tan delta'
measurement by disconnecting the connection to station ground.
6.3.3 LV BUSHINGS
Six numbers (two per phase) 7500 Amps. 24 KV, cover mounted, oil filled shaded
porcelain bushings are provided for LV termination. The bushings have impulse
strength of 55/125 KV, total creep age of 600 mm and protected creep age of 226
mm. A bus termination hood is provided for terminating the bus duct on to the GT.
'Tan delta' measurement for individual winding, Is possible, since all terminals are
brought out.
Following current transformers are provided for generator transformer.
-One 800/1 Amps. class PS (KPV not less than 200 volts and RCT not greater than 4
ohms) on the phase leads from winding, to the bushings.
-One 800/1 Amps., class PS (of the same parameters as above) in the neutral lead
from star point to the neutral bushing.
-One 800/1 Amps., 15VA, P10 in the neutral lead for backup ground over current
protection.
-One 800/2 Amps., 30 VA, class 0.5, on A and B phase leads for feeding winding
Temp’ indicator. (The B phase CT is spare).
6.5 TANK
The tank is of bell shaped construction. It is provided with an oil tight bolted flanged
joint at the bottom. The part of the tank above the joint can be lifted off to provide
access to the core and coils. The tank is shielded against stray fluxes to avoid temp.
rise in tank. For this purpose silicon steel treated with Carlit insulation is used. Non-
Rev. No. : 02, Oct. 2008
magnetic materials are used for LV bushing flanges and bushing mounting turrets to
avoid heating by high currents. The top of the transformer tank is sloped for
rainwater to trickle down.
6.6 BASE
The base of the GT is provided with eight numbers flanged bi-directional rollers, for
movement of the GT. These rollers are anchored to the foundation by bolted
connections to prevent movement of GT under earthquake conditions. The entire GT
with its auxiliaries are suitable for an earthquake co-efficient of 0.5 g.
6.7 CONSERVATOR
The conservator is mounted on a support extending from the GT tank and is

connected to the tank by a pipeline with a shut off valve. The conservator is provided
with blanked oil filling hole at the top, a drain valve at the bottom, a dial type
magnetic oil level gauge and two silica gel breathers. GT conservator is provided
with atmoseal, which prevent oil and atmosphere contact.
6.8 TAP CHANGER
The tap changer has three separate handles (one for each phase). The tap changer
assembly is located such that there is easy operating access (Kept at a lower height
on the GT tank). Indicators are provided to indicate the tap position and provision is
made for pad locking the tap changer handle with the tap in any desired position.
6.9 PRESSURE RELIEF DEVICE (PRD)
Two PRD are provided on the GT and each PRD is provided with its own micro-
switch which are hooked up in protection circuit..
6.10 THERMOSYPHON FILTER
GT is provided with the thermosyphon filter connected to transformer frame. When

the transformer is under operation, Feeble current of oil flow there, filter which has a
absorbent (activated alumna grade G-80) there by absorbing slag, acid, peroxides
and any ionic infinities from oil which may accelerate a going of oil. The regenerating
absorbent is regenerated after periodic interval.
6.11 MANHOLES
Three manholes are provided for access to HV bushing connections and tap changer
connections. Additional manholes are available for access to LV lead connection, HV
neutral connection.
6.12 EARTHING TERMINALS

Two numbers earthing terminals suitable for connection of 4 AWG earth conductors
from station grounding system are provided for the transformer.
Rev. No. : 02, Oct. 2008
6.13 MARSHALLING BOX
An outdoor type marshaling box housing temp indicators are mounted on the side of
the GT tank. All CTs leads and contacts of magnetic oil-level gauge and pitot delay,
PRD are terminated in the marshalling box.
7.0 COOLING SYSTEM
The transformer is forced oil/forced water-cooled unit provided with two 100%
capacity oil to water, horizontally mounted heat exchanger. The scheme provides
necessary pipe work and valves so that any one cooler can be taken out of service
water requirement are as follows
Water flow 1200 liters/minute.

Water inlet temp. 32 degree Celsius.
Water outlet temp. 44 degree Celsius.
Inlet water pressure 1 Kg/sq. cm.
The cooling water supply is drawn from station LP process water system. Necessary
pressure reducing arrangement is part of the LP process water system.
Heat exchanger is specified for water flow rate of 1200 liters/minute, maximum inlet
water temp. of 32 degree Celsius. Two hundred percent oil pump, each of 7.5 hp
rating are provided for circulating hot oil into and out of heat exchanger. The system
feature ensures that oil pressure will always be more than water pressure, so that
leak of water into oil is not possible. For this purpose head-breaker is provided in the
water circuit. A set of stand pipes for preventing siphoning of water is also provided
to measure pressure differential between oil outlet and water inlet. This initiate an
alarm incase of low-pressure differential.
8.0 COOLER CONTROLS
The cooler controls schematics are given in NAPP/51210/2536/ED. The following is

the brief description of the control system (to be read with the above mentioned
drg.).The oil pumps (two numbers) are rated for 7.5 hp.
All the cooler control equipment is mounted in a separate cooler control panel
located adjacent to the transformer. The cooler control kiosk incorporates following
control elements.
-Auto-off-test selector
-Pump#1-Pump#2 selector
-Heat exchanger selector switch (to sense the respective oil flows through oil
flow meter-1 or oil flow meter-2 for auto control of the cooler scheme).
-Test push buttons for test starting of any pump.
-Control supply 'main' and 'standard by'.
-Control transformer selector switch “main” and standby.
Rev. No. : 02, Oct. 2008

For normal operation, the auto-off-test selector should be in the auto position.
Auxiliary 'NO' contacts of the Generator field breaker or voltage relay connected to
the generator terminals initiate auto starting of the pumps.
(Selection is determined by the position of pump selector switch). The selected
motor contactor picks up and seals itself. Auxiliary timer 88Y1 (88Y2) is also
energized. In case pump#1 is selected and oil flow is also energized. In case
pump#1 is selected and oil flow is still low, auxiliary contactor '48-1' will energized,
which in turn will initiate closing order for pump#2 contactor '88P2'. The auxiliary
contactor 48-1 (similarly 48-2) seals itself and has to be reset-by-reset pushbutton
PB-1).
If the selected pump contactor (ex. 88P1) fails to start then timer 88Y4 gets
energized and initiate auto start of pump # 2. This circuit can also be effective for
local starting of alternate pumps. (Selector in 'test' position, pump selector in 'pump #
1' position will energize '88Y4' which after time delay will start pump # 2). Duplicate
feeders are provided for the AC supply to the pump motors and there is an automatic
changeover facility. The cooler control supplies are monitored for initiating
annunciations incase of their failure. Standby transformer is provided to take care of
main control transformer failure.
9.0 PROTECTION, INDICATIONS AND CONTROLS
9.1.0 GAS RELAY
Hitachi make "pitot relay" is provided in the place of the usual bucholz relay. This
relay avoids erroneous actions, of the GT protection, caused by self-vibration of GT
or by vibration under earthquakes conditions.
The construction is vibration proof to prevent erroneous actuation caused by
earthquake or by self-vibration of GT. The first step contact is of special float
construction to ensure that no erroneous actuation is caused even though vibration
exists, resulting from an accumulation of small amounts of gas, thereby considerably
heightening reliability.The first step contact actuates by collecting decomposed
gases of oil and insulation produced by internal abnormality of the GT. The second
step contact is actuated by Pitot tube pressure. It is not influenced by oil level
vibration in the conservator or by pressure variation of internally sealed gas, assuring
secure protective actuation.
9.1.2 FIRST STEP CONTACT
Gas generated by abnormality inside the GT passes through the connecting tubing
to the gas chamber of relay. As gas reaches a rated amount (400-500 cc), it is led
into a vibration proof cover by a conduit. The float lowers as the gas enters the
vibration proof cover, and a magnet actuates contact. So there is no change in level
of the float when the gas volume is less than the rated amount, no erroneous
actuation is caused by vibration. The gas being produced can be easily monitored
and detected by oil gauge and the gas extraction valve set in gas chamber.
9.1.3 SECOND STEP CONTACT

In addition, oil flow produced in the relay connecting tube, caused by a sudden
pressure rise at the time of an accident, gives rise to a pressure difference inside
Rev. No. : 02, Oct. 2008
and outside of the bellows through the Pitot tube. The different in level of the bellow
is transmitted to the magnet, actuating the contact. There is no pressure difference
inside and outside of the bellows during normal conditions; consequently, no
erroneous or by pressure change in the internally sealed gas. The second contact is
connected to the trip circuit, which cuts off the GT from line.
9.2 MAGNETIC OIL LEVEL GAUGE
A magnetic oil level gauge having alarm contact to indicate low oil level is mounted
on the conservator tank. A closing of the gauge contact initiates "alarm" in the control
room.
9.3 OIL TEMPERATURE INDICATOR
A dial type thermometer measures the top oil temperature. The indicator has two
sets of adjustable contacts. They are connected to give "oil temperature high" alarms
and "oil temperature very high" trip.
The main parts of the oil temperature indicators are

-Bulb
-Capillary tube
-Dial temperature indicator
The partly vaporized evaporating liquid in the sensing bulb is affected by

temperature changes in the surroundings. The vapor pressure changes of liquid in
the bulb are transmitted to the bourdon tube in the indictor through capillary tube
connection. As the bourdon tube moves, the temperature indicating hand also moves
over dial.
The oil temperature indicator is mounted in the marshalling box.
9.4 WINDING TEMPERATURE INDICATOR
A winding temp indicator measures indirectly the temp of the GT windings. It has two
contacts, one for "winding temp. high" alarm and other for "winding temp very high"
trip.
The winding temp indicator is similar to the oil temp indicator described above except
that is has an additional heating coil in the bulb case. The heating coil is connected
to CT in the GT HV lead and carries current proportional to the load current in the GT
windings. Hence the heating coil simulated in the GT windings, heating the winding
temp. Indicator is mounted in the marshalling box.
9.5 COOLER CONTROL FAILURES
Remote alarms are provided for the following conditions of the cooling circuits.
-cooler on standby supply

-Standby pump running
-Cooler control supply failure
Rev. No. : 02, Oct. 2008
-Water flow low

-Oil water differential pressure low.
Further, flow indicators are provided at Hx & differential pressure indicating meter is
mounted in control equipment room.
9.6 DIFFERENTIAL PROTECTION OF TRANSFORMER
A high speed, harmonic restrained, percentage biased differential protection is

provided as over all differential protection of generator and transformer. This
protection will cover all multiphase faults in the transformer HV and LV circuits and
also single phase to ground faults in HV circuit.
9.7 RESTRICTED EARTH FAULT PROTECTION
The HV ground faults are covered by high speed, high impudence circulating current
type zero sequence differential protection (restricted earth fault) for the transformer
HV winding The relay is connected to the CTs provided in the HV winding leads and
the neutral leads of the transformer.
9.8 EARTH FAULT PROTECTION FOR LV SIDE
Earth faults in the LV winding are covered by the stator ground fault protections of
the generator as the LV system is earthed through a high impendence by a
distribution transformer connected resistance in the generator neutral circuit.
9.9 BACKUP PROTECTION
IDMT over current protections are provided on the HV phases and neutral as backup
protection for GT internal and external faults. The CTs for backup phase over current
protection are located in the switchyard and for backup ground over current in the
GT bushing. The under impendence protection provided on the generator will also
service as backup protection for faults inside the generator transformer.
9.10 AUXILIARY PROTECTION
A three-stage time delayed over fluxing protection is provided with the first stage for
alarm, second stage for reducing the GT excitation and last stage for tripping the
unit.
The relays used for protections, are mounted in protection panel number B1 (B1 for
unit#2) -6A, 6B, 6C, 6D, 7A and 7B located in control equipment room.
9.11 LIGHTNING ARRESTORS
Three station type 198 KV, 10,000 amps nominal discharge lightning arrestor of w/s
Insulator make is provided near the GT HV bushings. The arrestors are mounted on
a separate structure inside the GT fencing. The lightning arrestors are located as
close to the GT as possible. However, while locating the lightning arrestors, a
Rev. No. : 02, Oct. 2008
minimum distance of the point of the arrestor from any nearby equipment is
maintained to prevent distortions in the arrestor characteristics. A minimum distance
(in mm) of 11 times the rating of the lightning arrestor (in KV) is normally
recommended by manufacturer and the same is adopted in Narora.
9.12 OVER PRESSURE PROTECTION OF GT TANK
Provision of GT-1 tripping on actuation of GT over pressure relief is provided.
10.0 ANNUNCIATIONS
The following annunciations are provided on panel 6610-PL-2.
10.1 WINDOW ANNUNCIATIONS
An-339 512-GT-1 Gas collection

An-341 512-GT-1 Oil/WTR differential pressure low.
An-342 512-GT-1 over fluxing alarm.
An-343 512-GT-1 over all differential prot. trip
An-344 512-GT-1 Cooler control supply fail
An-340 512-GT-1 Oil/Winding temperature
10.2 CRT ANNUNCIATIONS
An-2268 512-GT-1 Water/Oil flow low.

An-2269 512-GT-1 Standby oil pump running.
An-2272 512-GT-1 Oil level low.
An-2273 512-GT-1 Gas/Oil temp. Very high/wdg temp. very high
trip.
An-2279 512-GT-1 GT-1 PRD operated.
An-2274 512-GT-1 over fluxing trip stage#1.
An-2275 512-GT-1 over fluxing trip stage#2.
An-2276 512-GT-1 Restricted earth fault trip.
An-2277 512-GT-1 Cooler on standby supply.
11.0 TECHNICAL DATA
Name of the manufacturer Transformer & Electricals Kerala Ltd.

Manufacturer's type featureation SAFOCR-3NY5CP.
Type of construction 3 phases, core type, and two wdg
outdoor.
Full load rating 260 MVA
Rated no load voltage 235 KV
HV
LV 16.5 KV
Type of cooling 0FWF
Rating of winding HV 260 MVA
LV 260 MVA
Rev. No. : 02, Oct. 2008

Rated percentage impedance 14%
Frequency 50Hz
Winding connection HV Star
LV Delta
Vector group Yd11
Tapping on winding OFF CIRCUIT
Range +10% insteps of 2.5%
Provided on HV wdg.
Winding category as per IS 2026
HV winding Graded
LV winding Full
Impulse withstand for 1.2/50 micro-sec.
Wave
HV 950 KVP
LV 125 KVP
Power frequency withstand voltage (wet
and dry)
HV 395 KV (RMS)
LV 50 KV (RMS)
Guaranteed max temp rise
Oil by thermometer 43 deg. Celsius.
Wdg by resistance for OFWF cooling 53 deg. Celsius.
Losses
Load loss at rated current at 75 deg. 660-+10%
Celsius wdg temp.
Max. cooler losses at full load 8 KW
No. load losses at 100% voltage & 155 KW+10%
frequency
Approx. magnetising currents
When excited from LV side 91 Amps.
When excited from LV side with 110% 200 Amps.
voltage
When excited from HV side 14 Amps.
Max. flux density

At rated voltage 1.60 wb/sq. mt.
AT 110% rated voltage 1.76 wb/sq. mt.
Current density
HV 300A/sq. cm.
LV 300A/sq. cm.
HV bushing
Rated voltage class 245 KV
Impulse withstand to 1.2/50 micro sec. 1050 KVP
wave
Power frequency withstand dry & wet 460 KV (RMS)
Max. Creep age
Rev. No. : 02, Oct. 2008
Total 5600 mm.

Protected 2800 mm.
Vacuum withstand capacity Main tank 1 Kg/sq. cm.
vac.
Radiators and accessories 1 Kg/sq. cm.
HV bushing 1 Kg/sq. cm.
Weight
Core and winding 147,000 Kg.
Oil 47,000 Kg.
Tank coolers and fittings 55,000 Kg.
Cooling oil pump
Rating 7.5 hp.
Numbers 2
Withstand time duration of transformer for combine voltage and frequency
fluctuation, which produce over fluxing of
120% 2 minute
135% 1 minute
140% 5 seconds
Heat exchanger Make M/s Serck Heat Transfer, UK
Heat dissipation 1000 Kw
Oil flow rate 3000 lit./min.
Oil temperature
Inlet 70 deg. Celsius
Outlet 58 deg. Celsius
Drop 12 deg. Celsius
Water flow rate 12000 lit./min.
Oil velocity 12 deg. Celsius
Water temperature rise 2.42 ft./sec.
Seismic withstand 0.5 g.
Water velocity 1.77 ft./sec.
Rev. No. : 02, Oct. 2008

CHAPTER 5
MAIN OUTPUT SYSTEM
(51300)
1.0 GENERAL
The power generated in NAPP is transmitted to 220 KV grid of Uttar Pradesh Power
Corporation Limited through the 220 KV switchyard. For transmission of this order of
generated power (2 x 235 MW), transmission voltages 400 KV and 220 KV were
considered. 220 KV has been finally adopted considering the initial investments
involved in the 400 KV system and the share of this cost to be borne by department.
2.0 SWITCHYARD LOCATION
The switchyard is located on the western side of the service building between grids
C and L, 13 and 18. The startup transformers are located inside the switchyard. The
generator transformers are located outside the turbine building on the western side.
The transformers are connected to the switchyard by 220 KV overhead lines passing
over the service building. Drawing NAPP 1, 2, /51300/6002/GA shows details of
these overhead connections. The startup transformers are connected to the 6.6 KV
station switchgear (located inside the turbine building) through XLPE cables
(4 nos. 1000mm2 A1/phase).
3.0 SWITCHING SCHEME
In all there are five 220 KV lines, two generator circuits and two startup transformer
circuits. Considering the number of circuits involved, "Two main bus and one transfer
bus" scheme has been adopted for this station. The scheme has following
advantages over the sectionalized main bus and transfer bus scheme adopted in
earlier nuclear plants.
a) Any element can be connected to any of the two main bus bars at any time.
b) Any one main bus can be taken out for maintenance by transferring all
elements to the other main bus.
c) Incase of bus fault, only elements connected to that bus would trip. These
elements can be immediately restored to the other main bus, which is not
possible in case of sectionalized main bus scheme.
d) The transfer bus can be connected to any one of the main bus bars. In case
of sectionalized main bus arrangement, two transfer bus breakers would be
required to achieve this.
In comparison to two main bus bar scheme (without transfer bus, but with transfer
isolators), the recommended scheme has the advantage that when one of the
elements is transferred to the transfer bus, the station can still operate with two main
bus bars with elements distributed between them. Any bus fault during this period
would involve loss of elements connected to that bus only.
Rev. No. : 02, Oct. 2008

4.0 SWITCHYARD LAYOUT

The switchyard layout is shown in the following drawings
1) NAPP 1, 2/51300/6006/GA - Switchyard plan
2) NAPP 1, 2/51300/6007 TO 6009/GA - Switchyard sections.
There are in all eleven bays consisting of five line bays, two generator bays, two
startup transformer bays, one bus coupler bay and one bus transfer breaker bay.
The five lines interconnect NAPP to UPPCL 220 KV grid, at Khurja (double circuit),
Moradabad, atarauli and Simbholi (Single circuits)
The main and transfer bus bars are made of 4"IPS Aluminum tubes run at an
elevation of 5 meters with a support span of 15 meters. The bus bars are supported
on post insulators. The individual bay bus bars are run in the transverse direction to
the main bus bars at 8.0 meter elevation and are of 2.5" IPS Aluminum tubes/Single
"Moose" ACSR conductors (except in case of the bus coupler bay where 4" IPS A1
tube/three "Moose" ACSR conductors are used). The Connection between the main
bus and bay bus bars are through "V" connection made of 1.25" IPS Aluminum tubes
(2" Aluminum tubes for Bus coupler Bay). The centerline distance between adjacent
bays is 15 meters.
All equipments except circuit breakers are mounted on galvanized steel structures
over concrete plinths. The circuit breakers are directly mounted on concrete plinth.
Steel gantries are provided for take off termination of lines & also for the strung
conductors of the bay bus bars.
5.0 FEATURE PARAMETERS AND BASIS
The major parameters of the switchyards are given below.
1) Type Outdoor
2) Nominal Voltage 220 KV
3) Max. Operating Voltage 240 KV
4) Basic impulse levels-
a) For transformer windings. 950 KV peak
b) For other equipment 1050 KV peak
5) 3 Phase fault level 10000 MVA
6) Short time current rating for all 23.6 KA/1 sec.
equipment
7) Minimum creep age distance 5600 mm Total and
for insulation and bushing 2800 mm Polluted
8) Number of strain/suspension 16 nos.
insulators/string 254 x 146 fog type
9) Specified Current Rating For
a) Main bus bars 2000 A
b) Bus Coupler Bay Bus 2000 A
c) Bay Bus of other elements 750 A
Rev. No. : 02, Oct. 2008

The basic insulation level (for 220 KV system) recommended by various standards
such as DS-162, IS-3072 and CBIP's manual on substation layout, are 900 KV and
1050 KV peak. The higher value of 1050 KV peak has been adopted for NAPP. The
insulation co-ordination is illustrated in drawing NAPP 1,2/51300/6051/ES. For
economical reasons, the BIL of power transformers have been choosen as 900 KV.
However dedicated arrestors located near their terminals protect these.
Corresponding to the BIL of 1050 KVP, the minimum clearances recommended by

standards and those adopted for Narora are given below
Phase to earth Phase to Phase Sectional

Clearance Clearance Clearance
BS-162/1961 2082 mm 2388 mm 4270 mm
IS-3072/1975 2300 mm 2700 mm 4900 mm
CBIP Manual 2300 mm 2700 mm 4900 mm
Clearance adopted
for NAPP 2300 mm 2700 mm 5000 mm
The creepage distances for polluted atmospheres as recommended by IS-2544/1973

have been adopted.
Liberal current ratings have been specified for the main bus bars, bus coupler bay
and other element bays over and above the normal currents they can be subjected
to under various operating conditions.
Fault level of 10,000 MVA, specified is well above the maximum fault level at NAPP
shown by fault level studies made by DAE and UPSEB.
Since all faults in the 220 KV system are to be cleared by high speed main
protections within about 0.1 seconds and back up protections in less than 1.0
seconds, the short time current rating for equipment is specified for one second
duration.
6.0 BRIEF DESCRIPTION OF EQUIPMENT
6.1 THE CIRCUIT BREAKERS
The circuit breakers are of air blast type, manufactured by M/s Hindustan Brown
Boveri. The circuit breakers for generators, transformers and bus coupler are of 3
Pole type and those of lines and transfer breaker are of single pole type. The control
scheme of line circuit breakers has provision for single pole tripping and reclosure/3
pole tripping and re-closure. The re-closing scheme has also provision for re-closure
on dead line or re-closing with synchronizing check feature.
Rev. No. : 02, Oct. 2008

There is a centralized compressed air system for feeding air to the circuit breakers.
The compressors are housed in the compressor room located on the eastern side of
the switchyard. The air piping is made of copper tubes and is run inside cable
trenches in the switchyard. A ring main system with two feed points and necessary
stop valves are provided in the piping to facilitate isolation of any breaker circuit
without disturbing air connection to the other circuits. Further details of the circuit
breaker and compressed air system are covered in the feature breaker and
compressed air system is covered in the feature manual titled "220 KV Air blast
Circuit Breakers".
6.2 ISOLATORS
The isolators are pneumatically operated type and are capable of remote control
from control room. The isolators are of M/s TMG make and are supplied by M/s
Voltas. Air supply for pneumatic control of the isolators is also available from the
same centralized compressor mentioned in Para 06.1 through separate reducers to
reduce the pressure to the required operating level(16.0 Kg./cm²) for isolators.
Grounding switches are provided on the line isolators. These grounding switches are
mechanically interlocked with the main isolators.
Lightning arrestors are provided on all the five lines at their entry into switchyard and
near the HV terminals of the power transformers. The arrestors are of heavy-duty
station type manufactured by M/s WS Insulators. The main parameters of the
arrestors are as below
Rating 198 KV
Discharge current 10 KA
Impulse spark over voltage 550 KV peak
Switching surge spark over 420/453 KV
min./max.
Power frequency spark over 1.5 times rated voltage
Reseal voltage 205 KV
The adequacy of arrestor rating can be seen from the insulation co-ordination shown
in the drawing 1 & 2/51300/6051/ES.
6.4 VOLTAGE TRANSFORMERS/ CAPACITOR VOLTAGE TRANSFORMERS
In line with the UPSEB's practice of providing CVT's for feeding distance protection
of lines, CVT's are provided on all 3 phases of the 220 KV lines. These CVT's serve
the dual function viz. VT for the line protection and coupling capacitor for carrier
communication.
Rev. No. : 02, Oct. 2008

Each main bus bar is provided with one set of electromagnetic VT for the purpose of
metering, synchronizing and feeding other protection circuits. One single phase CVT
is provided for the transfer bus for synchronizing purposes.
6.5 5 core CT's are provided for each of the elements of the switchyard. The ratio and
burden details of these cores are given in the drawing "Main output system one line
diagram". The general allocation of the 5 cores is as follows.
a) Bus differential protection 2 cores (One core for check feature

of differential protection if
necessary for the scheme adopted)
b) Main protection 1 core
c) Backup protection 1 core
d) Metering 1 core
M/s TELK supplied the CT’s. Further particulars of these are given in the data sheets
enclosed as Appendix-3.
6.6 CARRIER COMMUNICATION
Carrier communication facilities are provided for communication between NAPP

control room and grid substations connected to NAPP. Phase to phase coupling has
been envisaged for single circuit lines and inter circuit coupling has been envisaged
for double circuit line to "Khurja". Wave traps are provided on phases associated with
the "Communication".
The carrier communication channel is also used for transmitting signals for line
protection.
6.7 PROTECTION
Separate zones of differential protection are provided for the two main bus bars. The
faults on the transfer bus are discriminately cleared without affecting the main bus
zones.
The 220 KV lines are provided with three-zone distance protections with carrier aids
to operate as permissive inter tripping schemes. Directional over current relays are
provided for backup protection of lines.
Generator and transformers are provided with their conventional main and backup
protections.
Rev. No. : 02, Oct. 2008

The 220 KV breakers are provided with local breaker back up protection. Further
details of protection are covered in separate feature manual titled "Main output
system protection".
6.8 SWITCHING SEQUENCE

Sequence of switching the various isolators and circuit breakers for transferring any
220 KV circuit from one bus to the other, from main bus to the transfer or from
transfer bus back to the main bus are given below. Typical case of Line 1 is
discussed with identification of isolator numbers and circuit breaker numbers, the
process is identical for other elements.
6.8.1 SWITCHING LINE 1 FROM MAIN BUS 'B' TO MAIN 'C'
Since the line is connected to Bus 'B' isolators 513-DS-14, 513-DS-16 and then
circuit breaker 513-CB-4 will be in the closed condition in the beginning of the
operation.
Close 513-DS-4 and 513-DS-5 and then circuit breaker 513-CB-1 if they are not
already closed. Now main bus bars 'BU-B' and BU-C' are in parallel. Now close 513-
DS-15. Isolators to both the main bus bars now connect the line. Isolator 513-DS-14
may now be opened thus effecting if the element has to be transferred from 'BU-C' to
'BU-B'.
6.8.2 SWITCHING LINE 1 FROM MAIN BUS TO TRANSFER BUS
If the line was on main bus 'BUS-B' isolator 513-DS-14 and DS-16, circuit breaker
513-CB-4 will be in closed condition in the beginning of the operation.
Close isolator 513-DS-17 to energize the transfer bus from the line side.
Close isolator 513-DS-38 and DS-40 and then transfer circuit breaker 513-CB-10.
Now the line breaker CB-4 is in parallel with transfer breaker CB-10.
Open circuit breaker CB-4 of the line. The line is now transferred to the transfer
breaker. Isolators DS-16 and DS-14 can now be opened thus completing the
transfer.
6.8.3 SWITCHING LINE 1 FROM TRANSFER BUS TO MAIN BUS
Isolators 513-DS-17, DS-40, Ds-38 and circuit breaker CB-10 will be in the closed
condition (Assuming the transfer bus was connected to main bus BU-B).Close
isolators DS-16 and DS-14 and then circuit breaker CB-4. Then the line circuit
breaker CB-4 is in parallel with transfer circuit breaker CB-10 on the main bus BU-B.
Trip transfer circuit breaker CB-10 and then open isolators DS-40, DS-38 and DS-17
thus completing the transfer.
6.8.4 OPERATION OF LINE GROUNDING SWITCH GS-1

Before operating the grounding switch GS-1 for earthing the line for discharging, the
following should be ensured
Rev. No. : 02, Oct. 2008

a) Line circuit breaker CB-4 and isolator DS-16 should be open.

b) The transfer isolator DS-17 should be open.
c) The line should have been disconnected at the remote substation and is in
de-energized condition. (This condition is sensed by relay 27 LVT connected
to line CVT).
Similarly, before recharging the line from remote end, it should be ensured that the
grounding switches are opened.
6.9 SYNCHRONISING ARRANGEMENTS AND REMOTE CONTROL
The remote control for the switchyard circuits is provided on the control panel 6610-
PL-7 in the plant main control room. Synchronizing facilities are available for
synchronizing any element to the live bus bars. The details of the synchronizing will
be covered in the feature manual titled "Emergency transfer and synchronizing
schemes". Provision is also available to bypass the synchronizing check feature and
charge the dead lines or the dead bus. These operations should be done carefully
after physically assuring that the lines or bus are in de-energized condition. All
isolators can also be controlled remotely from the central control room. However, the
grounding switches have to be operated manually at the switchyard.
6.10 INTERLOCKS
Following interlocks are provided for the operation of the isolators. As a typical case
Line-1 isolator interlocks are described here. Similar interlocks are applicable for all
other elements. These interlocks are provided in the 250 V DC circuits of isolator and
are applicable for both remote and local electrical operation of isolators and the
operator has to ensure that the necessary conditions are satisfied before starting a
manual operation. Isolator DS-14 can be opened or closed only if –
a) If transfer isolator DS-17 is open, then main isolator DS-15 and circuit breaker CB-4
should be opened.
b) If transfer isolator DS-17 is open and main bus isolator DS-15 is closed, then the
bus coupler isolators DS-4 and DS-5 should be closed and the bus coupler break
CB-1 should be closed.
c) If transfer isolator DS-17 is closed, then main isolator DS-15 and circuit breaker CB-
4 should be open, but transfer breaker isolators DS-38 and DS-40 should be closed
and transfer breaker CB-10 should be closed.
Similar conditions are applicable for the operation of isolator DS-15 of the line.Except
- c) transfer breaker isolators DS-39 and DS-40 should be closed and transfer
breaker CB-10 should be closed.
The circuit breaker isolator DS-16 can be opened or closed only if the grounding
switch is open and the circuit breaker CB-4 is open.
The transfer bus isolator DS-17 of line-1 can be closed or opened only if the transfer
breaker CB-10 and its associated isolators are open, the grounding switch 'GS-1' is
open and no other 220 KV element is selected for transfer. The last condition is
Rev. No. : 02, Oct. 2008
monitored by auxiliary relays 'HSX' provided for each element in the 48V DC
schematics.
The isolators DS-4 and DS-5 of the bus coupler can be closed or opened only when
the bus coupler breaker CB-1 is open.
The transfer breaker isolator DS-38 can be closed or opened when:
a) The other isolator DS-39 is open and the transfer breaker is open.
b) If the other isolator DS-39 is closed and then the bus coupler breaker CB-1 and its
associated isolators DS-4 and DS-5 are closed.
Similar conditions are applicable for isolator DS-39. The transfer breaker isolator Ds-
40 can be closed or opened only when the transfer breaker CB-10 is open.
6.11 220KV AIR BLAST CIRCUIT BREAKERS
This section covers the description of 220 KV air blast circuit breakers (ABCB), its
controls, indications and protections.
6.12 BRIEF DESCRIPTION
The power generated in NAPP is delivered to UPSEB 220 KV grid through five
numbers 220 KV lines. These lines interconnect Narora to the following substations
of UP grid
Moradabad Single circuit line

atarauli Single circuit line
Khurja Double circuit line
Shimboli Single circuit line
An outdoor 200 KV switchyard is provided in NAPP for this output system. Two main
and transfer bus system has been adopted for this 220 KV outdoor switchyard.
There are in all eleven bays in the switchyard. five for lines, two for generator
transformer circuits, two for each start-up transformer circuits, and one each for bus
coupler and transfer bus breakers . The switchyard is located on the western side of
the service building between grids C and L, 13 and 18.
6.13 INSTALLATION
The circuit breakers are mounted on steel/RCC structure Refer Drg.
NAPP/51322/6002/DD.
Pneumatically operated 220 KV, off load isolators are provided on either side of the
breakers for isolation during maintenance work. These isolators can be controlled
from control room in addition to the local control available in the switchyard.
Following clearances are provided
Phase to phase spacing 2700 mm

Minimum phase to earth clearance 2300 mm
Sectional clearance between bays 5000 mm
Ground clearance of equipment 2500 mm
insulator
Rev. No. : 02, Oct. 2008
6.14 PARAMETERS
Fault level of 10000 MVA has been adopted for the NAPP 220 KV switchyard. This is
well above the maximum fault level at NAPP shown by fault level studies made by
NPB and UPSEB. The circuit breakers at the receiving end of the lines to UPSEB
are rated for 7500 MVA or 10000 MVA. Hence 10 MVA symmetrical rupturing
capacity 26.3 KA for circuit breaker is considered adequate.
The air blast circuit breakers supplied by M/s. HBB has the following ratings.
Symmetrical breaking current 31.5 KA
Asymmetrical breaking current 1.22 times the symmetrical current

(equal to 38.43 KA)
Making current 2.55 symmetrical
Further, the manufacturer has confirmed that the generator circuit breaker is capable
of breaking the fault current fed by generator and generator transformer unit into 220
KV system.
This fault current though much less in magnitude compared to the rupturing capacity
will have a high DC time constant of the order of 250 millisecond.
The relevant parameters of the circuit breakers are as follows
Service voltage 220 KV

Rated voltage 245 KV
Nominal current 2000 A
Symmetrical breaking capacity 26.3 KA (rated)
31.5 KA (tested)
Asymmetrical breaking capacity 38.43 KA
Making capacity 80.33 KA
Short time current rating 55 KA for 3 seconds
Operating duty 0-3'-C0-3' - CO for non auto re-closing
type
0-0. 3 sec-CO-3' CO for auto re-closing
type
Total break time 45 millisecond for auto re-closing type
and 65 millisecond for non re-closing
type
Total closing time 60 millisecond for auto re-closing type
80 millisecond for non auto re-closing
type
Insulation level of the breakers
Rev. No. : 02, Oct. 2008

1.2/50 micro second impulse +ve and - 1050 KV

ve
Switching surge 750 KV wave shape 250/3000
One minute power frequency withstand 460 KV rms
voltage
Minimum creep age distance 5600 mm
The circuit breakers to be adopted for the lines are specified to be suitable for single
phase/three phase trip and auto re-closing duty. The circuit breaker for GT, SUT and
bus coupler circuits is specified for three phase tripping and non auto re-closing type.
Since the transfer breaker has to serve as substitute for line breakers it is also for
single phase/three phase trip and auto re-closing duty.
6.15 GENERAL FEATURES
The air blast circuit breakers of the five outgoing lines and of the transfer bus are
suitable for single and three phase auto re-close duty. These are provided with
separate controls and control block for each phase operation.
The circuit breakers of generator transformers, start up transformer and bus section
breakers are specified for non re-close duty and they have common control and
control block for all the three poles and pneumatic inter connection between the
poles for transmission of control signals.
The circuit breakers consists of the following main parts

-Air tank with control blocks mounted on it.
-Supporting insulator column.
-Interrupting chambers (two numbers).
-Control and blast valve.
-Control cubicle.
The breakers have vertical air receiver with control blocks mounted on it. The
supporting insulator assembly mounted over air receiver, supports the horizontal two
chamber interrupting unit together with its control and blast valve assemblies. The
auxiliary switches are mounted in the control block, a separate common control
cubicle for all these poles, houses the necessary pressure switches. Control
switches, anti pumping relay and pole discrepancy timers.
6.16 DESCRIPTION OF PNEUMATIC OPERATION
The working of the air blast circuit breaker is described below. The description has to
be read in conjunction with fig attached.
Rev. No. : 02, Oct. 2008

6.16.1 Opening Operation
In the closed position of the breaker, the nozzle type contacts 3130 and 5140 are
closed. The interrupting chamber 5000 the insulator column '4000' and the
compressed air tank 1000 are under service pressure.
An electric opening commands given to the control block 2000 unlatches the opening
spring charged mechanism 2313 and compressed air flow to cause the primary
control valve 2700 to changeover. The compressed air enters the driving piston 1112
and the pressure on both sides is balanced. The compressed air acting on the lower
side of the control valve piston 5230 pulls the control valve 4100 upwards. The
inrushing compressed air actuates the blast valve piston 5302 and at the same time
arrives under the exhaust valve disc 5428 via control insulator 5180.
The blast valve 5300 and the exhaust valve 5420 open and ventilate the interior of
the nozzle shaped contacts 5130 and 5140. The driving mechanism tube 5480 is
slided by the exhaust valve 5420 through contact lag distance. The exhaust valve
further moves to its end position, opens completely thereby pushing the driving
mechanism tube 5480 in front of it, which pulls the contact 5140 into extinction
position.
The compressed air present inside the interrupting chamber flows through the
nozzles of contacts 5130 and 5140 and provide an intensive double blasting of the
opening arc which as a result is extinguished during the current zero.
The hot arc gases are released to the atmosphere through the open exhaust valve
5420 and blast valve 5300. After pneumatically controlled time delay the moving
contact 5140 goes to its end position (isolating distance), the exhaust and blast
valves close, the compressed air flow is interrupted. The breaker has now attained
its open position. The interrupting chamber and insulator column remains filled with
fresh compressed air. The open isolating stretch is filled with air under pressure. The
contacts remain open until a new closing order is given.
6.16.2 CLOSING OPERATION
A closing command unlatches the closing spring charged mechanism 2333 in the
control block. This ventilates the main valve 2770. The piston is pushed to its bottom
end position and the tie rod 4100 is pulled down to its end position. The control valve
piston 5230 closes rapidly. The trapped compressed air lifts the exhaust valve cover
5218 and the cylinder of the driving mechanism tube 5480 closes the moving contact
5140 very rapidly. During the closing movement of the contact the retarding valve
5315 causes a momentary impulse type opening of the blast valve 5302 so that the
probable pre closing arc is immediately pulled into the nozzle of fixed contact 5130
by the inrushing compressed air. This prevents deposition of gaseous contact
material residues in the interrupting chamber and a simultaneously given opening
order is carried out after completion of the closing operation safely.
Rev. No. : 02, Oct. 2008

6.16.3 EMERGENCY PNEUMATIC OPERATION
The circuit breaker can be tripped or closed by direct operation on the pneumatic
circuit by operating the emergency ON and OFF push button located on the CB tank.
This operation should be restored to only when all electrical controls have failed with
due care taken by operator on the consequences of such closing or tripping
operation of the overall system.
6.17 DESCRIPTION OF ELECTRICAL CONTROLS
The control schematics for single pole re-closing and non-auto re-closing breakers
are given in NAPP/51310/2521/ED and NAPP/51310/2530/ED.
6.17.1 250 DC CONTROLS OF LINE BREAKERS (ReferNAPP/51310/2521/ED)
Each breaker is provided with three separate 250V DC supplies, one for remote
closing circuits, second for trip coil II and third for trip coil I. The DC supplies for
remote closing, for trip coil II are routed through the protection Panels of respective
220 KV elements, and their fuses are located in these panels.
DC supply for trip coil I is brought from DC board directly to one of the breakers in
the switchyard and Looped from there to other breakers. Each breaker circuit of this
supply has its own fuses in the control cubicle of the breaker.
All main protection trips and remote hand trips are wired to the trip coil II. The local
hand trip (for testing purpose), the back up protection trips and pole discrepancy
protection trip are connected to the trip coil I.
The remote close command from control switches in control room is wired in the
closed supply circuit. However, for the local close command from local control switch
(for testing purpose only) the closing coil I DC supply. This is achieved through the
contacts of local remote selector switch.
For any local operation, the local remote selector switch should be placed in the local
control position. The remote close and trip commands are possible only when the
local/remote selector is in the remote position. All protective trips are wired direct to
the trip coil and do not depend on the position of local/remote selector switch.
The following interlocks are provided in the closing coil 52CC circuit and trip coil
circuits
- Pressure switch 63C permits closing only when air pressure is above a set value
of 27.8 kg./sq. cm.
- Anti pumping relay, 52 X 1 prevents pumping of breaker when the close

command is persisted during which period an auto trip command also arrives.
Rev. No. : 02, Oct. 2008

- Pressure switch 63T1 via an auxiliary contactor 63 X 1 lockout trip coil I circuit in
case of abnormal fall in air pressure (set at 27 kg/sq. cm.).
- Pressure switch 63T2 via auxiliary contactor 63 X 2 lockout trip coil II circuits in
case of abnormal fall in air pressure (set 27 kg/sq. cm.)
- Pressure switch 63A in conjunction with timer 63AX. Initiates alarm annunciation
'breaker tank on low pressure'. This annunciation should precede the action of
closing and tripping lockouts mentioned above. The pressure setting for this is to
be adopted accordingly.
- Pressure switch 63AR permits auto re-closure only if air pressure is above 30.5-
kg/sq. cm. Its auxiliary relay 63AX initiates alarm annunciation whenever-closure
is locked out for want of adequate air pressure.
The timer 62 gets energized whenever there is discrepancy in the position of the
breaker of the three poles and initiates tripping command to the trip coil I.
Red and green lamps are provided in the control cubicle for ON and OFF indications.
Auxiliary switch with 9 NO & 7NC contacts are available in the control block of each
pole. The contacts of all the three poles are wired in series to give overall ON and
OFF indication of breaker position.
6.18 AUTO RECLOSE CIRCUITS
The type of auto re-closure is decided by the position of control switch CSS-1. This
has four positions viz.
-Single-phase re-closure.
-Single and three phase auto re-closures.
-Three-phase re-closer.
-Non-auto re-closures.
The circuit when selected for single-phase auto re-closure, trips and auto recloses
the faulty phase for zone I earth fault only, locks out on zone II and Zone III faults, all
multi phase faults, and faults during the subsequent reclaim time.
The circuit when selected for single and three phase faults, trips and auto recloses
the faulty phases only for zone I earth faults trips and auto recloses all three phases
for multiphase zone 1 faults and locks out in all other cases. Dead line/check
synchronizing facility is available with the three phase re-closing.
When selected for non-auto position, locks out auto re-closure for all types of faults.
The exact type of auto re-closing to be adopted for the Narora lines has to be
finalized in consultation with UPSEB.
The auto re-closing scheme provides separately adjustable deal time for single,
three phase re-closures and adjustable reclaim time to suit recovery time of the
Rev. No. : 02, Oct. 2008
circuit breaker used. Dead times are adjustable over a range of 0.06 second to 0.6
seconds and reclaim time is adjustable over a range of 2.5 to 25 seconds. Contacts
are available for alarm annunciation of "auto re-close operated" and "circuit breaker
tripped and locked out". The auto re-close is initiated from the single phase & the
three phase trip relays of distance protection.
6.19 250 DC CONTROL OF NON-AUTO RECLOSE BREAKERS

(SUT. GT, and bus coupler breaker)
The control scheme is generally similar to that of line breaker & is briefly covered
below
- Pressure switch 63C permits closing only when air pressure is above 27.8-kg/sq.
cm.
- Anti pumping relay, 52X prevents pumping of breaker when close command is
persisted during which period auto trip command also arrives.
- Pressure switch 63T (via auxiliary relay 63X1) and pressure switch 63T2 (via
auxiliary relay 63X2) lockout trip coil II and I respectively when air pressure falls
below 27 kg/sq. cm.
- Pressure switch 63A (with auxiliary relay 63AX) initiates low-pressure alarm.
- Closing coil 52C and trip coil 52TC-1 & 52TC-2 are common for all the three
poles of the breaker.
- One auxiliary switch with 8NO+8NC contacts is common for all three poles and
is located in the common control block.
6.20 250 DC CONTROL CIRCUITS OF TRANSFER BUS BREAKER
The controls are similar to that of the line breakers. Transfer bus breaker has to
substitute for line breakers also.
Further, the following additional features are incorporated in the control scheme ;
-The protective trips coming from the protective relays of the element which the
transfer breaker substitutes are relatively connected to the trip coil of the transfer
breaker trip coil II. This is achieved through interlocks of transfer bus isolator and
additional auxiliary relays DSX for each transfer bus isolator. Further details on this
are covered in 48V DC schematics.
-The transfer bus breaker is provided with a separate auto re-close relay. The auto-
re-close is again initiated selectively from the protection relays of the element under
transfer through the interlocks of associated transfer bus isolator.
Rev. No. : 02, Oct. 2008

6.21 48V DC CONTROL 220 KV line breakers
(Drg. No. NAPP/65130/6003/ED and NAPP/65230/6013/ED)
All the five line breakers are normally remote controlled from control panel 6610-PL-
7 in the main control room. Each breaker is provided with a discrepancy type control
switch and two push buttons for synchronizing selection.
The tag numbers for the control switch & push buttons are as follows
Synchronise Line Discrepancy Synchronizing

Switch control switch selection PB
S-14 line-1 HS-7017 PB (L) - 7021
S-14 line-2 HS-7018 PB (L) - 7022
S-14 line-3 HS-7019 PB (L) - 7023
S-14 line-4 HS-7020 PB (L) - 7024
S-14 line-5 HS-7022 PB (L) - 7026
For remote control from control room is operative through synchronizing check
feature operation of PB-7021 (for line 1) selects line I breaker 513-CB-4 for
synchronizing. The line voltage is compared with selected bus voltage. If
synchronizing exists or achieved after adjustments of generation, the manual
synchronizing check relay 6523-25M
permits closure of the breaker. Operation of the control hand switch HS-7017 will
energize 3C relay, which in turn closes its contacts in 250V DC closing circuits. If
the breaker has to be closed on, dead line or dead bus, the synchronizing check
feature has to be bypassed by the PB-7019 and subsequent operation of HS-7017
will permit dead line closing.
When control switch HS-7017 is put to trip position, relay 3T picks up and transfers
the trip command to the 250V DC trip coil II. The control switch has built in lamp,
which will glow steady whenever the control switch position (after close or after trip)
corresponds to breaker position. In case of any discrepancy between switch position
and breaker position the lamp indication will also disappear. The hand switch should
then be operated to a position corresponding to that of breaker.
6.21.2 Startup transformer circuit breaker (Drg. NAPP/65130/6014/ED)
Both the start up transformer circuit breakers 513-CB-3 and 513-CB-5 are also
controlled from control panel 6610-PL-7 in the main control room. Each breaker is
provided with a discrepancy control switch with tag numbers as follows
SUT1 513 CB # 3 HS7060

SUT2 513 CB # 5 HS7061
There is no synchronizing check feature in closing of the SUT breakers. However the
following interlocks are provided in 3C circuit.
-Main and back up protection trip relay are in reset position.
Rev. No. : 02, Oct. 2008
-The link isolator on the 6.6 KV side is in closed position with its door closed.
-The 6.6 KV (LV side) circuit is in off position or the SUT is already charged
through transfer bus breaker.
The closing command will be permissive only when all the above interlocks are
satisfied.
-The tripping and control panel indications are similar to those of the line
circuit breakers.
6.21.3 Generator transformer breakers (Drg. NAPP/65130/6008/ED)
The generator transformer breaker 513-CB-2 of unit I is normally remote controlled

from control panel 6610-PL-2. In switchyard panel 6610-PL-7, there is a dummy
control switch for this breaker, which is used only for position indication. Both the
panel are in main control room. For unit II the remote control is from on 6610-PL-2
and a similar dummy switch is provided on 6610-PL-7 for indication purpose.
The tag numbers for the various switches are as follows
CB GT HS/PANEL Synchronizing Selection

PB
513-CB-2 GT-1 1-HS-7049 1-PB-7043 (synchronizing
6610-PL-2 selection)
1-HS-7062
6610-PL-7
513-CB-9 GT-2 2-HS-7049 2-PB-7043
6610-PL-2
2-HS-7063
6610-PL-7
The 3C circuits of the generator breaker incorporates the following interlocks
-The trip relays of generator and generator transformer are reset.
-The generator field breaker is closed.
-Manual or automatic synchronizing is selected.
The manual synchronizing procedure is similar to those described for lines. In this
case, the generator speed and voltage has to be manually adjusted to achieve
synchronizing.
There is also provision for automatic synchronizing of the generator. In this case
once, the generator breaker is selected for automatic synchronizing, the speed and
voltage adjustments are automatic and the auxiliary relay 6523-25A closes it
contacts in 3C circuit when synchronism is achieved, the generator breaker control
switch should be kept in the after close position to complete the circuits 3C relay.
Rev. No. : 02, Oct. 2008
The tripping and indication are similar to those of line breakers described earlier. The
dummy control switch in switchyard control panel provides necessary indications in
that panel provided the dummy operation on this switch are close whenever the
control switch in panel is operated.
6.21.4 Bus coupler breaker (Drg. NAPP/65130/6011/ED& NAPP/65230/6013/ED)
This breaker is normally remote controlled from control panel 6610-PL-7 in the main
control room.
The tag numbers for the control switch and synchronizing selection push button are
given below
513-CB-1 bus coupler HS-7016 PB-7020

6610-PL-7 6610-PL-7
Only manual synchronizing feature is envisaged for this breaker and the scheme is
similar to other explained earlier, the temperature and indication arrangement are
also similar.
6.21.5 Transfer bus breaker (513-CB-10)

(Drg.NAPP/65130/6011/ED& NAPP/65230/6013/ED)
This breaker is controlled form control Panel 6610-PL-7 in the control room, however
dummy control switches are provided in the generator control panels 6610-Pl-2 of
unit I and unit II for position indication.
Following interlock is incorporated in the 48V DC circuit of the breaker
-Only one 220 KV elements can be transferred to transfer breaker at any time. For
this purpose, each transfer isolator is provided with a auxiliary relay DS-HSX. Once
a 220 KV elements is selected for transfer the circuit of other DS-HSX relays are
cut off from DC supply. DS-HSX relay is a latching type relay with a separate coil
and a rest coil. Once operated through operating coil the contacts remain latched in
the operated position till reset coil is energized (by isolator opening operation).
The contacts of HSX relay is used to select the necessary interlocks in the closing
and tripping circuits of the breaker to relate it to the appropriate element
transferred. For example when SUT-1 is selected for transfer control switch of
transfer isolator DS-13 energize DS-13-HSX relay. The NO contact of this HSX
relay introduces interlocks of SUT in the 3C circuit, which are
(i) All SUT trip relays air reset.

(ii) SUT LV side links are closed.
(iii) SUT LV breaker is open or SUT 220 KV breaker is closed.
Rev. No. : 02, Oct. 2008

All similar interlocks pertaining to other 220 KV elements are introduced by the
respective DS-HSX relays.
-The transfer circuit breaker can be closed with synchronizing check facility. Only
manual synchronizing is provided. Relay 62523-2M-6 closing permission on
achieving synchronization.
6.22 COMPRESSED AIR SYSTEM

(Drg. NAPP/51310/2524/ED)
The centralized compressed air system is located in a separate compressor room on

the eastern side of the switchyard. It consists of the following.
-Three numbers Ingersol Rand make compressors of capacity 52-meter cube/hour

and rated pressure 60-kg/sq. cm. with 20 HP 415V electric motors.
-Four numbers storage reservoirs of 650 liters each (two before air driers and two
after air driers).
-Two numbers air driers.
-Safety valves one per reservoir.
-Two numbers pressure reducing valve unit (60-kg/sq. cm. to 31 kg/sq. cm.)
-Contact manometer.
-Necessary stop valves and drain valves & non-return valves.
The centralized air system is operated as a ring main system with two parallel paths
and inter connection between the parallel at the compressor outputs, before air
driers and after air driers so that the compressors can operate with any combination
of the two sets of reservoirs. At the outlets of the two parallel paths, two numbers tap
off connections per path are provided to tap off compressed air system for isolator
controls. Pressure reducer’s 31/16 kg/sq. cm. are provided on these tap off
connections to reduce the air pressure to 16 kg/sq. cm. suitable for isolator controls.
the ring main system of compressed air distribution inside switchyard is by copper
tube supported and run along cable trench walls.
The central compressor system when fully charged has capacity for two close/open
operation of 11 breakers and 33 numbers isolators. Air drying plants ensure that the
compressed air delivered to the system is free of moisture. The local reservoirs have
storage capacity for two close open operations of the breakers.
COMPRESSOR CONTROLS
(NAPP/51310/2523/ED)
The rated pressure of the HP side of the system is 60-kg/sq. cm. when the pressure
falls down from this value the automatic starting of the three compressors are
envisaged.
Rev. No. : 02, Oct. 2008

At any time, any compressor can be chosen as the leader, followed by a follower and
the third as the standby unit. Selector switch b4 has three positions 1/2, 3/1 and 2/3
when selected for 1/2 the first compressor will be the leader and the second follower
and the third standby. Similar sequence applies for other positions. Contact
manometers P1, P2 and P3 are set for three stages of starting viz 56-kg/sq. cm., 53-
kg/sq. cm. and 52.5-kg/sq. cm. They will stop the running compressors when
pressure reached to 60 kg/sq. cm.
A typical starting sequence for position 1/2 will be as follows
-When pressure falls to 56-kg/sq.-cm.-pressure switch P1 will energize auxiliary relay

D-11 that seats itself.
-Auxiliary relay D-11 will through 1-A1 contact of the selector switch will energize
auxiliary relay D1, which in turn will start contactor C1 of the compressor #1 when its
auto-off-man control selector is in auto position. The compressor will run as long as
the contact manometer P-10 has not changed over its contacts. At 60 kg/sq., cm.
energize contact to D12, which will reset D11.
-Incase pressure continues to fall further below 56 kg/sq. cm. manometer P-2 will
initiate D-21 at 53 kg/sq. cm. This will in turn initiate D2 and C2 in the same manner
and resetting will be identical.
-If the pressure falls still further manometer P3 will initiate relay D3 provided the
compressor#1 and compressor#2 have not started. This will in turn start the standby
composer.
In addition to the automatic control, it is possible to start any compressor manually

by selecting hand control position of its selector switch B1 (or B2 or B3).
Manometer P4 is set to operate on fall of pressure to 50-kg/sq. cm. to give low-

pressure annunciation and the same again change over at 64-kg/sq. cm. to give
high-pressure annunciation. Common annunciation compressor trouble' and
'compressor control supply fail' are provided in the switchyard control panel.
6.24 ANNUNCIATION
The following annunciations are provided in the control room for the 220 KV breakers
and isolators
6.25 Common window annunciation of 6610-PL-7
AN 434 220 KV breaker tank low pressure.

AN 380 220 KV breaker trip lockout on low pressure.
AN 429 220 KV breaker close lockout on low pressure.
AN 431 220 KV breaker re-closure lockout on low pressure.
Rev. No. : 02, Oct. 2008

AN 366 220 KV system air compressor trouble.

AN 375 220 KV breaker protection supply failed.
AN 374 220 KV breaker control supply failed.
AN 381 220 KV breaker pole discrepancy.
6. 26 CRT annunciation of individual breaker

(6610-PL-7)
AN 2369 514-L-1 CB-4 Trip lockout on low pressure

AN 2374 514-GT-1 CB-2 Trip lockout on low pressure
AN 2375 514-GT-2 CB-9 Trip lockout on low pressure
AN 2376 521-SUT-1 CB-3 Trip lockout on low pressure
AN 2377 521-SUT-2 CB-5 Trip lockout on low pressure
AN 2378 513-220 KV bus transfer Trip lockout on low pressure
CB
AN 2379 513-220 KV bus coupler Trip lockout on low pressure
CB
An 2384 514-L-1 CB-4 Pole discrepancy trip
An 2389 513-220 KV transfer CB Pole discrepancy trip transfer CB
An 2390 514-L-1 CB-4 Tank on low pressure
An 2395 512-GT-1 CB-2 Tank on low pressure
An 2396 512-GT-2 CB-9 Tank on low pressure
An 2422 514-L-4 CB-8 Protection supply fail
An 2423 514-L-5 CB-11 Protection supply fail
An 2424 512-GT-1 CB-2 Protection supply fail
An 2425 512-GT-2 CB-9 Protection supply fail
An 2429 521-SUT-1 CB-3 Protection supply fail
An 2430 521-SUT-2 CB-5 Protection supply fail
An 2431 513-220 KV bus transfer Protection supply fail
CB
An 2432 513-220 KV bus coupler Protection supply fail
CB
An 2331 514-L-1 Reclosed
Rev. No. : 02, Oct. 2008

AN 2300 Switchyard compressor pressure high/low
AN 2301 Switchyard compressor DC control supply fail
AN 2308 220 KV system isolator control air pressure low
The other chapters to be referred while reading this chapter are as follows
Main output protection Chapter-17.
Emergency transfer and synchronizing Chapter-18.
6.27 TECHNICAL DATA
Manufacturer M/s Hindustan Brown Boveri

Ltd.
Manufacturer type featureation DLF 245 nc 2

Type of circuit breaker Air blast circiut breaker, outdoor
Standard applicable IEC 56
Service voltage 220 KV
Rated frequency 50 Hz
Continuous rated current 2000A for bus section breaker
and 1250 A for other
breakers
Rated short time current 55 KA (rms) for 3 seconds
Rated duty cycle 0-3' -CO-3' -CO

Interrupting capacity based on duty cycle as
above
Symmetrical at rated voltage 31.5 KA
Asymmetrical at rated voltage 1.22 times symmetrical capac
Symmetrical at service voltage 26.3 KA

Making capacity 2.55 times symmertical breaking
capacity
Minimum creep age distance 5600 mm
Protected creep age distance 2800 mm
Ambient temperature ensured for feature
Maximum 50 degrees Celsius
Maximum daily average 40 degree Celsius
Maximum temperature rise over ambient when 35 degree Celsius
carrying rated current
Interrupting time at 100% interrupting duty For 45 milliseconds
auto re-close type breaker
Rev. No. : 02, Oct. 2008
For non auto re-close breaker 50 milliseconds
Closing time for auto re-close type of breakers 60 milliseconds
Closing time for non auto re-close type of 80 milliseconds

breakers
Number of breakers in series/pole 2
Total length of break/pole 2 x 55 mm
Rated transient recovery voltage
First pole to clear factor 1.5
Value of TRV 1 KV/microseconds
Recovery voltage when circuit breaker is tested As per relevant standard
at 100% rated breaking capacity
Rate of rise of restricting voltage at breaking
30% breaking capacity 5 KV./microseconds
100% breaking capacity 1 KV/microseconds
Maximum voltage factor of the circuit breaker
when switch in OFF
Unloaded transformers 2
Loaded transformers 2
Open circuited lines 2
When switching off a synchronous system
Maximum current 25% of fault current

Maximum recovery voltage Between contacts or 200% of rated voltage
one pole
Insulation level of the breakers
One-minute power frequency withstand voltage 460 KV rms

Switching surge withstand Test Voltage 750 KV wave shape 25/3000
microseconds
1.2/50 microsecond impulse withstand test 1050 KV peak
voltage
Type of contacts Butt
Material of contacts Copper
Thickness of silver coating 20 microns
Contact pressure 1200 kg.
Min. clearance between phases 2300 mm
Min. clearance between live points & earth 1968 mm
Whether circuit breaker is fixed trip or trip free fixed trip
Type of mechanism
Closing electro pneumatic
Tripping electro pneumatic
Control supply 250 V DC
Permissible variation 170-275 V DC
Power for closing coil 660 watts
Power for trip coil 420 watts
Current rating for trip coil 3A
Rev. No. : 02, Oct. 2008
Number of openings circuit breaker is capable of

performing without inspection or replacement of
contacts or other main parts
At 50% rated current 1000
At 100% rated current 1000
At 50% rated breaking capacity 30
At 100 % rated breaking capacity 10
Breaker air receivers Pressure 31 kg/sq. cm
Limits of pressure before correct Operation 27-31 kg/sq. cm.
Quantity of free air required to close at rated air 1200 liters
pressure
Capacity of local receiver 1830/3 liters (rack pole)
Quantity of free air required for One Opening 2800 liters
operation
One closing operation followed by one opening 3600 liters
operation
One opening operation followed by me closing 5900 liters
operation and immediately followed by one
opening operation for re-closing duty breakers
Compressed air plant
Air compressor
Type Reciprocating
Make M/s. Ingersoll Rand
Number of compressor Three
Capacity of each compressor 52 meter cube
Compressor outlet pressure 60 kg/sq. cm.
Compressor motor rating 20 HP, 415V, 50 Hz.
Compressor auto starts at 56 kg/sq. cm.
Comp. System. High pressure alarm 64 kg/sq. cm.
Comp. System low/high pressure alarm 50/64 kg/sq. cm.
Time for air comp. to charge the central air 40 min. (with two compressor
receiver working)
From atmospheric pressure at Which compressor
starts at 56 kg/sq. cm.
From pressure 56-60 kg/sq. cm. 10 min. (with two compressor
working)
Rev. No. : 02, Oct. 2008

CHAPTER 6
START UP TRANSFORMER
(52110)
1.0 This chapter covers the description of start up transformer (SUT), their parameter
selection, cooling systems, neutral grounding arrangement, protections,
annunciations and control. As per existing practice for Nuclear Power Plant in India,
dedicated start up transformers are provided to divert any SUT to any unit in case of
emergency needs.
2.0 The rating of the SUT and UT is arrived on the basis of their normal loads on unit
and station sections and the total load the SUT has to carry in case of non-
availability of unit transformer.
3.0 The D2O upgrading loads provision is not made, hence if one section either unit
section or station section bus trips D2O U/G loads have to be curtailed so that load
does not exceed 31.5 MVA. However specified capacity has adequate margin for
D2O loads on SUT during normal operation.
The ONAN rating of 22 MVA specified is about 70% of the ONAF rating which is the
normal range for such dual rated transformers.
The transformer is specified with a voltage ratio of 220/6.9 KV. The HV voltage
corresponds to the voltage of the HV buses of the main output system. The LV
voltage of 6.9 KV is the no load voltage of the LV side. On load, the voltage drop in
the SUT will reduce the terminal voltage to 6.6 KV with proper selection of tap.
The star/star connection for HV/LV winding were chosen in order to obtain proper
vector matching of 6.6 KV unit and station systems. The SUT is also provided with a
unloaded tertiary winding for third harmonic circulation in view of the star/star
connection. The tertiary has a power rating of about 1/3 of the main winding. The
choice of percentage impedance for the transformer depends on the fault level
obtainable on the LV side and the voltage drops under full load conditions and motor
starting conditions. Percentage impedance of 9% specified limits the LV fault level to
500 MVA and the voltage drops to permissible levels.
The transformer is specified with an on load tap changer to maintain steady voltage
at the 6.6 KV bus. The on load tap changer has a range of ±12% in steps of 1.5%.
Though the BIL of the 220 KV systems is 1050 KV (peak) For economical reasons
the transformers are specified with a BIL level of 980 KV (peak). However they are
protected by dedicated lightning arrestors located near the transformer HV terminals.
The impulse spark over voltage of the lightning arrestors is 550 KV (peak) and hence
the transformer is adequately protected. The tertiary winding and the LV winding are
not directly exposed to the atmospheric over voltages and hence are specified with
an impulse level of 100 KV (peak) and 60 KV (peak) respectively.
Graded insulation for HV winding is adopted for reason of economy. In fact, this
requirement of grade insulation has guided to choice of star connection for HV
winding.
Rev. No. : 02, Oct. 2008

Since the majority of faults in the LV system are single phase to ground, it is
desirable that single phase to ground fault current is limited to reduce the damage
the equipment. Hence single phase to ground fault current is limited to about 1000
Amps by providing a 3 ohms resistor in the LV neutral to earth connection. This
magnitude of ground fault current is considered adequate for discriminating ground
fault protection of secondary circuits. The neutral grounding resistor has a current
rating of 1350 Amps. for 10 seconds.
4.0 INSTALLATION
The two SUT for the station are located on the eastern side of 220 KV switchyard.
The transformers are installed on the rails on an RCC foundation, their wheelbase
anchored to the RCC foundation, and their wheel base anchored to the foundation
by anchor bolts to prevent movement of the transformer when in service. The rail
track from the foundation extends up to the road on the eastern side of the 220 KV
switchyard.
A soak pit is provided around each transformer foundation for collecting oil form the
transformer in the event of any untoward explosion to prevent fire accidents. A
common underground burnt-oil pit has a capacity for about 1/3 oil content of the
transformer and the burnt oil tank has 100% capacity for both the transformers.
Connections on the LV side are by means of 12 numbers (4 per phase) 11 KV grade,
1000 sq. mm. single core, XLPE cables. The cable box is provided with a
disconnection chamber and is mounted on separate supports, to facilitate withdrawal
of the transformer without unsealing the cables. Raychem terminations are adopted
for terminating above cable.
The neutral grounding resistors for the 6.6 KV winding of the transformers and the
220 KV, lightning arrestors are installed on separate structure. The lightning
arrestors are located about 4.39 meters from the HV terminals of the transformer.
5.0 RATINGS AND TESTING FIGURES
Rating of SUT specified 22/31.5 MVA ONAN/ONAF

Normal load on SUT including 20.8 MVA
D2O upgrading plant of 7 MVA
Load on SUT when unit transformer 34.8 MVA
is not available including D2O
upgrading plant, load 7 MVA
Rating of tertiary winding 10.5 MVA
Type of transformer Outdoor, 3 phase, core type
Rated voltage 220/6.9 KV

Rated frequency 50 Hz
Winding connection Yodlyo
Percentage impendence (HV-LV) 9%
Basic insulation level 900 KVP
Winding temp. rise Not to exceed 50
Degrees Celsius over
50 degree Celsius ambient.
-Standard Is-2026/1977
Rev. No. : 02, Oct. 2008
5.2 GUARANTEED TECHNICAL PARTICULARS
The essential guaranteed technical particulars and corresponding test figures are
given below. for other test results refers test certificate.
ITEMS VALUE TOLERANCE SUT-1 SUT-2
PERMISSIBLE
No load losses at 50 rated 50 +15% 43.652 43.653
voltage and rated frequency
(KW)
No load losses at 110% 63.07 61.842
excitation (KW)
Load loss at 31.5 MVA and at 105 +15% 103.771 117.385
rates tap corrected to 75
degrees.
Temp. rise degree Celsius At ONAN/ONAF
principal tap
(i) Oil 45 39/38.5
(ii) winding by resistance degrees 43.5/42.5
50
degrees
Total losses (excluding coolar 155 +15% 147.423 160.908
losses)
Cooler losses (KW) 2.0 2.076 2.04
Efficiency at rated load and 99.5 99.49
rated tap U.P.F. (%)
Regulation at rated tap at
31.5 MVA at 75 deg. U.P.F.
%) 0.769 0.7625
0.8 LAG (%) 5.948 5.83
Impendence volts at 75
degrees Celsius Minimum tap
(%) 9.439 9.269
Rated tap (%) 9% +10% 9.439 8.836
Maximum tap (%) 9.413 9.166
Magnetizing current
(secondary values)
At rated voltage (A) 18 +30% 15.45 12.033
At 110% rated voltage(A) 45 +30% 38.58 25.0
Acoustic noise level (dB) 80 +2dB 74.94 75.0
Zero phase sequence
impendence
HV-LV tertiary LV open (%) 9.418 9.203
HV-LV tertiary closed (%)
7.994 8.057
Rev. No. : 02, Oct. 2008

6.1 The transformer is three phased core type. The core is made of CRGO silicon steel
laminations of low loss grade. It is three limbed stepped construction. The core
laminations are 45 degree mitered and interleaved to avoid local heat and reduce
losses. Bounded glass tapes bind the core limbs.. The manufacturer has specified
flux density as 1.7 wb/sq.m, which is the normal acceptable value for this capacity of
transformers.
6.2 The LV wdg is star connected and is provided with uniform insulation to earth. The
neutral of the LV wdg is brought out through a separate 17 KV bushing to a cable
box for connecting to a neutral grounding resistor.
The HV wdg is star connected and is provided with graded shield wdg in order to
distribute impulse voltage of the HV wdg is brought out through a separate 36 KV
bushing for solid earthing.
On all the three phases of HV wdg., 17 taps are provided near the neutral end for
voltage variation of -12% to +12% in steps of 1.5% for normal voltage of 220 KV.
As the LV and HV wdg are star connected (vector ground Yy0), an unloaded delta
connected tertiary wdg is provided for the suppression of harmonics. This wdg is
rated for 10.5 MVA. The two terminals of the open delta wdg are brought out through
36 KV bushing and shorted by a link and earthed at the body of the transformer. The
availability of the terminals enable testing such as continuity check and meggering.
6.3 TERMINATIONS
6.3.1 Three 400 Amps. weather proof, cover mounted, viscous fluid filled, porcelain clad,
condenser type, 6100 mm. creep age distance, 220 KV nominal, 460 KV/1050 KV
BIL bushing are provided for HV termination. The 220 KV MOOSE ACSR leads are
connected to the HV terminals by bimetallic multibolt corona-free champs at the pin
type leads of transformer bushing.
6.3.2 One 630 Amps., weather proof, cover mounted, oil filled shedded porcelain bushing
of 36 KV nominal, 75/170 KV BILL bushing is provided for HV neutral termination.
Two copper buses 25mm/6mm supported on insulators fitted on to the transformer
tank are provided from the HV neutral bushing terminal to near the base of the
transformer and from there connections are made to the station ground grid for direct
earth.
6.3.3 LV phase terminals are brought into a cable terminal box through three (one per
phase, 3150 Amps., 17 KV nominal, 35/95 KV BIL) porcelain bushings. Twelve (four
per phase), single core, 1000 sq. mm. aluminum conductor, paper insulated, mass
impregnated, non-draining, screen type, lead alloy 'D' sheathed, hard drawn
aluminum wire armored overall PVC served, 11 KV grade cables are connected to
the terminals of cable and potheads in the above cable terminals box. The LV phase
terminals of the transformer and the terminals of cable potheads are connected by
copper flexible.
Rev. No. : 02, Oct. 2008

6.3.4 LV neutral is brought out to a cable sealing box through one 1000 Amps., 17 KV
nominal, 35/95 KV BIL porcelain bushing. From here, it is connected to a terminal of
a three ohms neutral grounding resistor by a single core, 1000sq. mm., aluminum
conductor, PVC insulated, aluminum wire armored, PVC sheathed, 6.6 KV grade
cable and the other end of the neural grounding resistor is connected to station
grounding system.
6.4 BUSHING CURRENT TRANSFORMERS
Bushing type CT are provided on HV and LV side of station startup transformer as

follows
One CT per phase of ratio 100/1A, Class PS, KVP>200 volts, RCT<1 ohms is
provided and is used for restricted earth fault protection. The KVP and RCT
requirements are based on the requirements of high impedance type differential
relays for restricted earth fault protections. Another CT 100-50-30/1 A, 15 VA (class
1.0 at 100/1 tap, class 3 at 50/1) is provided as a spare core for temporary metering
purposes. This should be kept shorted when not in use.
-One CT of ratio 100/1 A, class PS, KVP> 200 volts, RTC<1 ohm is provided for
restricted earth fault protection. Another CT of ratio 100/1, VA, 5P20 is also
provided as spare and should be kept shorted, as it is not used.
-One CT per phase of ratio 3000/1 A, class PS, KVP> 600 volts, RCT< 12 ohms is
provided for restricted earth fault protection. Another CT of ratio 2640/2.5 A, 25 VA,
accuracy class 3.0 is also provided on B phase for feeding wdg temperature
indicator.
-One CT of ratio 3000/1 A, class PS, KPV>600 volts, RCT<12 ohms is provided for
restricted earth fault protection. Another CT of ratio 100/1 A, VA, 5P20 is provided
for back up earth fault protection.
TAP CHANGER
The transformer is provided with an on load tap changer (OLTC). The voltage class
of OLTC equipment is 66 KV and is rated for 150 Amps. The tap changer is
contained in the transformer tank. There are in all 17 taps/phase near the neutral
end of HV wdg These taps are contained in an internal cylinder. The connections
from the wdg terminate on this outer cylinder.
The 6.6 KV bus voltage are computed for various conditions of 220 KV system
voltages for SUT loadings of 0%, 50% and 100% for various OLTC settings. Voltage
variations for UT will be less stringent as the fluctuations are less. Following table
gives values for SUT only.
HV system voltage Transformer OLTC % LV KV

220 KV (100%) 0 + 1.5 6.80 KV
+ 3.0 6.70 KV
50% - 1.5 6.79 KV
0 6.69 KV
100% - 4.5 6.80 KV
- 3.0 5.70 KV
Rev. No. : 02, Oct. 2008
245 KV (111.36%) 0 +12.0 6.86 KV

50% +12.0 6.65 KV
+10.5 6.75 KV
100% +6.0 6.85 KV
+7.5 6.64 KV
198 KV (90%) 0 -7.5 6.72 KV
50% -9.0 6.62 KV
-10.5 6.72 KV
100% -12.0 6.62 KV
187 KV (85%) 0 -12.0 6.69 KV
50% -12.0 6.49 KV
From the above table, it is observed that acceptable 6.6 KV voltage level can be
achieved under all conditions of 220 KV system voltage, in the range, in the range of
198 KV to 245 KV.
The oil in the tap changer is separated from the oil in the transformer tank. The main
conservator is compartmentalized into two sections, one section is connected to oil
in transformer tank and other to the oil in the OLTC. The compartmentalization of
conservator is such that a common air column exists over both the oil compartments.
The compartment for the OLTC has a separate oil level indicator. An oil operated
pressure relay is provided in the oil pipe leading to the OLTC.
Following are the controls of the tap changer
- Manual mechanical control
A detachable crank handle is kept in the driving mechanism box. Irrespective of the
mode of operation for which the mechanism is set electrically, the crank handle can
be inserted for manual mechanical mode of operation. When the handle is so
inserted the electrical mode of operation both local and remote is cut off. After
extreme tap positions are reached, further cranking declutches the mechanism
automatically and thus over cranking is prevented.
- Electrical control
The tap changer can be electrically set for automatic voltage control or local or
remote, modes of operation. The control has electrical interlock such that when it is
set for one mode other mode is not possible. Manual control is adapted and auto
Central in never resorted to.
(a) If switch LOCAL is selected on local/remote switch 'CSS', the tap changing
can be controlled through local pushbutton b1 and b2. If CSS is kept in
REMOTE position, and the auto/manual selection switch 'AMS' kept in manual
position, then the operation is controlled through push button in the control
room which energize relays 3C3 and 3C4 through push button b1 and b2.
(b) If 'CSS' is in "remote" position and 'AMS' in 'auto' position, the tap changing is
carried out automatically through contacts of automatic voltage regulating
relay 'AVR'
Rev. No. : 02, Oct. 2008
(c) In case of emergency, the OLTC motor can be tripped through a push button
in control room.
(d) Limit switch are provided to prevent the mechanism operating beyond
extreme tap positions.
(e) Tap position indicator is provided in the control room.
AUTOMATIC VOLTAGE REGULATION
The OLTC is provided with automatic voltage regulating relay type VINCM13 of
ENGLISH ELECTRIC make to provide close and accurate automatic voltage control.
Undesirable and frequent changing operation on transient voltage fluctuations is

avoided by built in time delay in the relay. The length of this time delay is inversely
proportional to the degree of voltage variation. There is also an under voltage block
feature for preventing tap changing when voltage fall drastically due to faults. A line
drop composition feature is also available which at the sending end.
When the regulated voltage moves outside the dead band set by the sensitivity
control, the voltage high or voltage low circuits in the relay are initiated after time
delay. The appropriates tap changer control auxiliary relay closes its contact to
initiate tap changing. The 'voltage high' and 'voltage low' auxiliary relays are
electrically interlocked to prevent simultaneous operation. At voltage below 80% of
normal, operation of voltage regulating relay is blocked to prevent tap changing on
high fault currents.
The voltage regulation can be set in the range of ±10% of 110 volts continuously.
The setting should be such as to achieve 6.6 KV voltage at full rated current. The
sensitivity is adjustable between ±0.%5 to 3% of regulated voltage and should be set
at about +-1%. There are five choices for the time delay with levers at a, b, c, d, e
(refer relay catalogue) and lever 'b' is recommended. The line drop compensator
should be set at minimum value of 1% (available range up to 20%).
6.6 TANK
The tank is of elliptical shaped constructing. It is provided with an oil tight bolted
flanged join near the top. The top cover can be lifted off after the removal of
bushings and disconnecting few pipes, conduits etc. Inspection manholes are
provided on the top and sides of the transformer. However, for any work on the core
and coils, the core-coil assembly, has to be lifted off from the tank. The transformers
are installed on rails on RCC foundations and their wheel base anchored to the
foundations to prevent movement of transformer while in service.
6.7 BASE
The transformer base is fitted with four bi-directional flanged roller assemblies. Rail
gauge for movement of the transformer on wheels is 1676 mm.
Rev. No. : 02, Oct. 2008

6.8 LIFTING HOOKS AND JACKING PADS
Four lifting hooks and four jacking pads suitable for lifting the entire tank with core-
coil assembly and oil are provided.
6.9 PULLING ARRANGEMENT
Eight pulling eyes are provided for moving the transformer on rollers.
6.10 INSPECTION MANHOLES
A total of five manholes on the top and sides with suitable covers are provided to
facilitate inspection of internal parts and disconnection/connection of wdg leads.
6.11 VALVES
The tank is fitted with the following valves
-Six numbers one each for top oil outlet and bottom oil inlet, 6" BSP shut off valves
for cooler connection pipes.
-Two numbers 2" BSP filter valves for tank with oil sampling plug on blanking plate-
one near the top and the other near the bottom on diagonally opposite sides.
-One number 4" BSP shut off valve for tank near the bottom.
-One number 3" BSP shut off valve for pipes connection between tank and a min
conservator and one number 1" BSP shut off valve for pipe connection between
tank and OLTC conservator.
-Two numbers 1/2" BSP sampling valves at top and bottom.
6.12 EARTHING TERMINALS

Two earthing terminals are provided on the transformer tank on opposite ends. They
are connected to the station grounding grid by 4/0 AWG stranded tinned copper
conductor.
6.13 EXPLOSION VENT
One explosion vent is provided from the top of the tank. An equalizer connection is
provided from the conservator.
6.14 CONSERVATOR
The conservator is mounted over the top header of oil cooler bank and supported
from the main tank. The conservator is partitioned and has common air column
inside the conservator tank. The bigger of the two partitions is connected to the
transformer main tank by a pipeline with a 3" BSP shut off valve and gas pressure
relay. The portion is provided with one blanked oil film hole, dehydrating silica gel
breathers and dial type magnetic oil level gauge. The other portion is connected to
on load tap changer tank and compartment by a pipeline through 1" BSP shut off
valve and on a one inch drain valve with blanking plate and an oil level gauge for oil
level indication.
Rev. No. : 02, Oct. 2008

6.15 MARSHALLING BOX
An outdoor type marshalling box housing temp. Indicators, is mounted on the

transformer. Another cubicle housing auxiliaries of cooler control supply is mounted
separately near the transformer. The boxes are provided with a space heater, a hand
lamp and a three-pin plug socket each with a switch.
6.16 DRIVING MECHANISM BOX
An outdoor type of box housing drive motor and a few auxiliaries for OLTC are
mounted on the side of the transformer tank. This box is provided with a space
heater with automatic thermostat control and a manual switch.
7.0 COOLING SYSTEM
The transformer is provided with ONAN/ONAF cooling. The ONAN rating is 70% of
rating of the ONAF rating of transformer (i.e. 22/31.5 MVA).
7.1 RADIATORS
The cooler bank consists of detachable bolted flanged type of radiators connected to
one top and one bottom headers which in turn are connected to transformer main
tank by pipes, each radiator is provided with top and bottom shut off valves, air
release plug, drain plug.
7.2 FANS
Fifteen Nos. of fans are provide for air blast cooling. These are divided into five sub
groups, each sub group consisting of three fans. Two sub groups form a group.
Either or both of these groups can be started by manual operation by selection of
auto/manual selector switch. In auto mode, any or both groups function through
initiating contacts of winding temp. sensor. The contact of winding temp. indicator
(sensor) are set such that the all group (fifteen fans) of fans start when the temp. is
60 degree & all fans are stop to 55 oC.
8.0 PROTECTION INDICATION AND CONTROLS
8.1 BUCHOLZ RELAY
Hitachi make pitot relay is provided in place of bucholz relay. This is a two-stage gas
accumulation and pressure relay, which avoids erroneous action caused by self-
vibration of transformer or by vibration under earthquake conditions.
The first stage operates for slow gas accumulation and is wired to annunciation for
alarm in control room. The second stage operates on violent gas formation during
internal faults and this contact is wired to trip the transformer.
Rev. No. : 02, Oct. 2008

8.2 OLTC SURGE PROTECTION

The operation of this oil surge relay provided on the OLTC indicates fault of major
nature resulting in sudden oil surge into the relay. The contact of this relay is wired to
trip the transformer.
8.3 MAGNETIC OIL LEVEL GAUGE
Two magnetic type level gauge (one for main conservator and other for OLTC
conservator) having alarm contacts to indicate low oil level, are mounted on the
conservator. Operation of the gauge contacts gives an alarm in the control room.
8.4 OIL TEMPERATURE INDICATOR
A dial type thermometer measures the top oil temp. The indicator has two sets of
adjustable contacts. The lower setting is wired to give "oil temp high" alarm in the
control room. The higher setting is wired to give tripping signal to remove all 220 KV
and 6.6 KV power in-feeds to the transformer.
8.5 WINDING TEMPERATURE INDICATOR
A temp. sensitive element is enclosed in the thermometer, which is heated by a

current proportional to the load current (in B phase) of the transformer. The
thermometer bulb is located on the transformer top cover and measure the top oil
temp. This is combination with the above sensitive element measures a simulated
winding temp. The indicator has two sets of adjustable electrical contacts. The lower
setting is wired to "winding temp. high" alarm in control room. The highest setting is
wired to give a tripping signal which removes all 220 KV and 6.6 KV power in feeds
to the transformer.
8.6 FAN CONTROL AND FAILURE
Two sets of fan contacts on winding temp. indicator are used for fan control. Failure
of any group of fans to start when called for initiates a time delayed alarm in the
control room Each of the fan motors are provided with a thermal O/L protection and
each group of fans are protected by a common fuse.
8.7 ELECTRICAL PROTECTIONS
The start up transformer is provided with the following main and back up
protections. These are standard protections provided for transformers. These acts to
trip both HV and LV breakers.
-Differential protection
-HV side restricted earth fault protection.
-LV side restricted earth fault protection.
-Directional back up over current protection for phase and ground fault on HV
side.
-Non-directional back up over current protection on the LV side for phase and
ground faults, (connected to CT in the 6.6 KV switch gear.)
-Back up ground over current protection connected to LV neutral CT.
Rev. No. : 02, Oct. 2008
8.8 CURRENT TRANSFORMER FOR SUT PROTECTIONS
One 220 KV CT/phase has been provided in the 220 KV switchyard for start up
transformers. This CT has got five cores, one core for differential protection, second
core for back up protections, third core for metering, the fourth core for bus
differential protection. The fifth core is spare and kept shorted.
The transformer HV bushing is provided with two CT cores one of which is spare and
other is used for restricted earth fault protection of the LV side and other for LV back
up ground fault protection. The LV phase leads are also provided with one CT core
for restricted earth fault protection and the other core in (one phase only) is used for
wdg temp. indicator.
The CT cores on the LV side for transformer differential protection are located in the
6.6 KV SWGR cubicle.
The SUT HV terminals are connected to three (one per phase) lightning arrestors.
The arrestors are located adjacent to transformers and mounted on separate
structures. The arrestors are WS make and are provided with grading ring and
discharge counters. The major parameters are given below, In addition to these
lightning arrestors, the transformer bushings are provided with adjustable horn gap
where settings are adjustable between 1250 mm. Setting of 1400 mm is provided.
Parameters of lightning arrestors

Nominal discharge current 10 KA
Max. Impulse spark over voltage 550 KVP
9.0 NEUTRAL GROUNDING RESISTORS
Since the majority of faults in the LV system are single phase to ground faults, it is
desirable that the single phase to ground fault current is limited in magnitude to
reduce the damage on equipments. Hence single phase to ground fault current is
limited to about 1000 Amps. This resistor is rated for 1350 Amps. for 10 sec’s. and a
nominal voltage rating of 4 KV.
The grounding resistance box is of M/S. Pan India Traders, Calcutta make. The
resistor is made of heavy-duty cast iron alloy. The grid elements are assembled in
mica insulated tie rods in grid elements are assembled in mica insulated tie rods in
rigid steel frame work and grid blocks are interconnected by copper jumpers. The
structure is made of mild steel channels and angles in welded construction with
aluminum covers on all sides. The enclosure stands on porcelain insulations. The
terminals are brought out through outdoor porcelain bushing.
Rev. No. : 02, Oct. 2008

10.0 ANNUNCIATIONS
The following annunciations are provided in the main control room for SUT
WINDOW ANNUNCIATIONS
(1) An 351 SUT differential relay protection

trip.
(2) An 352 SUT gas collection
(3) An 419 Oil/wdg temp. high alarm
CRT ANNUNCIATIONS
(1) An 2287 SUT back up protection trip.

(2) An 2287 SUT TR/OLTC gas trip
(3) An 2359 SUT overload
(4) An 2291 SUT oil/wdg temp. very high
(5) An 2292 6.6 KV back up protection trip.
(6) An 2261 SUT cooler on standby supply.
(7) An 2289 SUT cooler bank failure.
(8) An 2414 SUT voltage regulator fail
LOCAL LAMP INDICATION
- Control supply for cooler 'ON'

- Group-1 fan motors 'ON'
12 TECHNICAL DATA
Manufacturer Transformer and Electricals Kerala LTD.

Standard IS-22026/1977
Construction 3 phase core type, outdoor type
Phase and frequency 3 phase, 50 Hz.
Winding insulation Graded for the HV & full for other windings
Rating 22/31.5 MVA ONAN/ONAF
Type Outdoor
Transformer ratio 220/6.9 KV at normal tap
Vector group Yodiyo
Impedance 9% on normal tap position on 31.5 MVA
Basic insulation level Power Test voltage Impulse test voltage
frequency (r. m. s.) (1.2/50 per sec)
HV winding 395 KV 900 KV
HV neutral 38 KV 95 KV
LV winding 22 KV 60 KV
Rev. No. : 02, Oct. 2008
Full load current 22 MVA (ONAN) 31.5

(ONAF)
HV 57.70 A 82.7 A
LV 1840 A 2640 A
Taps +12% to -12% in steps of 1.5% on HV side is
provided
with on load tap changer gear-type MK
Method of cooling ONAN/ONAF
Temp. Rise Not more than 45 degrees Celsius in oil and 50
degrees Celsius
by resistance of winding over max. ambient of 50
degree Celsius.
Cooling equipment (fans) Twelve fans
Max. flux density at rated 1.65 wb/sq. mt.
voltage.
Max. flux density at110% 1.82 wb./sq.mt.
voltage
Current density in LV winding 300 A/sq. cm.
Min. clearance 2750 mm phase to phase
2100 mm phase to ground
HV bushing 245 KV/400 A ;impulse withstand
1050 KV (P) total creep age 6100 mm
Protected creep age 2900 mm
LV bushing 17 KV/3150 A Impulse withstand 95 KPV
Minimum creepage 280 mm
Tertiary bushing 36 KV/630 A Impulse withstand 170 KPV

Vacuum withstand capacity 1.0 kg/sq. cm.
Percentage impendence
between
HV-LV 9%
MV-MV 10.5%
MV-LV 1.5%
Seismic withstand 0.5 g
weight
complete unit 90 tones
Core and winding 44 tones
Oil in transformer tank 22.384 tones (25, 150 ltr's.)
Rev. No. : 02, Oct. 2008

CHAPTER -7
UNIT TRANSFORMER
1.0 INTRODUCTION:
This Manual gives a description of the Unit Transformer, their parameter selection, cooling
systems, neutral grounding arrangement, protections, annunciations and control. The
following description given for NAPS-1 Unit Transformer (UT-1) is equally applicable for
NAPS-2 Unit Transformer (UT-2).
As per the existing practice for Nuclear Power Plants in India a dedicated Unit Transformer is
provided for each Unit.
The rating of the transformer is arrived on the basis of the normal loads on the Unit and
Station sections and also the total load the Unit Transformer UT) has to carry in case of
non-availability of the Start-up Transformer (SUT). Appendix-1 gives the connected and
operating loads of the Unit and Station sections. A summary of this appendix is listed below:
(a) Rating of UT specified : 22 / 31.5 MVA (ONAN / ONAF)

(b) Normal load on UT : 14 MVA
(c ) Load on UT when SUT is not : 34.8 MVA
available (including D20
upgrading plant load of 7 MVA)
At the time of ordering the UT, the D20 Upgrading Plant loads were not considered and hence
provision was not made for these loads. However, during single transformer conditions
the D20 plant loads have to be curtailed so that the total load does not exceed 31.5 MVA.
The ONAN rating of 22 MVA specified is about 70% of the ONAF rating which is the normal
range for such dual rated transformers.
The transformer is specified with a voltage ratio of 16.5/6.9 KV. The HV voltage corresponds
to the voltage at the turbo-generator output terminals. The LV voltage of 6.9 KV is the no
load voltage of the LV side. The on load voltage drop in the transformer will reduce the
terminal voltage to 6.6 KV with proper selection of the tap.
The vector group of 'DY1' is selected for matching 6.6 KV unit bus voltage with the 6.6 KV start-
up bus fed from the SUT.
The choice of percentage impedance for the transformer depends on the fault level obtainable
on the LV side and the voltage drops under full load conditions and motor starting
conditions. Percentage impedance of 9% limits the LV side fault level to 500 MVA and the
voltage drops to permissible levels. For further details on this, design manual for Basic
Electrical Systems (NAPP-50000) may be referred to.
Rev. No. : 02, Oct. 2008

The transformer is specified with an 'on load' tap changer to maintain a steady voltage at the
6.6 KV buses. This has a range of ±12% at 1.5% steps.
To restrict single phase to ground fault currents, in the LV system, to permissible values, a
neutral grounding resistor of 3 ohms value is connected in the LV neutral to earth
connection. The single phase to ground fault current is limited to about 1000A and is
considered adequate for discriminating ground fault protection of secondary circuits. The neutral
grounding resistor has a current rating of 1350A for 10 seconds.
The transformer is connected by 1000A isolated phase bus ducts on the HV side.
These bus ducts are tap-offs from the 1000A bus ducts emanating from the generator
terminals.
A nominal rating of 1000A was specified for tap-off bus duct considering rating of 25 MVA for
Unit Transformer, as in MAPP. However, after finalising the rating of UT as 31.5 MVA, the
bus-duct sizes were checked during vendor drawing review and temperature rises were found
to be below the allowable limits (85 deg. C for bus bar and 65 deg. C for enclosure) for a
continuous current of 1300 A.
The LV side is connected to the 6.6 KV switchgear by cables. These are 4 Nos. of 1000 sq.
mm Aluminium Conductor XLPE Cables per phase.
A soak pit is provided around each transformer foundations for collecting oil from the transformer
in the event of any untoward explosion to prevent fire accidents. A common underground burnt-
oil RCC tank is provided for both the UT and the GT. The soak pit has a capacity for about
1/3 oil content of the transformer (including radiators) and the burnt oil pit.
The Unit Transformer is specified to withstand an earthquake of 0.5g acceleration.The

following drawings may be referred to for the connection of the UT in the main output system:
(a) NAPP-1,2 / 50000 / 6001 / ED Key One line diagram

(b) NAPP-1,2 / 52411 / 6002 / ED 6.6 KV Switchgear One line diagram.
2.0 STANDARDS APPLICABLE:
(1) Power transformer IS - 2026 (1977)

(2) Fittings and Accessories IS - 3639
(3) High Voltage Porcelain Bushings IS -2099 (1973)
(4) Insulating oil for Transformers and Switchgear IS - 335
(5) Guide for loading of oil immersed transformers IS - 6600
(6) Neutral Grounding resistors IEEE - 32
Rev. No. : 02, Oct. 2008

3.0 INSTALLATION:
3.1 Transformer and Accessories:
One Unit Transformer per generating set is installed just outside the Turbine Building on
the western side between grids 9 and 10 for OT-1 and 23 and 24 for UT-2.
The transformers are installed on rails on RCC foundations. The transformer wheel bases
are anchored to the foundation by clamps to prevent movement of the transformer when it is
in service. The wheels are bi-directional (rollers) and can move on a broad gauge rail track
of 1676 mm.
To move the transformer into the maintenance bay the radiator and conservator
connections to the tank are isolated; the HV and LV terminations removed and then with
the help of the haulage holes (on the jacking lugs) the transformer can be moved on the rails.
The rails have a 4 way 'turn around' at which the roller orientation can be changed to move
the transformer into the Turbine Building maintenance bay.
The radiator banks with the conservator (which is mounted above it) are located to the North
of the transformer tank. This is supported by an 'A' frame of MS channels. This frame is
welded on to MS pads which in turn are anchored on to RCC foundations.
The cable boxes for the LV side are supported by channels which are welded to MS pads
anchored to the ground on RCC foundations. Separate supports have been provided for the
LV phase terminals cable box and the LV neutral terminal cable box. The LV cable box is
located just above the trench which takes the cables to the 6.6 KV switchgear room.
The marshalling kiosk for the transformer is mounted on the transformer along with
the OLTC drive.
The neutral grounding resistor is mounted at a raised elevation near the northern side wall.
3.2 Soak Pit:
A soak pit is provided around the transformer for collecting oil emerging from the
transformer in case of fire. A 200 NB pipe with a perforated intake is used to transfer the
collected oil from the soak pit to the burnt oil collection pit. Two such pipes are present; one
starting from the transformer tank region and the other from the radiator bank area. The burnt
oil pit is a common one for both the Unit Transformer and the Generator Transformer.
3.3 Reference Drawings:
The following drawings may be referred in connection with the layout of the transformer.
NAPP-l / 22000 / 7001 / GA
NAPP-1 / 22000 / 7002 / GA
NAPP-l /29720 / 7078 / DD
NAPP-l / 29720 / 7079 / DD
Rev. No. : 02, Oct. 2008

4.0 RATINGS:
The main parameters of the transformer are given below. Further details are covered in
the technical data given at the end.
(a) Rating of Transformer : 22 / 31.5 MVA (ONAN / ONAF)
(b) Type : Outdoor, 3 phase, core type
(c) Rated voltage : 16.5 / 6.9 KV
(d) Rated frequency : 50 Cycles / Sec
(e) Winding connection : DY 1
(f) Percentage impedence (HV-LV) 9%
(g) Basic insulation level : 125 KVP
(h) Winding temperature rise : Not to exceed 50 Deg. C over 50 Deg. C

Ambient.
(i) Standard : IS – 2026 (1977)
5.0 CONSTRUCTIONAL FEATURES:
5.1 Core:
The transformer is three phase core type. The core is made of Cold Rolled Grain
Oriented Silicon Steel laminations of law loss grade. It has three limbed Stepped
construction. The core laminations are 45 Deg. mitred and interleaved to avoid local
heats and reduce losses. The core limbs are bound by bonded glass tapes.
5.2 Windings:
5.2.1 HV & LV Winding:
LV Winding is star connected and is provided with uniform insulation to earth. The neutral of
the LV winding is brought out through a separate bushing to a cable sealing box for
connecting to the neutral grounding resistor.
HV winding is delta connected and consists of two parallel paths. The windings are provided
with uniform insulation.In each parallel winding there are eight tap positions which
are combined suitably by tap changer to obtain a total tapping range of 17 positions
to give + 12% variation at 1.5% intervals.
Rev. No. : 02, Oct. 2008

5.2.2 HV Phase Terminations:
HV windings are terminated on to 3 NOS. 36 KV 2000A oil filled bushings provided on the
transformers top cover. The mounting arrangement incorporates a flange plate for terminating
the 16.5 KV bus duct at the transformer.
5.2.3 LV Phase Terminations:
The LV phase terminals are brought out through three numbers 11 KV, 3000A
bushings to the oil filled disconnecting chamber. This chamber houses the flexible
connections for disconnection and also current transformers. The LV connections
are brought out the disconnecting chamber through 17.5 KV / 3150 ampere
bushings. The LV box provides connection of 4 Nos. 1000 sq. mm, Al, XLPE cables
per phase through cable sealing ends. 11 KV class oil filled sealings are supplied by
transformer manufacturer for the termination of PILC cables. An earthing pad of non-
magnetic stainless steel is provided for earthing the LV cable box.
5.2.4 LV Neutral termination
The LV neutral terminal is also brought out to the LV neutral cable box in a similar
manner through a disconnecting chamber arrangement. The LV cable box provides
for connection of one 400 sq. mm AL Core PVC cable for connection to the neutral
grounding resistors. An earthing pad similar to that on the LV phase cable box is
also provided.
5.2.5 Current transformers:
Following current transformers are provided on the LV side:
(a) One current transformer per phase of ratio

3000/1A, Kneepoint voltage greater than 600V
and resistance of CT less than 12, excitation
current at 300V not more than 25 milli-amperes
(for restricted earth fault protection).
(b) One current transformer in the neutral lead of same parameters as above
(for restricted earth fault protection).
(c) One current transformer in the neutral lead of 100/1A ratio, 30 VA, 5P20
(for back-up ground fault protection).
(d) One current transformer ( on 'W’ phase ) ratio 2635/5A. 10VA, class 5.0,
for feeding line drop compensator. (An interposing CT of 5/0.5A is
provided in the main output system panels for LDC).
Rev. No. : 02, Oct. 2008

The following CTs are provided on the HV side of the transformer:
(a) One set of two nos. 700/5A, 20VA, 5P10 CTs are provided in the 'U’
phase windings for over-current protection of OLTC.
(b) One CT of 636/2.65, 2.8, 2.9A, 10 VA class 5 for feeding Winding

Temperature Indicator.
5.3 Tank:
The tank is of rectangular shaped construction. It is provided with an oil tight

bolted flanged joint near the top. The top cover can be lifted off after removal of
bushings and disconnection of few pipes, conduits etc. Inspection roan-holes are
provided on the top cover and on sides for access to bushing connections.
However, for any work on the core and coils, the core-coil assembly has to be
lifted off from the tank. The tank without radiators is designed to withstand full
vacuum. The transformer is installed on rails on RCC foundations and has its
wheel base anchored to the foundation to prevent movement while in service.
5.4 Base:
The transformer base is fitted with four bidirectional flanged roller assemblies.
Rail gauge is 1676 mm.
5.5 Lifting hooks and Jacking Pads:
Four lifting hooks (bollards) and four jacking pads suitable for lifting the entire
tank with the core-coil assembly and oil are provided. Pulling 'eyes' are present
on these jacking lugs / pads for moving the transformer on rollers.
5.6 Valves:
The following valves are present:

(a) One no. conservator drain valve with blanking plate (25 mm flanged).
(b) 3 Nos. shut off valves for OLTC pipe connection (25 mm flanged ).
(c) One No. drain valve for OLTC compartment (25 mm flanged).
(d) 2 Nos. shutoff valves on either side of Buchholz relay (80 mm
flanged).
(e) One tank drain valve with blanking plate (80 mm flanged).
(f) One top filter valve with blanking plate (50 mm flanged).
(g) One bottom filter valve with blanking plate (50 mm flanged).
(h) One top sampling valve with blanking plate and sealing plug (25 mm
flanged).
(i) One bottom sampling valve with blanking plate and sealing plug (25 mm
flanged).
Rev. No. : 02, Oct. 2008
(j) One no. filter cum drain valve on the top and bottom header of the
radiator bank (50 ram flanged).
(k) One drain valve for the LV cable box disconnecting chamber (25 mm
flanged).
(l) One shut off valve on the connection (oil) pipe to the LV disconnection
chamber (25 mm flanged).
(m) One shut off valve on the pipe connecting the radiator top header and the
tank (top cover) (50 mm flanged).
5.7 Earthing Terminals:
Two earthing pads are provided on the transformer tank. These are 80 x 80 x 12 mm
thick and are of non-magnetic stainless steel (AMSI-316). They are connected to the
station grounding grid by 4/0 AWG stranded tinned copper conductor.
5.8 Explosion Vent:
One explosion vent is provided from the top of the transformer tank. A separate
breather is also provided for this explosion vent.
5.9 Conservator:
The conservator is mounted over the header of the oil cooler bank. The conservator
is partitioned and has a common air column inside the conservator tank. The bigger
of the two partitions is connected to the transformer tank through the Buchholz relay
with 80 mm flanged shut-off valves on either side. This portion is also provided with
one blanked oil filling pipe and a drain valve with a blanking plate, a dehydrating
silica gel breather and a magnetic oil level guage.
The other smaller partition is connected to the OLTC compartment by a pipe line
with a pressure surge relay. This portion also has a blanked oil filling plug with a
drain valve and a magnetic oil guage for oil level indication.
6.0 COOLING SYSTEM:
6. 1 Radiators:
The cooler bank consists of 12 nos. radiators connected to one top and one
bottom header which are in turn connected to the transformer main tank by pipes.
Each radiator is provided with bottom shut off valves between header and radiator,
air release plug and drain plug. Each header is provided with an air release plug, thermometer
pocket and a filter cum drain valve. The pipe connections from headers to the transformers are
provided with shutoff valves.
6.2 Fans:
4 Nos. fans mounted below the radiators and supported from radiator support structure
provides air blast cooling. Three fans are adequate for the full rating of the transformer and the
Rev. No. : 02, Oct. 2008
fourth one is provided as standby. The fans can be started either manually or automatically
through the initiating contacts of the winding temperature indicator. In automatic mode the
standby fan will start automatically with a time delay when any one of the first three fans fails to
start.
6.3 Operation of Cooler Control:
(Ref. M/s Crompton Greaves Drg. No. T31B1054F)
(NAPP / 52210/ 2504 / ED)
Four fans each of 1.4 KW are provided for cooling the transformer, when required.
The fan control can be selected through control switch 'FCS' (Auto / Off / On). In 'On'
position all the four fans are switched on through contactors FSTR-1 to 4. In ‘Auto'
mode the fan switching is initiated through the contact ‘WTC’ of winding temperature
indicator. In this mode, when ‘WTC’ closes, three fans are switched on. The fourth
fan is a stand-by and is through a time delay relay TDR.
The power supply to the cooler fans is duplicated and on failure of the main supply,
the standby supply is switched in automatically. When the main supply fails, the
contactor SC-A and timer TDR-A connected to the main supply through a control
transformer drop-off. The 'NC contact of SC-A energises timer 'TDK-B' and contactor
SC-B in the standby circuit and the standby supply is thus brought in. The timers
'TDR-A' and 'TDR-B' are provided to ensure that when the supplies are switched on,
the supply to which the timer with a lower time delay is connected switches in first
through its contactor. The contactor de-energises the timer in the second circuit and
thus prevents the contactor of the second-circuit from closing. With proper time
settings on these timers, any of the suppliers can be made as the main supply and
the other as standby.
7.0 TAP CHANGING GEAR:
In NAPS-1, On load tap changer (OLTC, type – 2X VIII 350 D, M/S Easun – MR
make) is provided for the Unit Transformer. In NAPS-2, On load tap changer (OLTC,
type – CIII 350 D, M/S Easun – MR make) is provided for the Unit Transformer.
There are two sets of tap changers for parallel paths of the HV winding. These are
contained inside the transformer tank. The active switching part of the tap changer is
contained in a cylinder and is enclosed by an outer cylinder. Thus the oil in the tap
changer is different from oil in the transformer tank. The connection from the
transformer taps are taken to steps in the outer cylinder. OLTC has the following
parameters:
Step Voltage 1400 Volts

Tapping Range (+)12% to (-)12%
Total no of steps 16 steps
Total no of positions 17 positions
Rev. No. : 02, Oct. 2008

7.1 Controls for OLTC:

The tap changing gear is provided with the following controls:
(a) Manual mechanical control.
(b) Local electrical control.
(c) Remote electrical hand control.
(d) Remote electrical auto control through AVR relay.
The local manual control effected by means of a detachable hand crank which cuts
off all other controls. The control schematics for local and remote controls and auto
controls through the AVR are given in Drawing No. N-1,2/65130/6008/ED and
NAPP/52210/2505/ED. Following accessories are provided in the Main control room
(6610-PL-2) for the purpose of remote control:
(a) "Local-Remote” selector switch

(b) "Manual-Auto” selector switch
(c) Hand switch for 'Raise-Lower' operation
(d) Reset push button
For remote hand control the selector switch 'Local - Remote' must be in remote
position, and the 'Manual-Auto' switch in the manual position. The raise lower switch
will then accomplish necessary operation. For remote auto control the selector
switch should be in 'auto' position and the 'Local-Remote' selector switch should be
in remote position. The contacts of voltage regulating relay will accomplish the
necessary tap changing automatically.
7.2 Control Operation:
A brief description of the control operation is given below :
7.2.1 Local Electrical Control:
NAPS-1 OLTC
1) Selector switch 'remote-local' (HS-7069) in 'local' position energises ‘3C1'

relay.
2) ‘C3’ Coil energises through b9 (Mechanically operated cam/steping switch).
3) Operation of local push button ‘bl' energises contactor 'C1'.
4) C1 closes the motor supply circuit. The motor runs clockwise.
5) After 33 revolutions, b9 changes the position. C3 & C1 coil de-energises and C4 coil
becomes active. After reaching Upper limit , Contact of Limit switch b6 (C3 circuit) also
opens.
6) Contact 'C1' drops out and opens motor circuit.
7) In emergency condition, press local emergency push button (LEPB), SRC coil will
become active and open power circuit of motor through MPR (a1).
This completes one step-raise operation in the tap position. Contactor 'C1' and Contactor 'C2'
have interlocks so that simultaneous lower operation is not possible.
Rev. No. : 02, Oct. 2008

The lowering operation is similar except for the initiation is through push button 'b2'
which emergises contactor C2.
NAPS-2 OLTC
1) Selector switch 'remote-local' (HS-7069) in 'local' position energises ‘3C1' relay.

2) Operation of local push button ‘bl' energises contactor 'C1' through contact 3C1
and *NC contacts b2 and 'dl7' relays. 'CI' contactor seals itself through 'NC
contact (71-72) of 'dl7' "No' contact of ‘b8' (handle interlock) and ‘No' contact of
circuit breaker ‘al’.
3) C1 prepares motor supply circuit and also energises break contactor ‘C3'. This is
in turn removes the short on motor terminals and closes the supply circuit. The
motor runs clockwise.
4) Direction memory cam switch ‘b14' closes its contact to provide second sealing path for
contact 'C1'.
5) Cam switch ‘b13' closes its contact 'b13' in 'd17' relay circuit.
6)Auxiliary contactor 'd17' is energized and opens the circuit of push button of 'b1' and also sealing
circuit of CI contactor. Now ‘C1’ is sealed through ‘b14’ contact only.
7) Relay 'd17' seals itself through its own contact and contact (43-44) of 'C3' contactor.
8) Cam switch 'b13' now opens it contact 'b13'.
9) Direction memory switch 'bl4' also opens, removing seal in circuit of 'C1' contactor.
10) Contact 'C1' drops out, opens motor circuit, de-energises 'C3' and also removes its self-
seal-circuit.
11) Contactor 'C3' drops out, opens motor circuit and short circuits its terminals. The motor
is stopped. 'C3' also breaks seal in circuit of 'd17' and de-energises it.
12) This complete operation of one step-raise in the tap position. Push button 'b1' and contactor
'C1' have interlocks with contactor 'C2' circuit so that simultaneous lower operation is not
possible.
13) The lowering operation is similar except for different direction memory cam switch
"b12'.
14) The initiation is through push button 'b2' which emergises contactor C2.
7.2.2 Remote Control:

The selector switch HS-7069 (in control panel 6610-PL-2) in remote position
transfers the control to the control room. In this position, the OLTC can be made
to work in auto/manual modes through selector switch HS-7068 (6610-PL-2).
When HS-7068 is kept in 'Manual’, position the raising and lowering of the taps is
done through control switch H5-7067 (6610-PL-2), which energises auxiliary
relays 3C3 in raise position and 3C4 in 'lower' position. The contacts of these
relays initiate contactors C1 and C2 of the OLTC control and further operation of
the control is similar to (8.2.1) above.
With selector switch HS-7069 in 'Auto' position, auxiliary relay 3C2 is energised.
The contact of this relay initiates the control through voltage regulating relay
(VRR) which in turn initiates contactors C1 or C2 based on voltage condition.
Further operation is similar to (8.2.1) above.
Rev. No. : 02, Oct. 2008

Limit switches 'b6' and 'b7' ensure that motor is stopped at end positions of tap
changing. The circuit has also provision for tripping of breaker 'al' through remote
reset push button via relay '3C5' and interlocks to trip breaker 'al' through its trip coil
in case motor runs in opposite direction to that of intended operation (due to phase
reversal at its terminals).
Interruption of control supply does not reset the controls and the operation will
continue in the intended direction when control supply is restored.
An overcurrent relay 'OCR' is provided to prevent tap changing when transformer

current is in excess of rated current. A line drop compensator (LDC) is also provided
to correct for the voltage drop in the line.
7.3 Driving Mechanism box for OLTC:
An outdoor type box housing the drive motor (MA 2 Drive mechanism) and a few
auxiliaries for the OLTC gear is mounted on the side of the transformer tank. This
box is provided with a door switch operated lamp and a space heater with thermostat
control.
The DM box housing the Tap change Drive motor & associated gear with contactors
shall in addition to normal equipments required for its operation include the following:
a) A five digit counter to include the no. of operations completed by the OLTC.
b) Motor protection relay and protection for motor control circuits.
c) Potentiometer for remote tap position indicator.
Motor voltage – 415V, 50 HZ, 3 ph
8.0 MARSHALLING BOX:
An outdoor type marshalling box housing the temperature indicators and power and
control circuits for the transformer cooling fans is mounted on the transformer on the
side opposite to the LV cable boxes.
Doors are present on both sides and each door has handle operated latches with a
facility for padlocking in the closed position. The box has a degree of protection IP-
54. The box is provided with a space-heater with thermostat control.
9.0 PROTECTIONS AND INDICATIONS:
9.1 Buchholz relay:
A special buccholz relay type SOS-DR is provided for the transformer. It is provided
with 'Dry reed' switches instead of the traditional mercury switches which are liable
for mal-operation in case of earth quake tremors.
The relay comprises mainly an oil-tight bronze cast housing which contains the alarm
and tripping devices consisting of two floats hinged on a frame, one in the upper part
and one fitted with a flap in the lower part.
Rev. No. : 02, Oct. 2008
The upper alarm float is provided with a permanent magnet, the corresponding dry
reed switch is fixed to the frame in such a position that when relay is oil filled, the
switch is not affected by the magnetic field. The lower (trip) float is equipped in a
similar manner.
In the event of a slight incipient fault in the transformer small bubbles of gas are
generated in the fault aone and these while passing in the oil pipe towards the
conservator are trapped in the relay housing, thus causing its oil level to fall. As a
result, the upper (alarm) float rotates on its hinges the permanent magnet fitted on
the float approaches the corresponding switch and the reed contacts close to give
alarm annunciation.
In the event of a serious fault in the transformer the development of gas is violent
and the oil displaced by the gas rushes through the pipe to the conservator. In the
relay this surge impinges on the flap fitted on the lower float and causes rotation of
the float itself. The permanent magnet mounted on this float approaches the
corresponding reed switch and closes its contacts to trip the transformer.
9.2 Oil surge relay for OLTC:
The oil surge relay for 'OLTC is supplied by manufacturer of OLTC (MR Make).
The surge relay housing consists of corrosion proof light metal alloy and is provided
with 2 flanges for connecting pipes leading to tap changer and oil conservator. The
relay drive element consists of the flap valve with attached permanent magnet. The
magnet actuates the reed contact and serves for fixing the flap valve in position -
"Transformer in service". An intermediate position of the flap is not possible. The
protective relay is energised by oil flow from tap changer head to the conservator
only. The oil flow operates the flap valve being tripped into 'OFF' position. The reed
contact is
actuated, to trip the transformer. The protective relay is not energized with the tap
changer subjected to nominal load.
9.3 Magnetic oil level gauge:
Magnetic type oil level gauge having alarm contacts to indicate low level are
mounted on the compartments of conservator for main transformer and for 'OLTC’.
The operating principle is briefly as follows:
The movement of a float due to rise or fall in oil level is basically used. This
movement is transmitted to the driving magnet of a magnetic coupling (main
coupling). The follower magnet of this coupling is kept outside the conservator, there
being a metal wall between two magnets. The follower magnet of the main coupling
rotates the cam shaft which operates a switch and the magnet of secondary coupling
which moves the pointer on the dial.
Rev. No. : 02, Oct. 2008

9.4 Oil Temperature Indicator:
A dial type thermometer measures the top oil temperature. The indicator has
two adjustable contacts. The lower setting initiates alarm and the higher setting
initiates tripping of the transformer. The operating principle of "Accurate Controls
Ltd." model A131 is briefly as follows:
The operating mechanism consists of a liquid filled bellows, capillary tube of required
length and sensing element or bulb. This system is thermally balanced by
compensating bellows and a second capillary which terminates at the head of the
bulb. The two bellows are linked together via a lever in such a manner that
temperature changes on the capillary line or head are automatically compensated
for. The temperature changes on the bulb motivates the operating bellows only,
which is linked to the single rotating-switch-platform to which the indicating pointer is
attached.
9.5 Winding temperature indicator:
A temperature sensitive element (a heater coil around an operating bellow) of a

vapour pressure, dial type thermometer (Model A131 of "Accurate Controls Ltd.") is
heated by current proportional to the load current, of the transformer. The
thermometer bulb is located in a pocket on the transformer top cover and measures
top oil temperature. This combination with above sensitive element measures a
simulated winding temperature. The temperature compensation arrangement is
similar to that of oil temperature indicator. The WTI has 3 sets of contacts, one for
starting the cooler fans, the other for alarm indicators and the third for trip signal.
9.6 Restricted earth fault protection:
A restricted earth fault protection is provided for the secondary winding of the
transformer from 3000/1A CTS provided on the LV phase and neutral leads. The
relay is located in the unit transformer protection panel located in the control
equipment room. The operation of this protection trips the unit (GT breaker, Gen.
field breaker, turbine and UT breaker).
9.7 Back-up ground oyer current protection:
Back up ground over current protection for the LV side is connected to 100/1A CT in
the LV neutral. A long inverse time over current relay mounted in the unit transformer
protection panel operates to trip the unit.
9.8 Back-up phase fault protections:
IDMT over current relays are provided on the 6.6 KV incoming switchgear for backup
over current protection for external faults in the LV side. This protection operates to
trip the transformer LV breaker.Similar IDMT over current relays on the HV side
connected to bus duct mounted CTs, operate to trip the unit in case of uncleared
transformer faults.
Rev. No. : 02, Oct. 2008

9.9 Transformer differential protection:
The transformer is provided with high speed, harmonic restrained, percentage

biased differential protection for all internal phase to phase faults. CTs for this are
located in the bus duct on the HV side and 6.6 KV switchgear on the LV side. This
protection operates to trip the unit.
10.0 NEUTRAL GROUNDING RESISTOR:
Since the majority of faults in the LV system are likely to be of single phase ground, it
is desirable that the single phase to ground fault current is limited in magnitude to
reduce damage on equipments. Hence the single phase to ground fault current is
limited to about 1000 A by connecting a 3 ohms resistor to the neutral grounding
circuit. This resistor is rated for 1350 A for 10 seconds and a nominal voltage rating
of 4.0 V.
The grounding resistance box is supplied by M/s. Pan Indian Traders, Calcutta and a
brief description of the box is as follows:
The resistor elements are made of heavy duty iron alloy. The grid elements are
assembled in mica insulated tie rods in rigid steel frame work and grid slacks are
interconnected by copper jumpers. The structure is made of mild steel channels and
angles of adequate strength in welded construction with aluminum cover on all sides.
The enclosure will stand on porcelain insulators. The terminals are brought out
through outdoor porcelain bushing.
11.0 CONTROL ROOM CONTROLS & INDICATIONS:
Control switches for remote operation and indications (i.e. annunciations) pertaining
to the Unit transformer are mounted on the main control room panel 6610-PL-2.
11.1 Control switches and lamp indications:
a) HS - 7199 : 4 Position discrepancy switch with built in lamp for

control of 6.6 KV UT breaker 5241-CB-16.
b) LT-7013 : White indicating lamp for 5241-CB-16 synchronising.
c) PB(L)7013 : Lockable push button for 5241-CB -16 synchronising.
d) HS-7201 : Three position (UT / SUT / AUTO) stay put type hand
switch for control of SUT, UT, Bus-section and Tie-
breaker controls.
e) LT-7042 : Indicating lamp (white) for OLTC tap.
f) LT-7043 : Indicating lamp (amber) for OLTC overload relay
operation.
g) HS-7067 : Three position spring return-to- normal type hand
switch for OLTC "Raise-Lower" operation.
h) HS-7068 : Two position stay put type hand switch for OLTC
auto-manual operation selection.
Rev. No. : 02, Oct. 2008
i) HS-7069 : Two position stay put type hand switch for OLTC
local-remote operation selection.
j) PB-7043 : Remote emergency push button for OLTC trip.
11.2 Meters and Indicators:
a) AM-11 : (65241-BU-E-AM-11)
(0-3000A) 6.6 KV side ammeter for UT.
b) VM-22 : (65241-BU-E-VM-22)
(0-4.5-9.0 KV) 6.6 KV side voltmeter for UT.
c) WM-11 : (65241-BU-E-WM-11)
(0-30 MW) Bus wattmeter for UT.
d) TP2 : (522-TP2-UT-1)
Circular type OLTC tap position indicator.
e) CRC POINT 754: : Control room computer (analog input)
(0-30 MVAR) display for 65231-BU-E-VAR.
(LINEAR)
11.3 Annunciations:
A: Window Annunciations:
1) AN-347 : 522-UT-1 GAS COLLECTION

2) AN-348 : 522-UT-1 OIL/WDG TEMP HIGH
3) AN-349 : 522-UT-l DIFF/REF PROT TRIP
4) AN-350 : 522-UT-l BACK UP PROT TRIP
B: CRC Annunciations:
1) AN-2280 : 522-UT-l TRANSFORMER / OLTC

OIL LEVEL LOW
2) AN-2281 : 522-UT-l COOLER BANK FAILURE
3) AN-2282 : 522-UT-l OIL / WDG TEMP VERY HIGH TRIP
4) AN-2284 : 522-UT-l TRANSFORMER / OLTC GAS TRIP
5) AN-2295 : 522-UT-l COOLER CONTROL SUPPLY FAIL
6) AN-2286 : 522-UT-l COOLER ON STANDBY SUPPLY
7) AN-2336 : 522-UT-l 6.6 KV BACKUP PROT TRIP
8) AN-2337 : 522-UT-l OVERLOAD
12.0 Local Lamp Indicators:
(Located in Marshalling box)

a) Signal lamp (red) for control supply healthy.
b) Signal lamps (4 Nos.) for cooling fans ( 1 to 4 ) running.
Rev. No. : 02, Oct. 2008

12.0 TECHNICAL DATA:
1 Manufacturer : M/s. Crompton Greaves

Ltd.
2 Standard : IS 2026
3 Type of construction : Core type
4 Full load rating : 31.5 MVA
5 Rating assigned to various methods
of cooling.
ONAN : 22 MVA
ONAF : 31.5 MVA
6 No. of phases, rated frequency : 3 phase, 50 Hz
7 Rated voltage
a) HV : 16.5 KV
b) LV : 6.9 KV
8 Vector group : DY1
9 Rated percentage impedance : 9%
10 Basic Insulation level.
(1.2/50 micro second)
a) HV Winding : 125 KV peak
b) LV Winding : 60 KV peak
11 Power frequency withstand dry and
wet.
a) HV : 50 KV rms
b) LV : 22 KV rms
12 Maximum temperature rise over
ambient temp.
(Max.50 Degree C)
a) Oil (by thermometer) : 45 Degree C
b) Winding (by resistance) : 55 Degree C
13 Losses:
a) Load loss at rated current : 140.0 KW
b) No load loss at rated voltage & : 17.0 KW
frequency
c) Cooler losses at full load : 4.4 KW
14 Approx. magnetising current at rated
voltage and frequency.
a) When excited from LV side at : 0.5 %
100% voltage
b) When excited from LV side at : 1.6%
110% voltage
Rev. No. : 02, Oct. 2008

c) When excited from HV side at : 1.67%

110% rated voltage
15 Approx. maximum flux density

a) At rated voltage : 1.65 wb/M sq.
b) At 110% rated voltage : 1.81 wb/M sq.
16 Full load current
a) HV : 1102.2A
b) LV : 2635.73A
17 Approx. current density of HV & LV : 250 A/cm sq.
winding
18 Weights
a) Complete transformer including oil : 57.70 tonnes
b) Cooling plant including oil : 6.37 tonnes
c) Each OLTC with oil in diverter : 0.60 tonnes
switch
19 Oil quantities
a) Transformer (total) : 15700 litres
b) Cooling plant : 2140 litres
c) OLTC diverter switch (each) : 195 litres
20 Neutral Grounding Resistor
i Manufacturer : M/s. Pan Indian Traders
Calcutta.
ii Material of resistance : Heavy duty cast iron
iii Standards : IEEE-32
iv Ohmic value : 3 at 45 Degree C
v Tolerance on ohmic value : + 5%
vi Voltage rating : 4.0 KV
vii Current rating : 1350 A for 10 sec
viii Temperature rise for short time : 210 Degree C above
rating. ambient.
ix Terminal bushing
a) Rated voltage : 6.6 KV
b) Creepage distance : 200 mm
x Stand of insulator : Porcelain
a) Rated voltage : 6.6 KV
b) Cantilever strength : 300 kgf
Rev. No. : 02, Oct. 2008

14.0 REFERENCE DRAWINGS:
14.1 Vendor Drawings:
Sr. TITLE DRAWING NO.

No.
1. Layout of unit transformer. : T61B78888L
(NAPP/52210/2501/GA)
2. Foundation details. : T63B1151H
(NAPP/52210/2502/GA)
3. Foundation bolts. : T63B1231E
(NAPP/52210/2511/DD)
4. Assembly of 17.5 KV 3150 Amp : T52B576Q
bushing. (NAPP/52210/2520/GA)
5. Assembly of 11 KV 3000 Amp : T52B568Q
bushing. (NAPP/52210/2513/GA)
6. HT vertical indoor sealing and up to : T63B1361Q
1000 sq mm. (NAPP/52210/2521/GA)
7. Assembly of 36 KV 2000 Amp. : SK348 (NAPP/52210/2506/GA)
bushings.
8. Assembly of LV cable box with : T60B405H
disconnecting chamber. (NAPP/52210/2515/GA)
9. Schematic diagrams of transformer : T31B1054F
cooler control. (NAPP/52210/2504/ED)
10. Diagram plate : T62B775H
(NAPP/52210/2510/GA)
11. Name plate : T62B774H
(NAPP/52210/2509/GA)
12. General arrangement of marshalling : T34B717H
box. (NAPP/52210/2516/GA)
13. Schematic diagram for hand, auto, : T31B10503F
remote control of tap changer. (NAPP/52210/2505/ED)
14. Layout of bus ducts and auxiliary : 379/30010 of
equipment M/s Best & Crompton
(NAPP/51130/2513/GA)
15. Assembly of LV neutral cable box : T-60B406-H
with disconnecting chamber. (NAPP/52210/2514/GA)
16. Wiring diagram of marshalling box. : T-3181134-F
(NAPP/52210/2517/ED)
Rev. No. : 02, Oct. 2008

17. Assembly of conservator and : T-63B1379-Q

radiator with header. (NAPP/5:210/2519/GA)
18. Operation and maintenance manual :
of 31.5 MVA ONAN / ONAF
transformer.
19. OLTC Dimensions Drg. : R1200/8939569E*
20. OLTC Designation and survey : R1210/1*

of Tap Changer
21. OLTC – Phase diagram : N1940*
22. GA of MA2 Drive Mechanism : 1-80-081*
23. Bevel gear : D10-014*

24. Protective Relay RS-2001 : B21-000*
25. Coupling of OLTC and drive : B25-565*
26. Drive shaft arrangement : G5241*
27. Schematic Daigram of MA2 : 4-71-560 sht-1*

Drive mechanism
28. Proximity Switch and : 4-71-560 sht-1*
Indication
* These drawings are applicable for NAPS-1 only.
15.2 CONTROL SCHEMATICS:
1. 220 KV GT-1 Breaker 513-CB- : NAPP-l/65130/6008/ED

2 and UT-1 OLTC control.
2. 220 KV GT-2 Breaker 513-CB- : NAPP-2/65130/6008/ED
9 and UT-2 OLTC control.
3. Unit transformer breaker 5241- : NAPP-1,2/65241/6004/ED
CB-16 48 V DC Control.
4. NAPP-412-G1, 512-GT-l and : M/s. Asea drawing XIN 7210 3021-1
522-UT-l protection. (NAPP/65100/2964/ED XIN 7210
3021-2 (NAPP/65100 /2985/ED (for
unit-2 ).
Rev. No. : 02, Oct. 2008

14.3 DESIGN MANUALS:
1. Design manual for Electrical system. : NAPP-50000
2. Design manual for main output system : NAPP-65100

protection.
3. Design manual for 6.6 KV system. : NAPP-52410
4. Design manual for 22KV isolated phase bus : NAPP-51130

ducts.
5. Operation & Maintenance Manual on : B21-000*
type VIII 350 D OLTC
* Applicable for NAPS-1 only.
14.4 RELAY SETTINGS:
1. 6.6 KV switchgear unit : NAPP-1.2.65000/6016/SCH

transformer protective relay
settings.
2. Protective relay settings for : NAPP-1,2/65000/6022/SCH
Generator GT and UT (on
220KV side).
Rev. No. : 02, Oct. 2008

CHAPTER - 8
DIESEL GENERATOR SETS
(52314)
1.0 This chapter covers the details, controls, indications and protections provided for the
standby power diesel generator sets for Narora Atomic Power Station Center Units 1
and 2.
2.0 SYSTEM DESCRIPTION
The auxiliary power supply is shown in the key one line diagram NAPP-1,
2/50.000.6001/ED that may be referred to for details.
Each unit of the Narora Atomic Power Plant is provided with three standby diesel
generators of 1450 KW rating. DG-1 is connected to the 415V class III bus 5231-
BU-P and DG-2 is connected the 415 V class III bus 5231-BU-Q. Third diesel DG-3
can be connected to either 5231-BU-P or 5231-BU-Q at a time through 5231-CB -70
and 5231 CB-5 or 5231-CB-6 respectively. These bus bars are normally fed from 6.6
KV class IV supply system through two 2000 KVA, 6.6 KV/433V auxiliary
transformers one each for Bus-P and Bus-Q. There is also provision of extending
station supply to the class III bus bars through a 2000 KVA, 6.6 KV/433 V reserve
transformer i.e. 5242TR-1 through 5242 BU-J via 5231-CB-3/4.
2.1 OPERATIONAL REQUIREMENTS
The DG sets are designed and connected to the Class III power supply system to
satisfy the following operational requirements.
(a) Whenever class IV supply is lost, the DG set should be capable of automatic
starting to re-establish class III power supply with in 60 seconds.
(b) The DG set should be capable of parallel operation with the station class IV supply
through the 2 MVA class III transformers.
(c) The DG set should also be capable of parallel operation with other DG set of
the same unit or with the 325 KVA MG set of the class II supply system.
(d) The DG set is capable of starting satisfactorily a 145 KW motor when it is

already carrying a load of 60%. The transient voltage dip under this condition
will not exceed 30%.
(e) The DG set should be capable of withstanding a seismic acceleration of 0.4 g

horizontal & be operational for safe running/shutdown of the unit.
Rev. No. : 02, Oct. 2008

3.0 DESIGN CRITERION
3.1 CAPACITY:
The following is observed from this load schedule.
Maximum Normal operating load 1310 KW
Emergency load on each DG when two DGs are 2795 = 1397.5

available. 2
Emergency load (maximum) on one DG when 1928 KW

only one DG is available.
Specifications for the supply of DG sets called for DG sets of capacity 1800 KW and
2000 KW with ten percent overload capacity for 2 hours in a day. Since emergency
diesel sets are a very vital auxiliary of the power plant, it was necessary to order DG
sets from an indigenous manufacturer so that the manufacture and delivery are not
influenced by other national/international regulations and restrictions regarding
supply of equipments to Nuclear Power Plants of another country. Further availability
of spare parts during the entire life of the plant is another factor, which influenced the
choice of indigenous supply.
The DG set of M/s. Diesel Locomotive Works; Varanasi was the only indigenous set
which met the requirements of reliability and dependability. The maximum capacity
available is as given below.
Rated continuous output 1450 KW
Overload capacity for 2 hours 1750 KW
Overload capacity for 8 hours 1650 KW
Hence 1450 KW DG sets were ordered on M/s DLW and it was decided to take
necessary steps to reduce class III loads under one DG conditions so that the above
mentioned capacity of DG set is adequate.
In order to ensure that the DG sets 2 hours and 8 hours capacity are not exceeded it
may become necessary to effect automatic load shedding of selected class III
auxiliaries at the end of these time periods. For details of this load shedding scheme,
refer Chapter 20 'Emergency Transfer System.
3.2 SYSTEM GROUNDING
The Class III power supply system is designed as a 3 phase 3 wire system in order
to ensure that phase to ground faults are minimized. Further, the neutral of the diesel
generator is earthed through a resistance of 0.5 ohm to limit the ground fault current
to about 480 amperes or less.
Rev. No. : 02, Oct. 2008
This restricted magnitude is adequate for providing discriminative ground fault

protection for class III system to selectively isolate faulted branch.
3.3 The DG set has been specified to withstand seismic condition as mentioned in Para
2.1. The design groups of M/s DLW (RDS0, Lucknow) have confirmed the capability
of this Engine to withstand seismic factor of 0.4g horizontal.
3.4 FUEL OIL SYSTEM

3.4.1 STORAGE
The diesel engine is operable on high-speed diesel (HSD) oil. Each DG set has been
provided with one HSD storage tank of 64 K liter capacity (sufficient for operating
one DG for seven days as per ANSI-N195-1976) along with a day tank of 4 K liter
capacity (sufficient for operating one DG for 8 hrs) with necessary piping connections
and facility of pumping high speed diesel from storage tank to day tank. Detailed
calculation confirming the adequacy of these, capacities is given below.
STORAGE REQUIREMENT FOR DG SETS
HSD consumption 8.20 lit/min.

Hence, storage requirement 8.20 x 60 x 24 x 7 - 82.66 K lit
for operation for 7 days 1000
For two DG sets (one of 82.66 x 3 = 165.32 m3 -̃ 166 m3 (approx)
each unit) the requirement
STORAGE REQUIREMENT FOR FIRE WATER PUMPS
HSD consumption per day 2.0 m3 per pump

Hence, 7 days requirement 2 x 2 x 7 = 28m3
for 2 pumps
Total HSD storage 166 + 28 = 194 m
requirement
With 10% margin, the 1.1 x 194 m3
requirement
Hence, capacity of each tank 213.40 m3 =53.35 m3
4
Considering free space in the 1.15 x 53.35 =61.35 m3
tank, capacity of each tank
Storage tank (dimensions are 3.0 m dia, and 9.0 m length) 64 m3 (approx)
DAY TANK CAPACITY:
DG consumption for 8 hr day 8. 20 x 60 x 8 = 3.94 m3

1000
Hence, day tank capacity of 4 K lit is adequate.
Rev. No. : 02, Oct. 2008

STATUTORY REQUIREMENTS
This HSD manufactured in India is based on crude oil supplied from foreign
countries. Normally HSD manufactured in India has two pour points viz 18 deg. C.
and 6 deg. C. HSD having pour point of 6 deg. C. is normally supplied in winter.
However, in case of sudden drop in atmospheric temperature, the wax in HSD

solidifies and impedes the flow of HSD. Also, the inline filters get chocked due to this
wax solidification. Secondly it may not be possible to consider the HSD with higher
pour point completely before winter sets in and keep the bulk storage tanks empty to
store the HSD with lower pour point, especially because the DG sets are run only
under emergency conditions. Hence, the storage should not be too high. It can
neither be too low, since this may result in short supply of diesel oil, when DG is
required to run.
As per 'American National Standard Fuel Oil Systems for standby Diesel Generators-
ANSI-N195-1976', the on site oil storage shall be sufficient to operate the minimum
number of diesel generators following the limiting design basis accident for either
seven (7) days or the time requirement to replenish the oil from sources outside the
plant site following any limiting design basis event without interrupting the operation
of the diesel generator, whichever is longer.
Thus, the above standard recommends conservative approach for fuel oil storage
requirements. Hence, a total fuel storage assuming one DG per unit running
continuously for seven days at its rated capacity has been considered for NAPP.
As per Safety Committee Rules of Atomic Energy Regulatory Board (AERB), it has
been decided to keep the bulk HSD storage tanks underground.
From these underground tanks, fuel is transferred to the day tanks ( 6 nos for DG
sets and 3 nos for fire water diesel driven pumps) using pumps mounted on the
nozzle of each storage tank.
The following requirements of Inspector of explosives and safety review committee

of NPC have been incorporated in the layout
(i) The three day tanks (of each unit) are surrounded by 1.0 might all round dyke
wall. The clearance between day tank and dyke wall is 1.0 m on all sides.
Dyke volume available is 24 cu. meters.
(ii) The three-day tanks (of each unit) with supporting structure have been
provided with 1.80 meters high barbed wire fencing at a clear distance of 4.50
meters with a lockable gate for restricted entry of personnel.
(iii) RCC fire barrier wall 100 mm thick and 4.85 m high is provided between the
day tanks of each unit. This barrier wall is to prevent spread of fire to case
one day tank catches fire.
Rev. No. : 02, Oct. 2008

3.4.2 HEATING SYSTEM
The properties of HSD that will be available at site at the time of startup and
subsequent operation were obtained from Indian Oil and Bharat Petroleum. The
meteorological data indicates that the ambient temperature at Narora goes as low as
(-) 5 deg. C. in winter. AT present too, diesel operated trucks/jeeps at NAPP face lot
of problem for start up in winter due to solidification of wax. In view of this, it was
decided to design the HSD storage and handling systems to remain operational at
0 deg. C, by using self current limiting, low watt density and self regulating electric
trace heaters along with associated temperature controlling devices.
3.5 ENGINE EXHAUST SYSTEM
As per the layout, the day tanks, DG exhaust and storage tanks are located on the
same side of the Turbine Building. Temperature of exhaust flue gases coming out
from silencer is 484 deg. C. approx. and vapour coming out of HSD day tanks may
catch fire due to these hot flue gases. To avoid this a steel chimney is provided. The
rate of flow of exhaust fuel gases is 27252m3/hr (16050 CFM).
4.0 CONSTRUCTIONAL FEATURES
4.1 DIESEL ENGINE
The diesel engine is of M/s. Diesel Locomotive Works, Varanasi and is ALCO Model
251-BG with the following main parameters
Rating 2600 BHP
Type ALCO 16 Cylinder VEE-251B
RPM 1000
No. of Stroke/cycle Four
Aspiration Turbo Supercharged with charge air-cooling.
ENGINE BLOCK AND BASE
The block, the main structural member of the engine, is made entirely of fabricated
steel and steel forgings.
It is formed by forged steel saddles, to which decks and foundation plates have been
welded in a continuous process. The entire fabrication is stress-relieved after
welding.
The maximum possible block depth has been designed from the top deck to flange
rail, which is below the crankshaft centerline. Heavy steel inner side plates from the
water enclosures, and they are welded to the forged main-bearing saddles. The steel
outer sheets provided additional stiffening to the box structure.
Rev. No. : 02, Oct. 2008
The engine base, which serves as the oil sump, is also a fully welded steel structure
and has individual inspection covers for each main bearing on either side. It is also
provided with safety explosion doors. The base carries four mounting pads, which
support the engine structure and main generator.
CRANKSHAFTS
The crankshaft is a single piece, forged steel under slung, hardened component.
One end of the crankshaft carries the crankshaft split feat for the drive of camshaft
gears, and the main generator coupling flange and on the other end the crankshaft
carries an extension drive shaft for the lube oil and cooling water pumps, tensional
damper and auxiliary equipment.
The crankshaft has rifle-drilled oil passages for distribution of the oil from the main
bearings to the connecting rod bearings.
Counterweights are used at each end of the shaft, and at each center cranks, in the
same plane but rotated 180 degrees from the end weights. This arrangement
reduces internal moments to a minimum, but avoids large masses, which cause
serious torsion problems.
BEARINGS
All main and crank pin bearings in the engine are of the precision tre-metal type with
a steel back covered by a lead copper inner layer and faced with a tin lead overlay.
There are nine main bearings; each consisting of shells in two halves supported in
precision machined bearing seats. The center main bearing is wider and is of the
groove less type, which results in an exceptionally high load carrying capacity.
The bearing cap and saddle on the block are serrated fit. This assures positive and
easy alignment of both shells and thereby effects a uniform load distribution.
It eliminates the possibility of misalignment, which could wipeout almost any safety
factor in an engine's bearing feature.
CONNECTING ROD
The connecting rods are 'I' beam section of high grade, drop-forged steel, rifle drilled
for oil passage from big end bearings to the piston pin and piston crown for cooling.
Forged steel caps are fitted to the rods by means of four bolts is special feature.
Rev. No. : 02, Oct. 2008

PISTONS
The pistons are made of forged aluminum alloy and are oil-cooled. The aluminum
body of the piston carries a shrunk-fit ring carrier (also an aluminum alloy forging),
which in turn has a N Resist insert in the top ring groove. The insert, by considerably
decreasing wear of the top ring groove, prolongs the life of both rings and piston.
Oil from the connecting rods reaches the piston cooling grooves through passages
drilled in the piston, removes head flowing from the combustion chamber, and falls
free into the crankcase through a drilled outlet. The position of the cooling grooves in
relation to the rings assures adequate heat removal and freedom from deposits.
The piston is fitted with three compression rings and two oil scrapper rings, all of a
hardened, malleable cast iron.
CYLINDER LINERS
Made of high strength, close-grained alloy cast iron, heat treated to relieve stresses,
these liners have porous chrome plated inner surface.
When necessary, the chrome surface can be stripped and the liner re-plated,
restoring it to its dimensions.
The liners are of the wet type and 'O' ring seals are used both at top and bottom.
Head to liner joint is a metal-to-metal fit avoiding the use of gaskets or softer joints in
an area where they are subject to extreme pressure and temperature conditions. A
ring sleeve is applied at the lower liner-to-block seat, allowing easy replacement and
greatly increasing the life of the cylinder block.
CYLINDER HEADS AND VALVES
A special alloy cast iron is used in the cylinder head castings. Water cooling
passages are cored, with separate passages for the high-pressure fuel injection
lines.
Valves seat inserts are made of satellite to reduce wear and when wear limits are
reached, they can be easily replaced.
Each cylinder has two exhaust and two inlet valves, 2.85" in diameter. The valves
have a stem of alloy steel and a composite unit. Both exhaust and inlet valves are
alike and thus fully interchangeable.
CAMSHAFTS AND GEARS
The camshaft is made in replaceable sections of heat-treated precision mechanized

alloy steel with chromium.
Rev. No. : 02, Oct. 2008

The cams are former integral with the shaft, and the bearing and cam surfaces are
hardened by high-frequency induction. There is, for each cylinder, an inlet valve
cam, a fuel pump cam and an exhaust valve cam.
The camshafts are driven from the crankshaft through forged steel; heat treaded,
spur-type gear train of adequate diameter and face width.
TURBO SUPERCHARGER
The turbo supercharger is a water-cooled machine with inboard sleeve bearing

lubricated from the engine's main system without any pressure reduction.
It consists of a single flow, single stage centrifugal blower driven by an exhaust gas
driven turbine with replaceable blades, assembled as a single compact unit with a
comparatively low moment of inertia.
AFTER COOLER
Because the high turbo charging substantially raises input air temperature, after
cooling is employed. The after cooler comprises of an air to water heat exchanger.
Thus by reducing input air temperature; a denser, cooler, air charge is fed to the
cylinders, allowing a high output without raising the mean cycle temperatures.
In addition, engine exhaust temperatures are held at a reasonable levels, extending
exhaust manifold and turbocharger life.
FUEL INJECTION EQUIPMENT
Each cylinder has an individual fuel pump, which is mounted outside the block for
easy in checking and maintenance. The pump are of the constant stroke type and
their output is regulated by the rotation of a helically grooved plunger of 15mm
diameter,
actuated by a rack which receives the indication of the governor through a control
shaft and a spring loaded individual are along the engine bank.
Individual pump adjustments are possible, and each pump can be isolated and held
in the 'no fuel' position by a latch engaging on a groove in the rack.
A snubber valve, fitted over the delivery valve minimizes pressure induced high
frequency vibrations in the high-pressure line from the pump to the injector and so
reduces line erosion and injector nozzle wear.
All joints where fuel leaks might occur are located outside the engine. The high
pressure line reaches the injector through a cored passage in the cylinder head. All
leaks are thus led back to the tank through the injector leak-off. The pump mounting
is also external, and a welded angle running inside and along the block. All
possibility of lube oil dilution by fuel oil is thus avoided.
The fuel system incorporates superior fuel oil primary and secondary filter units, both
of which are engine mounted.
Rev. No. : 02, Oct. 2008
OVER-SPEED PROTECTION
The engine is protected against over speed by a positive acting mechanical device,
which trips and brings all fuel pump racks to the 'no fuel' position in case the engine
over speeds.
This device is reset manually. Over speed, protection through relay '12X' is also
provided.
LUBRICATION
Pressure lubrication is provided for all engine moving parts, including the
turbocharger rotor bearings, by means of a heavy duty, high volume, positive
displacement type gear pump, engine mounted at the free end, and driven off the
engine crankshaft through a gear train.
The system includes separate lube oil strainer, cooler and filter units of which the
strainer is engine mounted.
COOLING WATER CIRCUIT
Circulation of cooling water, which is chromate treaded to provide corrosion

protection, is accomplished by a centrifugal type, high capacity pump mounted on
the engine at the free end and driven off the engine crankshaft through a gear train.
The cooling water goes first to the cylinder in block, up around the liners, into the
cylinder heads and out through the outlet header.
VIBRATION DAMPERS
Vibration dampers of the paddle wheel type are provided on the crankshaft as well
as camshafts to reduce the amplitude for the torsional vibrations in these rotating
members and keep them well within acceptable limits.
EXHAUST MAINFOLD
The single pipe exhaust manifold, which is a streamlined one, is made entirely of
stainless steel turbine and bellows joints. It consists of a number of identical
sections, any single one of which may be removed or replaced by unbolting the
associated parts.
No sliding joints are used. Instead, a bellows connector is placed between each
section, which joints a pair of cylinders.
This arrangement eliminates wear and galling caused by sliding motion of the parts.
Rev. No. : 02, Oct. 2008

4.2 CONSTRUCTION FEATURES OF GENERATORS
The generator is of revolving field type having only one bearing, the rotor extension
having a half coupling for connection to the diesel engine.
4.2.1 STATOR FRAME
The stator frame is built of steel plates, welded together to make a rigid structure of
hollow box form.
4.2.2 STATOR CORE
The stator core consists of segmental varnished punching of cold reduced silicon
alloy sheet steel. The punching are assembled on dovetail bars, which are welded,
to the stator frame during the core assembly. The core body and teeth support
fingers are compressed between thick segmental mild steel end plates, the finger
being welded to the end plates. Radial air ducts are formed by steel separation
inserted at intervals along the core for ventilation purpose.
4.2.3 STATOR WINDINGS
The stator winding is of the double layer single turned pulled diamond coil type in a
two layer lap wound arrangement, arranged in open slots. Each turn comprises of a
number of insulated rectangular copper strips to minimize eddy current losses.
The main slot insulation is rigid and consists of epoxy mica tapes or flexible tapes
apply by hand and presses to gauge limits. The end windings are insulated with
appropriate layers of Acrylic Mica Tapes is held in place by means of a glass tape.
The complete insulation is of class 'F' quality.
Packing blocks are tapped between coil sides in the end windings and these
together with non-metallic support rings carried boxes mounted on stator frame, give
adequate rigidity to the end windings. Copper is brought inside fabricated boxes on
phases to each phase and neutral side. Provision is made to connect cables to each
phase inside the main box. The neutral box has 3 double core CT's and the phases
are shorted inside it.
4.2.4 FIELD COILS
The field coils are fabricated from straight lengths of bare copper silver soldered at
the corners and having turns at intervals for cooling purposes. The insulation
between turns consists of specially treated asbestos paper with epoxy varnish.
Insulation to ground is of epoxy glass laminates and insulation washer of epoxy
glass laminates. These insulations are suitable for full class 'F' insulation.
Rev. No. : 02, Oct. 2008

4.2.5 ROTOR AND SHAFT
The rotor spider body is forged integral with the shaft and half couplings.
The poles are of laminated construction and are fixed to the spider by means of a
dovetail projection on the poles engaging in similarly shaped slots on the spider
secured by means of taper keys.
The rotor shaft and spider are a one piece forging having dovetail notches on the
periphery of the spider. The rotor shaft has a solid forge coupling which is suitable
for bolting to the flywheel.
4.2.6 SLIPRING AND BRUSHGEAR
The slip ring is of steel shrunk on to an insulated mild steel sleeve, which is keyed on
to the generator shaft. The brush gear is carried from the adjacent bearing pedestal.
A number of carbon brushes per ring are fitted and held to the slip ring under
adjustable spring pressure. A wire screen mesh guard is provided to cover the slip
rings.
4.2.7 BEARINGS
The generator bearing is of the journal type suitable for ring lubrication cooled by a
coil carrying cooling water, having a white metal lined case iron shell. The pedestal is
of the fabricated type with mechanized feet for bolting to the common base plate. It is
insulated from round to eliminate shaft currents. A resistance type temperature
detector is provided to monitor the bearing temperature.
4.2.8 ENCLOSURE
The generator is of open ventilated screen protected drip proof type, the ends for the
machine bearing protected by wire mesh and air is discharged through the top of the
stator frame into the surrounding atmosphere.
4.2.9 TEMPERATURE DETECTORS
The generator is provided with 6 nos. of resistance type temperature detectors

embedded in the slots and these are connected to a temperature-indicating
instrument.
4.2.10 ANTI-CONDENSATION HEATERS
Heaters to prevent condensation in the machine during shut down period are
mounted in the end windings enclosure and brought on to a terminal box on the
stator frame.
4.2.11 TERMINALS
The alternator is provided with suitable side terminal box for line and neutral ends of
each phase. The generator terminals are suitable for connecting 5 nos. single core
1000 sq. mm. PVC cable per phase and the neutral terminal is suitable for 2 nos.
Rev. No. : 02, Oct. 2008
single core 1000 sq. mm PVC cable. The terminal box is also provided with 3 Nos.
3500/5A double core current transformers.
4.3.0 STATIC EXCITATION EQUIPMENTS (APPLICABLE FOR DG-1, 2)
The digital SEE type VSD-31 has been provide for 1-DG-1&2, which automatically
regulates the generator voltage from no load to full load by supplying controlled
excitation to its field winding. It ensures very fast recovery of generator voltage
following changes in load demand. The protective features ensure safe operation of
Generator.
The basic system consists of two channels. Auto channel with closed loop generator
voltage regulation and manual channel with closed loop field current regulations.
Both the channels employ a common three phases fully controlled thyristor bridge as
the out element. Initial field flashing facility has been provided for voltage build up,
when generator speed is more than 90%, which build up voltage of generator with
soft start for smooth built up of voltage there after control is taken over by controller
(DECS-300).
The auto control loop compares the generator voltage (reset signal) with a fixed
voltage (reference signal) to produce the auto control signal, which calls for an
increase or decrease in excitation as and when required.
When excitation is being controlled manually, control is switched over from auto
control loop (AVR mode) to manual control loop (FCR mode), which compares the
generator field current with the FCR reference to decide the level of excitation.
All the above are achieved through the use of a microprocessor based controller
used for generator power management. Front panel operation or serial
communication links using PC soft ware makes the system user friendly and easy to
operate from local or remote location.
When the machine is synchronized to the grid, the PF regulation and the VAR
regulation modes come into picture automatically, which, control the PF and the VAR
respectively at preset levels.
A three phase fully controlled thyristor bridge forms the output stage for both the
control loops. It is fed from a 415V/80V, 3phase transformer connected to the 415V,
3 phase generator terminals. The output of the converter controls the alternator field
current, which is determined by the firing control signal to the thyristor Bridge.
Test mode facility is provided to check the healthiness of firing circuit and Thyristor
Bridge. It can also be used as an alternate channel for excitation in case of
extremely rare occasion of a controller failure. Test mode operation can be done in
presence of electrical maintainer only.
Rev. No. : 02, Oct. 2008

4.3.1 FEATURES OF SEE VSD-31 (FOR DG-1&2)
 COMPOUNDING
The reactive component of the generator output current is measured and a signal is
introduced into the voltage control loop changing the excitation as determined by the
load condition, thereby providing drooping characteristic to the generator voltage with
respect to reactive loading. This makes the parallel operation of the generator
possible.
 SET POINT CONTROL
Adjustment of the reference value of the active mode of operation is available either
through HS contact or communications with a PC.
 INTERNAL TRACKING (FOLLOW UP)
It ensures that non-active modes (auto / manual) are automatically adjusted so as to

match the level of the active mode (manual / auto) to ensure bump less transfer
during mode changeover (Auto to Manual change over and vice versa).
 UNDER FREQUENCY / VOLTS PER HERTZ LIMIT
When the generator frequency drops below the reference frequency for the under
frequency slope, the voltage set point is automatically adjusted by the DECS-300 so
that the generator voltage will follow the under frequency slope and an under
frequency annunciation occurs.
 UNDER EXCITATION LIMIT
The under excitation limiter senses the amount of leading reactive power and limits
the amount of excitation supplied to the field of the generator from dropping below
unsafe operating levels. This prevents the machine from possibly slipping poles and
from iron heating. It limits the amount of VARs being absorbed by the machine,
based on preset value.
Rev. No. : 02, Oct. 2008

 OVER EXCITATION LIMIT
The DECS300 senses the field current level and limits excitation so as to prevent
overheating of the generator field.
 STATOR CURRENT LIMIT
The stator current limiter senses the generator stator current and limits excitation to
avoid thermal overloading of the stator winding.
 PROTECTIONS
Following protections are provided by the DECS300.

1. Generator over/under voltage.
2. Field over voltage / over current / over temperature.
3. Loss of sensing.
SEE change over occurs in case protection of S.No. 1&3 from auto to manual mode.
Excitation trips if S.No. –2 protections operate which in turn trip the DG set.
 FIELD FLASHING
When machine is started, field flashing is employed for initial voltage build-up.
Provision is made for DC field flashing from the field flashing battery through a
dropping resistor and blocking diode arrangement.
 SOFT START BUILDUP

This feature allows the generator voltage to build up at a predetermined rate over a
pre-determined range so that damaging overshoots of field voltage and stator voltage
are eliminated.
 SERVICE / TEST MODE OF OPERATION

As the name suggested, other than the normal SERVICE mode of the SEE, a test
mode is provided that uses a potentiometer RV1 (mounted in the switch fuse panel)
to set the control signal level to the firing circuit thus deciding the firing angle of the
thyristors and the output level of SEE.
Rev. No. : 02, Oct. 2008

4.3.2 CONTROLS ON EXCITATION CONTROL PANEL:
The following controls / devices are provided on front panel of SEE control panel.
(a) Auto / Manual selection. (CSS-3)
(b) Excitation OFF/ON (CS-S2)
(c) Reference / Manual Control (RAISE/LOWER) (CSS-9)
(d) Local/Remote control Selection Switch (CSS-1).
(e) Fault reset push button (PB-1).
(f) Voltage selector switch (VSS).
(g) Lamp Test Push button (PB-2)
(h) Digital Controller (DECS-300).
(i) Service test mode selection switch (CSS-5 inside control panel).
(j) Two nos. buzzers to identify trip alarm and non-trip alarm separately.
4.3.3 INDICATIONS & ANNUNCIATIONS ON STATIC EXCITATION PANEL:

Following indication and annunciations are provided on front door of SEE panel.
S.No. Indications Annunciations Significance

1. Pre start checks OK (SL-1) - All the supply MCBs are ON
and trip lock out NOT operated
(4S relay).
2. Excitation OFF (SL-2) - System is de-energized (4X
relay drop out).
3. Excitation ON (SL-3) - System is energized (4X relay
pickup).
4. Auto control ON (SL-4) - Auto channel (AVR mode) in
service (K4).
5. Manual control ON (SL-5) - Manual channel (FCR mode) in
service (K4).
6. Service mode(SL-6) - System is in service mode
(CSS-5).
7. Test mode (SL-7) - System is in test mode and it is
applicable for testing purposes
by electrical maintainer (CSS-
5).
8. Field flashing fail (SL-8) Field flashing After initiating start signal if field
failed. flashing does not close. (90VR
controller).
Rev. No. : 02, Oct. 2008

9. Field O/C, O/V / over temp. Field O/V / O/C / Field current, field voltage &
(SL-9) Over temp. over temp. Exceed from pre
set limit. (K3)
10. Controller watchdog Controller Controller (DECS-300) internal
operated. (SL-10) watchdog fault. Excitation get trip on it
operation. (K2).
11. Thyristor bridge main fan Thyristor bridge In case of MCB trip or power
failed. (SL-11) main fan failed. supply fail (88T1). Standby fan
get started.
12. Thyristor bridge standby fan Thyristor bridge Under this condition also
failed. (SL-12) stands by fan system will continue to run. If
failed. thyristor temp. exceed the limit
excitation will trip (88T2).
13. Thyristor bridge fuse fail Thyristor bridge Excitation will trip on any one
(SL-13) fuse failed. out of six fuse fails (60T)
14. Loss of sensing voltage. Loss of sensing SEE control change over from
(SL-14) voltage. auto to manual (90VR) due to
failure of PT signal (feed back
signal) to controller (single, two
or three phase failure).
15. AVR limiter in operation AVR limiter in In case of exceeding any
(SL-15) operation. limit (OEL/UEL/SCL) setting
respective limiter start to
operate till parameter come in
under limit (90VR).
16. Control supply PS-5 failed. Control power In case failure of power supply
(SL-16) supply PS-5 (PS-5) 240V AC / 48V DC or
failed any internal fault of power
supply (80S-5). System will trip.
17. Control relay supply fail. - 48 V DC control supply for
(SL-17) relaying fails (80A). System will
trip.
18. Firing circuit power supply Firing circuit Any one power supply fail out
fail. (SL-18) power supply fail. of PS-1 to 4 due to loss of
supply or internal fault (80S-1
to 80S-4). System will trip
19. - Over / under Generator voltage is more
voltage at 110% or less than 85% .SEE
generator control change from auto to
terminal. manual mode.
4.3.3 METERS ON EXCITATION LOCAL CONTROL PANEL:

Following meters are provided on SEE panel.
i) Field current.
ii) Field voltage.
iii) Generator voltage.
Rev. No. : 02, Oct. 2008
4.3.5 DISPLAY ON CONTROLLER (DECS-300) AT EXCITATION CONTROL PANEL:
Following displays are provided on controller.
i) LCD Screen –
It is the primary source for receiving information from the controller or when
locally programming. It displays system parameters and general settings.
ii) Null balance LED –

Lights when inactive modes (AVR, FCR) match the active
mode (FCR, AVR).
iii) Internal tracking LED –

All inactive modes (AVR, FCR) track the active mode to
accommodate a bump less transfer when changing active
modes (FCR, AVR).
iv) Pre-position LED –
Lights within the limits of the set points of the active mode.
v) Lower limit LED – Lights at the minimum set point.
vi) Upper limit LED – Lights at the maximum set point.
vii) Reset pushbutton –
Used for resets alarm relays and alarm annunciations. It can be used as a
quick-access to the metering screen.
viii) Scrolling pushbuttons –
Scrolls UP/DOWN/LEFT/RIGHT through the menu tree or when in the EDIT

mode.
4.3.6 INDICATION PROVIDED IN MAIN CONTROL ROOM( 6610 PL-2):

i) AVR Auto ‘ON’ (LT-7069 / 7060)
ii) AVR manual ‘ON’ (LT-7068 / 7061).
4.3.7 EXCITATION TRIP

Excitation trip may take place due to one of the following faults in the SEE.
Excitation is interrupted only when the generator CB is off:
Rev. No. : 02, Oct. 2008

 Stabilised supply failure (80S1 & 80S2 or 80S3 & 80S4 drop)
 Standby fan failure (88T2 picks up)
 Thyristor bridge fuse failure (60T picks up)
 Generator voltage build-up failure (K1 picks up)
 Field over voltage or over current or over temperature (K3 picks up)
 On operation of Watchdog relay (K2).
 Excitation off command from the front door switch CSS-2, when generator CB is
open.
4.3.8 OPERATION SEQUENCE:
4.3.8.1 INITIAL CONDITION:
(i) No alarm is present on annunciator & following indications are available on the
front door of excitation panel in DG control room.
 SEE in service mode.
 Excitation OFF.
 Pre start checks OK.
 AUTO control “ON”
(ii) Local / Remote control selection carried out as per requirement.
NOTE: The excitation cannot be started in case of a missing PRE-START CHECKS OK
indication. Indication is provided by 4S relay contacts. The relay 4S is energized
when.
 MCBs Q3, Q6 & Q13 are “ON”.

 Either MCB Q1 is on or Q11 & Q12 are “ON”
 No trip conditions exist.
 No SEE lockout conditions exist.
4.3.8.2 NORMAL OPERATION:
VOLTAGE BUILD-UP
 When DG gets start signal initiated through EMTR or manually through start HS
in local or control room.
Rev. No. : 02, Oct. 2008
 Excitation on command is initiated automatically when engine speed is more

than 90%.
 Field flashing gets ‘ON’ signal through 90 VR controller (DECS-300).
 Voltage build up 60% of generator voltage by field flashing.
 Soft start take place at 60% of generator voltage & build up the voltage up to 85%
of generator voltage within 5 sec.
 Controller comes in service at 85% of generator voltage and maintains the
desired voltage as per reference signal
 During starting of machine when speed is more than 90% following annunciation
will appear on front door panel of SEE which should be acknowledge and rest
by operator.
i) Thyristor bridges main fan fail.
ii) Control supply PS-5 failed.
iii) Firing circuit power failed.
iv) Loss of sensing voltage.
4.3.8.3 AUTO CONTROL (AVR MODE) OPERATION:
 Select auto control channel with the help of CSS-3 (normally system to be kept
in auto control mode).
 Raise or lower the auto reference-using RAISE / LOWER at local through CSS-
4 or HS –7218 (7215) in control room.
 Set generator voltage as per requirement.
4.3.8.4 MANUAL CONTROL [Field Control Regulation (FCR) MODE] OPERATION:
 Select controller Auto to manual with help of CSS-3 ensuring null balance
 Raise or lower the reference using RAISE / LOWER switch CSS-4 at local
panel or HS –7218 (7215) in control room and observe the field current.
4.3.9 AUTO/MANUAL CHANGEOVER:
Changeover from auto to manual takes place due to one of the following:
 Loss of sensing.
 Generator over/under voltage (59/27G).
 Manually by selector switch (CSS-3) located on the panel.
Rev. No. : 02, Oct. 2008

4.3.10 MANUAL /AUTO CHANGEOVER:

 Manual to auto changeover can be done by the operator by HS (CSS-3) in
auto mode after ensuring the null balance indication on the controller (DECS-
300).
4.3.11 ON LOAD OPERATION OF EXCITATION:
A) ISO MODE OPERATION:
i) Check the generator voltage and maintain it nominal voltage.
ii) Close generator out put circuit breaker (when class-3 bus is de-energized)
after ensuring healthiness of engine and excitation parameter.
iii) Operate raise / lower control from local through CSS-4 or from control
room through HS – 7218 (7215) to adjust voltage as per requirement.
B) PARALLEL OPERATION WITH CLASS-IV:

i) Synchronize the generator with respective Cl-III bus as per procedure.
ii) Load the generator and operate raise / lower control to obtain required
VAR out put from local through CSS-4 or from control room through HS –
7218 (7215).
4.3.12 DE-EXCITATION:
(i) With the generator OFF load condition i.e. generator circuit breaker open,
operate raise / lower control from local through CSS-4 or from control room
through HS – 7218 (7215) to maintain nominal voltage.
(ii) Trip the DG set through switch HS-1 in DG local control panel if HS: 7214
(HS-7219 / HS- 7256) is in local position or through stop push button PB:
7071 (PB-7058) in control room if HS: 7214 (HS-7219 / HS- 7256) is in
remote. This operates relay ‘4 T’ which in turn resets relay ‘4’.
4.3.13 TEST MODE OPERATION:
Normally SEE works in service mode, it can be put in to test mode through HS
CSS-5 mounted on switch fuse panel. This is provided to check healthiness of
firing circuit and Thyristor Bridge. It can also used as an alternate channel for
excitation in case of controller failure. This facility can be used in the presence of
electrical maintainer only.
Rev. No. : 02, Oct. 2008

4.4.0. STATIC EXCITATION EQUIPMENTS (APPLICABLE FOR DG-3)

Static excitation equipment mainly consists of regulating rack, pulse control rack,
follow up and protection rack and a three phase full wave full controlled thyristor
bridge. It monitors the mean generator voltage through PTs, rectifiers, filters &
compares with a built in reference in the reference circuit (in regulating rack).
The difference, which is the error, is amplified by the D.C. amplifier (in the regulating
rack) and is fed to the firing circuit (in pulse and control rack), which controls the
firing point of the thyristor to vary field current to maintain constant voltage over the
full load range of the generator.
For example, a sudden application of load causes the generator voltage to 'fall'. This
is sensed by the voltage sensing circuit, and compared with the reference (give the
error). The D.C. amplifier further amplifies the error and the output from the amplifier
causes the firing angle of the thyristor to advance through the firing circuit thus
providing more power to the field.
The gain of the D.C. amplifier is very high and given a linear D.C. amplification.
Thus, a very small change in A.C. generator voltage causes the thyristor to conduct
fully and forces the voltage to rise again. Also when load is removed similar
sequence of events occur which brings down the generator voltage to its present
value.
Power to D.C. Amplifier and firing circuit is fed from a highly established
transistorized power supply unit, which has negligible ripple, the output voltage of the
power supply unit remaining constant even if there is variation in the input voltage. It
leads to better stability of the regular.
4.4.1 SPECIAL FEATURES
(i) STABILISATION
A circuit incorporated in the regulator prevents hunting on instability in the A.C.
generator voltage. Means are provided to adjust over shoot / undershoot with setting
time of generator voltage.
(ii) SURGE PROTECTION

Surge suppression networks consisting of resistor and capacitor are provided across
the thyristor and other semi-conductors for protection against transient over voltage.
(iii) PARALLEL OPERATION

A compounding circuit of quadrature injection type is included to ensure stable
sharing of reactive power between generators when operating in parallel. The
current single required for this has been taken from a CT.
(iv) VOLTAGE BUILDUP
The AC generator voltage shall be built up from a dead station by mean of

independent dc obtained up to 60% rated voltage and from 60% to 110% the build
up is controlled by hand control.
Rev. No. : 02, Oct. 2008

(v) HAND CONTROL
Hand control for starting and for emergency purposes is provided. A continuous
steeples control of generator voltage is obtained with hand control form no load to
full load.
It also provides easy maintenance on auto side without any disturbance on the AC
generator. A motor operated voltage adjusting potentiometer (RV3) is provided which
controls the input to firing circuit controlling the firing point of thyristor. The excitation
power is obtained from AC generator via a step down transformer. Potentiometer
(RV4) is provided in the pulse control rack to limit the control range of RV3.
(vi) MANUAL/AUTO CHANGEOVER
Means are provided for switching the generator voltage control manually or
automatically by auto to manual change over relay RL2 in the relay panel.
(vii) HV/LV TRIP CIRCUIT
Means are provided for transferring voltage control from auto to manual, in case of
high/low voltage on the generator.
(viii) CURRENT LIMIT AND TRIP CIRCUIT
Means are provided to limit the field current instantaneously. A CT has provided
current single required for this. A Thermal over load relay in the relay panel is
provided to switch off excitation if the field current exceeds 120% of rated current for
more than 2 minutes.
(ix) FIELD SUPPRESION
Field suppression achieved by a static suppressor, (No linear resistor) without

disconnecting the field.
(x) MAINTENANCE OF EXCITATION UNDER SHORT CIRCUIT CONDITION
Provision has been made to provide excitation under short circuit condition on the
generator. A current transformer and a diode bridge achieve this.
(xi) INDICATING MODULE
Indicating meters for generator voltage, field voltage and current are provided.
Indicating signals (Lamps) are provided to indicated semiconductor fuse failure,
manual control, auto control etc. Push button has been provided to check the proper
functioning of all the signal lamps.
Rev. No. : 02, Oct. 2008

(xii) ALARM CIRCUIT
Provision has been made to initiate alarm in case of auto to manual changeover and
in case of earth fault.
(xiii) FOLLOW UP CIRCUIT
The follow up circuit has been provided in the protection and follow up rack. It
enables the hand control settings to follow the setting of the automatic control
excitation, which helps in achieving smooth changeover from auto to manual.
(xiv) BALANCE CIRCUIT
Provision is made to compare the voltage of hand control output and auto control
output. The difference is indicated by a null voltmeter (Balance meter).
(xv) P T FUSE FAILURE PROTECTION
Provision has been made for changing the system from auto to manual in case any
of the fuses (provided for sensing PTs) fail. It is achieved by energisation of a relay.
(xvi) LOCAL/REMOTE CONTROL
Provision is made to select the control either locally or from remote position by a
local/remote switch.
4.4.2 CONTROLS ON EXCITATION CONTROL PANEL:
The excitation is provided with following controls:

(a) Converter trip
(b) Auto Control (RAISE/LOWER)
(c) Manual Control
(d) Lamp Test
(e) Local/Remote control Selection.
4.4.3 INDICATIONS ON STATIC EXCITATION PANELS:

Following indication and annunciations are provided on front door of SEE panel
Indications Significance
1. Field converter AC supply OFF. Converter is in de-energised condition
(41)
2. Field converter AC supply ON. Converter is in energised condition (41)
3. Field converter fuse failed. Any one fuse fail out of Six (87 X-1)
4. Field auto control ON. AVR in auto mode (43)
Rev. No. : 02, Oct. 2008
5. Field manual control ON. Manual in auto mode (43)

6. HV / LV circuit trip. Generator Over Voltage / Under Voltage
(40)
7. Fan ‘ON’. Thyristor Bridge Fan started
8. Short circuit excitation bridge Any one Fuse fail out of four of Short
fuse failed. Circuit Excitation Bridge.
9. Sensing fuse failed. PT Fuse fail (RLX)
10. Reference fuse failed R&F (PC-026) Supply Fuse fails (RLY).
11. Auto control potentiometer Auto Reference Maximum (70 V LS 4).
minimum
12. Auto control potentiometer Auto Reference Minimum (70VSL 3)
maximum.
13. Manual control potentiometer Manual Reference Minimum (70MLS 3)
minimum.
14. Manual control potentiometer Manual Reference Maximum (70MLS 4)
maximum.
15. Field failed. Excitation Trip (41 X)
4.4.4 METERS ON EXCITATION PANELS:

(i) Null balance meter (15-0-15VDC)
(ii) Ammeter for field current. (0-800A)
(iii) Volt meter for field (0-150V)
(iv) Voltmeter for Generator. (0-600V)
4.4.4 INDICATION PROVIDED IN MAIN CONTROL ROOM (6610 PL-2):

(i) AVR Maximum.
(ii) AVR Minimum.
(iii) Auto Control ON
(iv) Manual Control ON
4.4.5 EXCITATION TRIP:

Excitation trip may take place due to one of the following faults in the SEE.
Excitation is interrupted only when the generator CB is off:
(i) Sustained over load.

(ii) Generator voltage low and high.
(iii) Failure of auto circuit.
(iv) Failure of semi conductor fuses.
Rev. No. : 02, Oct. 2008

(v) Failure of generator field.

(vi) Failure of cooling fan.
In the event of fault, it is expected that the machine protection will operate to trip the
DG set, otherwise excitation equipment will be tripped through the thermal relay. In II
& III case the excitation control will be transferred to manual mode and thus is in safe
condition.
4.4.6 OPERATION SEQUENCE:
4.4.6.1 INITIAL CONDITION:
(i) Ensure that auto control pot 70V and manual control pot 70M are in minimum
position.
(ii) Following indications are available on the front door of excitation panel in DG
control room.
(iii) Field converter AC supply OFF.
4.4.6.2 NORMAL OPERATIONS:

VOLTAGE BUILD-UP
(i) With the generator running at rated speed field flashing circuits shall
be “ON”.
(ii) Ensure generator voltage builds up to 60% of nominal voltage, AC contractor
41 energizes.
(iii) Operate manual voltage raise/lower with switch (CS-3) and check that further
control of generator voltage is possible.
NOTE: -In case it is not possible to build up generator voltage on manual
control after field flashing, then field flashing should be increased by means
of time setting knob of timer mounted in Aux. Relay panel.
4.4.6.3 AUTO CONTROL OPERATIONS:
(i) Press the auto push button to ensure that the auto control circuit is through.
(ii) Check that both the motorized potentiometers are at minimum positions. If
necessary adjust them.
Rev. No. : 02, Oct. 2008
(iii) Ensure the machine running above 80% speed check that the field flashing
contactor 72 and timer TDR are energized. Once generator voltage builds up
to 60% 72 drops and control changes over to AUTO mode.
(iv) Operate the auto voltage raise/ lower switch CS2 to obtain the required
generator terminal voltage.
(v) Operate the manual voltage raise/ lower switch to obtain a null on the balance
indicator (BI)
4.4.6.4 MANUAL CONTROL OPERATIONS:

(i) Press the manual bush button PB3 and ensure that the control changes over to
manual.
(ii) Operate the manual voltage raise / lower switch to obtain the required generator
terminal voltage.
4.4.7 OPEN CIRCUIT EXCITATION:

(i) Operate manual voltage raise/lower switch to obtain required generator output
voltage.
(ii) Operate auto voltage raise/lower switch to obtain null point on balance meter
indicator.
(iii) Press auto control push button (PB-3) and check that control is taken over
smoothly.
4.4.8 ON LOAD EXCITATION
(i) If necessary synchronize the generator with the system.
(ii) Load the generator & operate raise/lower control to obtain required voltage/VAR
output.
(iii) If necessary adjust compounding pot far proper sharing of KVAR.
4.4.9 DE-EXCITATION:
(i) With the generator OFF load, operate the RAISE/LOWER control to reduce the
output voltage to minimum.
(ii) Wait for few seconds and switch off the static excitation equipment by means
of push button ( PB-1).
Rev. No. : 02, Oct. 2008

4.4.10 PROTECTION:
The equipment has been provided following protections:
(i) Sustained over load.
(ii) Generator voltage low and high.
(iii) Failure of auto circuit.
(iv) Failure of semi conductor fuses.
(v) Failure of generator field.
(vi) Failure of cooling fan.
In (ii) & (iii) case the excitation control will be transferred auto mode to manual mode
and this is in safe condition. In other cases excitation trips and machine trips on
excitation fault.
5.0 CONTROLS
The protective trip circuits are supplied from 250V DC and the start/stop functions
with interlocks from 48V dc.
5.1 STARTING
The sequence of operation for DG starting is given below. Information in brackets
corresponds to DG-2/DG-3.
(i) The master start up relay 3-1 is energized when:
(a) The DG Breaker 5231-CB-7 (CB-31/CB-70) is open & in-service position.
(b) Jacket water Expansion tank level is not very low.
(c) The starting air pressure (63 AX) is adequate.
(d) Lock relay-94 M in reset condition.
(ii) Through condition in (i) are not sufficient to ensure readiness of the engine to
start other conditions are not considered in the starting circuit mainly because of
the emergency under which the DG has to start. However an annunciation is
provided for these conditions, the operator has to take the decision whether to
run the DG or not.
These conditions are:
Hand switch for starting air compressor:
HS-7233 (HS-7234 / HS-7263) is in "ON" or "AUTO" position.
(a) Hand switch for crank case exhaust fan:
HS-7231 (HS-7232 / HS-7264) is in "ON" or "AUTO" position
Rev. No. : 02, Oct. 2008

(b) Hand switch for ventilation fan:
HS-7227 (HS- 7228 / HS-7270) and /or HS- 7229 (HS-7230/ HS-7271) are in
“ON” or AUTO position.
Even if any one of the above conditions is not satisfied an Alarm – DG AUX
HAND SWITCH POSITION NOT IN AUTO MODE will appear on control room,
control panel 6610-PL-1.
(iii) In “LOCAL” position of HS–7214 (HS-7219 / HS-7256) on control panel 6610-PL-

1 hand switch HS-1 on DCP (diesel control panel) is kept on “Start” position to
energize the “Operate” coil of relay ‘4’. In “Remote” position of HS-7214 (HS-
7219/HS 7256) on C/R control panel, 6610-PL-1, operate coil of relay (4) can be
energised through push button PB – 7070 (PB – 7059 / PB – 7112) in control
room, if HS –7032 (HS –7026 / HS – 7255) is in manual position or through the
initiating contact 5 P (5Q) in EMTR panel, if HS – 7032 (HS-7026 / HS-7255) is in
auto position.
NOTE: For detail refer DG logic Diagram:
NO. NAPS # 1,2 / 65231 / 6042 / ED R- 0,SI
5.2 STOPPING
This can be done through switch HS-1 (2) (3) in DG local control panel if HS 7214
(7219) (7256) is in local position. Direct stop from control room through push button
PB-7071 (7058) (7111) is also provided. These operate on relay 4T, which in turn
resets relay '4'.
6.0 PROTECTIONS
6.1 The following protections operate trip relay 94 M, which trips the generator breaker
and resets relay '4' for stopping the engine.
(i) Generator over speed through 'OSR'

(ii) Mechanically operated over speed protection. (12 MX)
(iii) Low Lube oil pressure (63 PLQX)
(iv) Low fuel oil pressure (94 MX)
(v) Fire protection (95 FPX)
(vi) Excitation failure (41 Z)
(vii) Incomplete start (48 X)
(viii) Loss of excitation (41 X)
(ix) High jacket water temperature (26 X)
Rev. No. : 02, Oct. 2008

6.2.1 The following protections operation through relay '94B' to trip the generator and reset
relay '4'.
(i) Over current protection (51BR, BY, BB)

(ii) Ground over current protection (51 BN) through timer 94 NY.
6.2.2 The following protections operate through relay '94' to trip the generator and reset
relay '4'.
(i) Differential protection (87 R, Y, B)

(ii) Reverse power protection (67)
Stage-1 Only gen. C.B. trip
Stage-2 DG trips if reverse power remains for 2.0 sec
7.0 INDICATIONS
7.1 The following indications are provided on the control room panel 6610-PL-1
7.1.1 LAMP INDICATIONS

(i) Engine ready to start.
(ii) Engine started
(iii) Engine stopped.
7.1.2 CRT ANNUNCIATIONS
(i) 5231-EG 1 (2) [3] Overload 2216, (2220), (2426)

(ii) 5231-EG 1 (2) [3] Under frequency 2217, (2221), (2427)
(iii) 5231-EG 1 (2) [3] Running and CB-7 (31) (70) open 2218 (2219),
(4306)
(iv) 5231-EG 1 (2) [3] CB-7 (31), (70) Not available 2224, (2225), (2439)
(v) 5231-EG 1 (2) [3] CB-7 (31), (70) Fail 307,(308), (2440)
7.1.3 WINDOW ANNUNCIATIONS
(i) 5231 EG1 (2) [3] Trip AN4282, (4283), (2435)

(ii) 5231 EG1 (2) [3] Electrical Trip AN4286, (4287), (2428)
(iii) 5231 EG1 (2) [3] Ground Fault AN4306, (4309), (2436)
(iv) 5231 EG1 (2) [3] Auxiliary Trouble AN4285, (4288), (496)
(v) 5231 EG1 (2) [3] Starting Air Pressure Low (AN 4281/4284),
(2424)
(vi) 5231 EG1 (2) [3] Fuel oil level low AN 4279, (4280), (2401)
(vii) 5231 EG1 (2) or CB7 Fail AN 4307, (4308)
(31) or CB [70]
Rev. No. : 02, Oct. 2008

7.1.4 METERING
a Ammeter 65231-EG 1 (2) (3) AM 71 (87)

b Frequency meter 65231-EG 1 (2) FM 1 (2) (3).
c KW meter (common for all) WM - 6004
d KVAR meter (common for all) VARM-6004
7.2 The following indications are provided in the local control panel of M/s DLW.
7.2.1 LAMP INDICATIONS
(i) Engine ready to start

(ii) Engine started
(iii) Engine stopped
(iv) Starting air compressor running
(v) Starting air compressor stopped
(vi) Pre lube oil pump running
(vii) Pre lube oil pump stopped
(viii) Fuel transfer pump running
(ix) Fuel transfer pump stopped
(x) Ventilation fan running
(xi) Ventilation fan stopped
7.2.2 METERS
The following meters are mounted on the DG control panel
(i) Ammeters
(ii) Voltmeter
(iii) Wattmeter
(iv) VAR meter
(v) Frequency meter
(vi) Speed indicator
(vii) Hour counter
(viii) Stator temperature indicator
7.2.3 ANNUNCIATIONS ON DG CONTROL PANEL
(i) 250 V DC failure (W. NO. 1)

(ii) Excitation faults (W. NO. 2
(iii) Lubricating oil temperature high (W. NO. 3)
(iv) Lubricating oil pressure low (W. NO. 4)
(v) Pre lubrication pump in operative (W. NO. 5)
Rev. No. : 02, Oct. 2008
(vi) Hand switch position not in auto / on mode (W. No. 06)
(vii) Bearing lube. Oil level low (W. No. 7)
(viii) Fuel oil day tank level low (W. No. 8)
(ix) Fuel oil day tank high (W. No. 9)
(x) DG pedestal bearing temperature high (75 c):
(xi) Fuel oil transfer pump 1 / 2 on (W. No. 11)
(xii) Air pressure below compressor auto start (W. No. 12)
(xiii) Air pressure low only two start possible (W. No. 13):
(xiv) Jacket water level low (W. No. 14):
(xv) Jacket water level very low (W.no-15)
(xvi) Diesel generator auxiliary trouble (W. No. 16):
(xvii) Jacket water temperature high (W. No. 17)
(xviii) Diesel is operating over 90% speed (W. No. 18)
(xix) In complete start (W. No. 19):
(xx) Fire protection operated (W.No.20)
(xxi) Mechanical over speed trip (W. No. 21)
(xxii) Over speed trip (W. No. 22):
(xxiii) Battery charger failure (W. No.23)
7.3 DETAILS OF DIESEL ENGINE INSTRUMENTATION
The following instrument have been provided on instrument control panel:
PG for lube oil filter inlet pressure

PG for lube oil filter outlet pressure
PG for bearing lube oil header pressure
PG for air pressure before PRV
PG for air pressure after PRV
Air manifold pressure
PG for fuel oil header pressure
LG for fuel oil day tank level
LG for jacket water expansion tank level
PG for fuel oil pressure secondary filter inlet
PG for oil pressure secondary filter outlet
PG for jacket water pumps discharge pressure
Pyrometer
Selector switch
8.0 DIESEL ENGINE AUXILIARY SYSTEMS
8.1 FUEL OIL SYSTEM
The central fuel oil storage system consists of two number 64,000 liters capacity
underground storage tanks for Unit 1 and similar capacity tanks for Unit 2.
The fuel central storage tank is pumped to day tanks (4000 liters) of each unit by fuel
oil sump pump. Each central storage tank is provided with one sump pump for this
Rev. No. : 02, Oct. 2008

purpose. There is provision in the piping for feeding any day tank of one unit from
any one of the two storage tanks.
Each DG set is provided with one-day tank. Provision is made in the piping circuits
such that any day tank of one unit can feed any one of the DG sets associated with
that unit.
A tie connection is provided in the piping circuits of storage tanks so that the storage
tanks of one unit can also feed the day tanks of other unit if necessary.
Electrical heat tracing is provided for storage tanks, day tanks and piping up to the
Diesel Engine to take care of cold weather conditions.
8.1.1 HEAT TRACING

As was discussed in item 3.4 the entire HSD storage and handing system are
provided with self current limiting, low watt density and self regulating electric trace
heaters along with associated controlling devices as under.
(a) Underground storage tanks are provided with

(i) Heat shrinkable type primary coating to prevent corrosion of steel plates of
storage tanks.
(ii) Electric heat trace elements cover primary protective coating.
(iii) Polyurethane foam (PUF) type thermal insulation to prevent heat loss.
(iv) Heat shrinkable environmental seal over thermal insulation.
(v) Thermostate to trip power supply to electric tracers in case of temp exceeding
set point.
(vi) Suitable earthing of each storage tank.
(vii) Condition level indicator for each storage tank.
(b) HSD handling piping and day tanks are provided with
(i) Electric heat tracing tapes
(ii) PUF insulation
(iii) Environmental seal (for out-door installations only)
(c) CONTROL PANEL
(i) Control panel is located beyond the fencing of bulk storage tanks.
(ii) Maximum length of each auto trace circuit is limited to 130 meters.
(iii) There are about 32 such circuits.
(iv) Each outgoing feeder consists of the following –Switch
-Earth leakage circuit breaker to trip circuit in case of leakage current due to earth
faults.
-Indicating lamps.
Rev. No. : 02, Oct. 2008

(d) CONTROL FOR HSD FUEL OIL SYSTEM

Ref. Drawings:
(i) NAPP 1,2/53530/6001/FS - flow sheet
(ii) NAPP1, 2/65353/0001/2 – DC control circuit for solenoid valve
(iii) NAPP1, 2/65353/6002- control and interlocks for diesel storage oil system
(iv) NAPP1, 2/65353/6003 – fuel transfer pumps EWD
The controls of HSD fuel oil system are covered in above-mentioned schematic
drawings. The gate valve of fuel transfer pumps are of manually operated type and
hence pre manual selection of the HSD fuel route by valve positions has to be done
for further automatic starting of fuel oil transfer pumps, when level in the DG day
tanks fall to the lower limit.
A control panel “ HSD fuel transfer control panel” is supplied by M/S Electrotek Co.
and located in the CW pump house near HSD storage tank. The panel has to be
manned by an operator.
The control switch HS-7245 is possible to start any of the fuel transfer pumps
manually by manual remote control after ensuring necessary valve opening.
Selector switch 7245 has three position viz pump 1 or pump 2 and manual. The first
two positions are for automatic starting of pump1 or pump 2 when level in the DG
day tanks fall (However the gate valve should have been kept open for the desire
selection of pump one or pump two).Provision has been made for stopping of
HSDfuel pump by opening emergency stop push button located near fire water
pump. The PB should be lockable in the operated positions and shall be released by
key operation.
The controls for fuel transformer pumps 3&4 ( of unit –2) are identical to that of
pump –1 and pump-2 .
The following indicating lamp are provided in this control panel .
1) LT-7136 Pump –1 ON
2) LT-7137 Pump –1 OFF
3) LT-7138 Pump –2 ON
4) LT-7139 Pump –2 OFF
5) 2-LT-7136 Pump –3 ON
6) 2-LT-7137 Pump –3 OFF
7) 2-LT-7138 Pump –4ON
8)2-LT-7139 Pump –4 OFF
The following annunciations are provided in this control panel.
1) 1-DG-1 Day tank –1level low
2) 1-DG-1Day tank –1level high
4) 1-DG-2 Day tank –2level high
6) 2-DG-1Day tank –1level high
8) 2-DG-2 Day tank –2level high
9) 1-DG-1 Day tank –1 solenoid valve open
10) 1-DG-2 Day tank –2solenoid valve open
11) 2-DG-1 Day tank –1 solenoid valve open
12) 2-DG-2 Day tank –2solenoid valve open
Rev. No. : 02, Oct. 2008
8.2 ENGINE STARTING SYSTEM
An air motor geared to the engine main camshaft at coupling end starts engine. One
compressor with two air receivers is provided for each engine. Pipe connections are
provided so that any of the compressors can supply to any starting motor.
The capacity of each air receiver is about 34 cu.ft. Six starts of one DG set with both
receivers are possible without recharging the receiver. The minimum starting air
pressure required for starting the engine is 6.5-10.5 kg/cm2 however, the pressure in
the air receiver is maintained between 14.25 – 17.5 kg/cm2 by automatic start/stop
of air compressors.
8.3 PRE-LUBRICATING OIL PUMP
For each engine, one pump in conjunction with timers is provided so that lube oil is
supplied intermittently when the engine is not in operation. In auto mode of pre
lubricating oil pump, it runs for 10 minutes followed by a rest period of 50 minutes
and this cycle is continued as long as the engine is not in operation. The time setting
can be adjusted to attain different cycle times, if required.
8.4 CRANKS CASE EXHAUST EJECTER
One ejector per engine is provided to exhaust the oil vapour in the crankcase when
the engine is in operation.
8.5 GOVERNING SYSTEM
Woodward make, governor with control box is provided with each engine. It can be
selected for either isochronously or speed droop is adjustable from 0 to 5%.
Electrical and mechanical over speed trip devices are devices are provided.
The isochronously mode of operation may be adopted when the DG set is working
independently. The speed droop mode should be adopted power source. The auto
characteristic mode may be adopted in either of the above cases. Normally electrical
governing will be in operation and will take care of speed variations of 5%.
For variations above this and in event of failure of electrical governor, the mechanical
governor will take over (as mechanical governor will be set above 5%) A booster
servomotor is provided with each governor to facilitate quick engine starting. An
adjustable load limit device is provided at the engine.
8.6 JACKET WATER HEATERS AND HEAT EXCHANGER
In the engine, jacket water heaters are provided and are switched on if the
temperature of water is low. They are controlled thermostatically and are
automatically switched off when the engine is started.
Rev. No. : 02, Oct. 2008
One jacket water heat exchanger for each engine is provided. The engine cooling
water is closed loop system. This water is cooled in the jacket water heat exchanger
by presser water, when the engine is running.
8.7 LUBE OIL HEATER AND HEAT EXCHANGER
In the lube, oil sump heaters are provided and are switched on if the temperature of
lube oil is low. They are controlled thermostatically and are switched off
automatically when the engine is started.
Lube oil to process water heat exchanger is provided for each engine for cooling the
lube oil.
8.8 ENGINE EXHAUST SYSTEM
As per the layout, the day tanks, DG exhaust, storage tanks are located on same
side of Turbine building. Temperature of exhaust flue gases coming out from silencer
is 484 deg. C approx. and vapour coming out of HSD day tanks may catch fire due to
these hot flue gases. To avoid this a steel chimney is provided. The rate of exhaust
gases at 484 deg. C is 27253 C3/hr (16050 CFM). Sampling point is provided in all
chimneys to collect sample for analysis of exhaust gases to monitor its impact on
environment.
Diesel exhaust system consists of exhaust duct from engine, expansion joints, and
silencer and steel chimney. Exhaust from engine is connected to silencer through
500 diameter MS duct. DLW has supplied the silencer having dimension 1410 x
4500 long. Outlet of silencer is connected to steel chimney. On either side of the
silencer, one expansion joint is used to avoid transfer of any vibrations form/to diesel
engine, silencer and chimney.
Details of stack
Stack height 37.0 M for DG-1, 2 and 14.0 M for DG-3

Stack inside diameter at base 1.750 M
Stack inside diameter at top 1.250 M
Height of sampling point 25.0 M for DG-1, 2 and 10.0 M for DG-3
No. of steel stacks 3 Nos. (one for two DG sets)
8.9 CO2 FIRE SYSTEM
CO2 fire protection system is provided to extinguish fire in DG room. Each CO2 fire
protection system consists of 18 nos of CO2 cylinders in two banks (9 each) and is
common for two DG sets. In the event of DG room temperature increasing from its
preset value (75 deg. C) sensed by temperature detector in any of the two DG sets,
CO2 fire system actuates to initiate hooter alarm in DG room, DG control panel room
and fire system area. After 1 minute of initiation, fire solenoid valve of respective DG
Rev. No. : 02, Oct. 2008
sets energizes to operate cylinder puncturing weight and directional valve of the
affected DG set. When CO2 is injected in DG room, the ventilation fans and dampers
are closed automatically. An alarm is initiated on DG control panel and in main
control room.
Important Components of CO2 fire system:
Detectors: Type - Heat Detector (06 Nos.)

Inside DG room, near the ventilation duct.
Control Panel: Unloading way -for DG-1 & 2.
Outside 1- DG -3 room - for DG-3.
Solenoid: Electrical trip
To release the wire ropes for opening of directional valve.
Directional valve: For releasing CO2 from cylinder to DG room.
Audible Alarm: For personal evacuation from DG room.
CO2 cylinder: 18 cylinders per bank.
Tubular cutter: To puncture the cylinder.
Locking pin: To block falling of weights while testing.
Trip push button:
Trip pull box:
Timer (0 -60 sec):
Discharge Nozzle & Associated piping.
Weight system for operation of direction valve and tubular cutters.
Mode of Operation:
- Auto through detector.
- Manual through trip push button.
- Manual through trip pull button.
- Testing through control panel.
4.5 Indication on control Panel:
220V DC Fuse Failure Red

220V DC Normal Green
24V DC Normal Green
System Normal Green
Fire Condition Red
CO2 release Red
Rev. No. : 02, Oct. 2008

Block Diagram of CO2 total flooding system
Trip Pull Box Trip PB (lo cal) Testing PB
Initiating Rela y
Solenoid Valve N
Hooter N N
D D
DG SET
Releasing of
Lo cking Pin D.V.rop e N N
D D
To Fall
To Fall D V weight N
D D N
CO2 Cylind er weight
To Open
To N N
Puncture DV N
CO2 GAS
Note : DG ROOM
D - Thermal Detector.
N - CO2 Discharge No zzle.
CO2 Cylinder DV- Directio n Valve
(18 No.)
Rev. No. : 02, Oct. 2008

8.10 TECHNICAL DATA
8.10.1 DIESEL ENGINE
Rating 2600 BHP

Type ALCO 16 Cylinder VEE 251B
RPM 1000
Direction of Rotation Clockwise
No of strokes per cycle 4 strokes
Cylinder Arrangement 2 banks of 45 deg VEE 8 cylinders per
bank
Bore 9" (228 mm) nominal
Stroke 10.5" (267 mm)
Compression ratio 12.5 1
Maximum firing pressure 1730 psi at 60 deg F. Ambient (121.7
kg/cm2 at 15.60C)
Mean piston speed 1750 fpm (533.4 m/minute)
Break mean effective pressure at rated 148 psi (10.41-kg/cm sq at rated load
load (BMEP) of generator
Mean Indicated pressure (MIP) at rated 174. 7 psi (12.3 kg/cm2)
load
Compression pressure 420 psi (29.5 kg/cm2)
Supercharging air pressure at rated load 30" to 33" (762 mm to 838 mm) of Hg
Cycling irregularity 0.5 %
Period of maximum engine rating 2 hours
Combined shaft system moment of 1279 1b.ft sq for engine alone
inertia
Supercharger critical speed Working speed 18000 rpm
approximately.
Firing order viewed from power take off 1R-1L-4R-4L-7R-7L-6R-6L-8R-8L
end 5R-5L-2R-2L-3R-3L
Jacket water temperature rise at rated 25 deg. F. at full load.
load
Jacket water pressure (at engine inlet) 25 psi (1.76 kg/cm2)
Fuel system injector pressure 3800-4000 psi (275-285 kr/cm2)
Fuel system booster pump pressure 50 psi (3.51 kg/cm2)
Fuel injection start timing 25 1/2" before TDC
Lubricating system oil pressure at pump 130-135 PSI (9.14 to 9.492 kf/cm2)
discharge
Lubricating system oil temperature in 170-190 deg, F (76.7-87 deg. C)
engine pump
Minimum acceptable lube oil 110-120 deg. F (43.3-49 deg. C)
temperature at start up
Lubricating oil consumption at rated load Approximately 2.0 lit/engine hr.
Valve timing - inlet valve opens 63 deg. 48' BTC
Valve timing - inlet valve closes 29 deg. 40' ABC
Rev. No. : 02, Oct. 2008
Valve timing - exhaust valve opens 41 deg. 28' BBC

Valve timing - exhaust valve closes 60 deg. ATC
Maximum time required to start the 30 sec.
diesel from cold and bring to rated speed
and in condition to take load casing oil
temperature
Make up water required 8 to 10 liters for 24 hours run approx.
Minimum allowable jacket water temp. at 155 deg. F
start up
Governor type 155 deg. F
9.2 DETAILS OF SUMP PUMP
Make/Type M/s Kirloskar make vertical submerged type

No. of sump pump Four
Feature capacity 12 m3/hr
Discharge pressure 3.5 kg/cm2
RPM 1450
Liquid to be handled High speed diesel oil
Size (Suction x delivery) 65mm x 40 mm
Bearing lubrication Self lubricated
Pump input 2.69 KW
Pump casing C1
Impeller Bronze
Shaft C-40
Kirloskar make vertical flanged induction motor suitable for 415V, 3ph AC, Flame
proof & weather proof, 7.5 HP (5.5 KW), 1450 RPM, TEFC, with 'Class F' insulation.
9.3 PROPERTIES OF HIGH SPEED DIESEL (HSD)
Viscosity C S 2.0 to 7.5

Density gm/m1 0.8441 to 0.7436
Flash point 38 deg. C
Pour point 18 deg. C in winter, 6 deg. C in summer
Thermal conductivity Kcal/he/m/ deg. C 0.0993 to 0.0814
Calorific value Kcal/kg 10800 (Gross) 101000 (Net)
Water content (% by volume) 0.05 (max.)
Ash content (% by wt) 0.01 (max)
Acidity Total m gm of KOH/gm 0.50 (max)
Sulphur content (% by wt) 1.0 (max)
Specific heat (Kcal/kg/deg. C) 0.4843 to 0.5729
Rev. No. : 02, Oct. 2008

9.4 GENERATOR OUTPUT PARAMETERS
Continuous output 2250 KVA, 1800 KW

Power factor 0.8 lag
Rated voltage 425 V
Rated current 3050 Amps
Speed 1000 rpm
Frequency 50 Hz
Field current 330 A at rated output and voltage
Insulation class F with class B temperature rise
9.5 MACHINE PARAMETERS

Synchronous reactance Xd, Xq 105% and 60%
Transient reactance Xd' 25%
Sub-transient reactance Xd' 19%
Zero sequence reactance Xo 10%
Negative sequence reactance X2 18%
Open circuit field time constant 2.6%
Short circuit ratio 100%
WR sq. of generator 300
Resistance of field winding at operating 0.14 Ohm
temperature
9.6 MACHINE PERFORMANCE

Full load losses 75 KW
Armature copper loss 18 KW
Rotor copper loss 20 KW
Core loss 15 KW
Stray losses 13.5 KW
Efficiency 1/4 load/ 1/2 load 3/4 load/Full 92.8/94.7/94.6/95%
load
Temperature rise over 45 deg. C Ambient
(i) Stator by Thermometer 75 deg. C
(ii) Field winding by resistance 85 deg. C
(iii) Core by thermometer 75 deg. C
9.7 NEUTRAL GROUNDING RESISTOR
Value 0.48 ohm

Current Rating 500A for 1 minute
Rev. No. : 02, Oct. 2008

CHAPTER - 9
POWER MOTOR GENERATOR SET
(52315)
1.0 This chapter covers controls, protections and annunciations of motor generator (MG)
set.
The class II system is intended to provide no break power supply to very important
auxiliaries. The motor generator sets described are meant for uninterrupted power
supply (415V, 3 phase, 50 Hz) to these auxiliaries. The DC motor of this MG set is
fed from class I 250 V DC supply. This class I system in turn is fed simultaneously
from two sources viz 500 KW ACVR from class III supply system and 2200 AH.
250VDC batteries permanently connected to the class I buses.
On loss of class IV supply, the class III system will also loose supply temporarily until
emergency DG sets start and restore class III supply. During this period, the 250V
DC batteries will continue to supply the MG sets so that the supply disturbance is not
perceived on class II buses. The batteries are capable of maintaining class II system
through MG set for about 30 minutes. The class III supply is expected to be resumed
within this period when the ACVR will supply class I and class II bus requirements in
addition to the boost charging of the batteries. There is a provision of a tie between
respective class III and class II systems, to restore class II supply in the event of
failure of MG SET. This tie is closed automatically through emergency transfer
scheme. The DG set has to be kept running during this period to ensure no loss of
class II supply on subsequent class IV failure.
3.0 FEATURE CRITERIA
3.1 SUMMARY OF LOADS CONNECTED TO THE CLASS II BUSES ARE AS
LOAD DESCRIPTION 5230 BU-S 5230 BU-T

Fuelling machine supply pump 94 KW 94 KW
Emergency injection system light 110 KW 110 KW
water supply circulating pump
Class II MCC M 67 KW -
Class II MCC N - 71 KW
Safety related MCC Q - 16 KW
Normal operating band 67 KW 87 KW
Rev. No. : 02, Oct. 2008

LOAD IF ONE DG OPERATING
Hot shut down/crash cooling 161 KW or 87 KW or 181 KW

condition 76 KW
Emergency core cooling condition 187 KW or 87 KW or 207 KW
67 KW
The maximum load on any MG set 207 KW 207 KW
Assuming efficiency of 0.9 and pf 0.8 for the combined loads the KVA requirement
207/0. 9X0.8 - 287.5 KVA. Hence, the selected capacity of 325 KVA for each MG set
is adequate.
3.2 STARTING METHOD
In view of the large size (290 KW) of the DC motor of the MG, set, starting with pony
motor has been preferred to resistor controlled starting on class I DC bus. Further
operating experience of RAPP and MAPP has shown this method as satisfactory.
The pony is specified for three successive starts of MG set in an hour.
3.3 VOLTAGE AND SPEED REGULATION
The MG set has been specified with the following regulation of AC voltage and DC
motor speed.
AC voltage Limits of voltage regulator variation +1% (0 to 325 KVA

continuous application)
DC motor speed Limits of speed regulation variation + 1% (0 to 325 KVA
continues application)
3.4 MOTOR STARTING DUTY
The MG set has been specified to limit the transient voltage drop to 20% on starting
a large motor of 120 KW rating (starting current of 1240A) on a base load of 140 KW
and the recovery time for the MG set to restore to 90% of the rated voltage on
application of this starting load is 0.5 seconds.
3.5 SUPPLY VOLTAGE EXCURSION
The nominal voltage of the DC bus will be 258V DC (with the battery in floating
condition) On sudden loss of AC voltage the battery voltage will fall down to about
250 V. When the MG set is fed from DC batteries only, this terminal voltage will
gradually drop further down to about 200 volts at the end of about 30 minutes when
the batteries will be fully discharged. Further down to about 200 volts at the end of
about 30 minutes when the batteries will be fully discharged.
Rev. No. : 02, Oct. 2008

Further, on restoration of AC supply ACVR will boost charge the battery when the
DC bus voltage will raise to order of 270 volts to 300 volts. It is necessary that the
MG set is able to operate and deliver the full capacity under all such varying supply
condition within the limits of speed regulation of +2.5%. These stipulations are
incorporated in the specification and tested to the extent possible either at the shop
or during commissioning.
3.6 SYSTEM GROUNDING
In order to reduce the fault current in the event of ground fault in the machine or in
class II system, the neutral of the AC machine is grounded through a neutral
grounding resistor of 0.4 ohm. This will restrict ground fault current to about 600
amperes or less.
3.7 PARALLEL OPERATION
The MG set can be paralleled to the DG set for taking the machine out for
maintenance or restoring the machine after maintenance shut down. For successful
parallel operation droop characteristics" have been specified for both voltage and
speed controllers.
3.8 INSTALLATION AND LOCATION
The MG set is supplied by M/S. Kirloskar Electric Company. Each set consists of a
DC motor, pony motor, alternator, tacho generator cum over speed switch all couple
to form a singles rotating system. The excitation is derived from machine terminal
through a saturating current and voltage transformer, which is mounted on the
alternator itself. The MG sets are located in turbine building in rooms T1-128 and T1-
134 for unit 1 and T2-128 and T1-134 for unit 1 and t2-128 and T2-134 for unit II.
4.0 CONTROLS
4.1 Starting of MG set is possible only from MG control panel. The procedure for the
same is as follows (figures mentioned in brackets are for MG-2)
Refer drawing number NAPP/52315/2503/ED and 52330/FS-5
- Master set up relay 'R4' monitors initial permissive conditions such as DC breaker
is off, overload protection not operated and over speed limiting gear has not
operated, MG output breaker is open and "DG over voltage relay not operated".
- Pony motor is started through control switch CS-2. The AC generated and DC
machine are kept under excited during starting of pony motor.(By Keeping the
FSS Closed.
- The motor field contracts ‘MCC’ is then closed by the operation of switch SS-
1.The motor terminal voltage is built up relay ‘72R6’ Pick up and its ‘NO’ contacts
closes in the DC breaker closing circuit. The DC breaker can be closed by
subsequent operation of ‘CS-1’ control switch the null voltmeter ‘V3’ is provided
Rev. No. : 02, Oct. 2008
for comparing DC machine voltage to the DC bus voltage before closing the DC
breaker.
- The pony motor trips on closing of DC breaker through auxiliary relay 72XX. The
field application contactor MFC is now bypassed by diode D to prevent loss of DC
machine due to field fuse failure or dropping of field contactor.
- The field shorting switch ‘FSS-1’ is then open. The generator terminal voltage is
built –up as full output.
- The voltage regulator contactor is now closed through control switch CS-3 with
selector switch SS-4 in auto position.
- The speed regulator contactor is closed by the operation of control switch CS-4.
- Regulation of voltage and speed of the machine is possible both from local
control panel as well as remotely from control room panel. For this purpose
selector switch, SS-2 has to be put in local or remote position respectively.
- Control switch CS-5 and CS-6 are for voltage and speed control from the local
control panel.
- Control switch HS-7205 and HS-7206 provided in the central control room (panel
6610-PL-1) are for the purpose of voltage and speed control from control room.
- The closing of AC breaker is to be normally affected from the central control room
through HS-7077 in panel 6610-PL-1.
- Field flashing is normally not required for initial building up of AC voltage.
However, scheme has provision for field flashing from AC auxiliary supply
rectified through rectifier REC-1. This flashing circuit is affected through the
normal position contact of selector switch SS-4.
- Whenever the MG set operates in parallel with other MG set or DG set, the droop
characteristics for the voltage and speed control is automatically selected through
the auxiliary contact of the breakers.
4.2 INTERLOCKS
Interlocks are provided in the MG control for the following.
- DC breaker closing cannot be accomplished unless the pony motor contactor and
the DC field contactors are closed.
- Voltage and speed regulator contactors can be closed only if the DC breaker is
‘ON’.
- AC breaker cannot be closed unless DC breaker is closed first and AC voltage is
built up.
4.3 SYNCHRONISING
MG set can be run in parallel with other MG set through the breaker 5230-CB-32
(5230-CB-33) or with class III system through class III to class II tie 5230-CB-19
(5230-CB-2-). This synchronizing should be normally done from control room. The
provision for synchronizing from MG control panel through exists in the scheme but
is not intended to be used.
The following control and selector switches and push buttons are available in the
control room panel
Rev. No. : 02, Oct. 2008

- HS 7014 selector for auto or manual synchronizing (common for all breakers)
- PB 7015 (PB 7012) for MG breaker selections.
- PB 7010 for class II buses & BU-T tiebreaker selection.
- PB 7008 (PB 7011) for class III to class II tiebreaker selection.
4.4 EMERGENCY TRANSFER OF CLASS II BUS
When the MG set trips due to any electrical or machine fault, the classes II bus BU-S
(BU-T) is automatically connected to corresponding class III bus BU-P (BU-Q)
through emergency transfer scheme. For this purpose hand switch HS-7028 (HS-
7027) in the control room panel 6610-PL-1 should be kept in ‘AUTO’ position.
5.0 PROTECTIONS
The following protections are provided for the DC motor, alternator and pony motor
5.1 DC motor protections
-Over speed protection R-12

- Under voltage protection R-27
-Over voltage protection R-59
-Under frequency and over frequency protection 81L&81H
-Main field under current protection R-40
-Motor overload protection OLR-1
-Inter trip on alternator fault
-DC breaker protection with thermal and magnetic O/L releases.
-Cutting off power supply to auxiliary field in the case of tacho generator failure
(sensed through 27-S) to prevent, over speeding.
5.2 ALTERNATOR PROTECTIONS
-Phase instantaneous over current protection 50 R, Y, B

-Back up phase over current protection 51 R, Y, B
-Restricted earth fault protection 64
-Back up over current protection for earth fault 51N
-Reverse power protection 32
-AC under voltage protection 27 (A&B)
-Field over current protection.
-Inter trip on DC motor trip.
5.3 PONY MOTOR PROTECTION
-Over load protection OLR-4
-Thermister sensed excess temperature protection.
Rev. No. : 02, Oct. 2008

6.0 ANNUNCIATIONS AND INDICATIONS
6.1 The following annunciations are provided in the control room panel 6610-PL-1.
(i) ANN 4291 (ANN 4295) -5231-MG-1 (5231-MG-2) DC machine trip, which is initiated
by any one of the following protections
- Under frequency or over frequency 81L/H
- Field failure relay of DC machine R-40
- Armature over load OLR-1
- DC over voltage R59-1
- Under voltage protection R-27
- Machine over speed R-12
(ii) ANN 4292 (ANN 4294) 5231-MG-1 (5231-MG-2) electrical trip in initiated by any one
of the following protections
- Alternator instantaneous over current 50 R, Y, B
- Alternator restricted earth fault 64
- Alternator reverse power 32
- Alternator back up phase over current 51 R, Y, B
- Alternator back up ground over current 51 N
(iii) Ann 4293 (Ann4296) 5231-MG-1 (5231-MG-2) auxiliary’s trouble is initiated by any
of the following protections
- Low output from tacho generator 27-S
- Pony motor thermal over load OLR-3
6.2 The following lamp indications/relay flag indications are provided on the MG control
panel, switchgear panel and DC breaker panel
6.2.1 MG control panel lamp indications
a. MG set trip (ALI)

b. MG set control available (WL)
c. Minimum voltage AL-5
d. Maximum voltage AL-6
e. Minimum speed AL-7
f. Maximum speed AL-8
g. Over/under Frequency trip of alternator.
h. Pony motor ‘OFF’
i. Pony motor ‘ON’
j. Synchroscope ‘ON’
k. 5232-CB-1 (5232-CB-9) Open
L. 5232-CB-1 (5232-CB-9) Close
m. 5231-CB-19 (5231-CB-20) Open
n. 5231-CB-19 (5231-CB-20) Close
o. 5231-CB-32 (5231-CB-33) Open
p. 5231-CB-32 (5231-CB-33) Close
q 5231-CB-34 (5231-CB-47) Open
r 5231-CB-34 (5231-CB-47) Close
Rev. No. : 02, Oct. 2008

Note: Numbers indicated in brackets above are applicable for MG-2
6.2.2 MG control panel relay flag indications
-DC breaker protective trip

-Speed control faulty
-Armature over load
-Over speed
-Alternator field over load
-Alternator under voltage
-AC breaker protective trip
-AC machine over current/earth fault
-DC field failure
6.2.3 Switchgear lamp indications
-AC supply healthy

-DC control supply healthy
6.2.4 Switchgear relay flag indications
-DC close supply fail

-AC over voltage
-Protective relay operated
-Back up over current relay operated (both phase and neutral)
-DC trip supply fail
6.2.5 DC board lamp indications
-DC breaker closed

-Dc breaker open
6.2.6 DC board relay flag indications
-DC close supply fail

-DC trip supply fail
6.3 METERING
MG control panel
-Ammeters for DC motor current meter shunt field (main and auxiliary) current, AC,
and field current. Voltmeter for DC motor for input, back emf meter, speed indicating
meter and null voltmeter
-Alternator field voltage, field current, AC machine output voltmeter, machine line
currents, Wattmeter, VAR meter and frequency meter
Rev. No. : 02, Oct. 2008

-Synchroscope, voltmeter and frequency meter for paralleling.
Control room meters
Control room meters;
-Ammeter 65231-AM-91 (97) for AC machine current.

-Frequency meter 65231-FM-92 (10).
7.0 SEISMIC DUTY
The MG set has been specified to withstand the horizontal acceleration of 0.5g and
vertical acceleration of 0.25g.
8.0 STANDARDS
The MG set and associated equipment supplied by M/S. Kirloskar conforms to BS-
2613-1970 for AC generator and DC motor, Natural grounding resistor conforms to
IEEE standard number 32.
9.0 TECHNICAL DATA
AC machine (frame XT5-6)
-Rated terminal voltage 425 volts
-Rated continuous output at 0.8 pf 325 KVA
-Over load rating for 30 minutes 360 KVA
-Synchronous reactance <100%
-Transient reactance 10%
-Sub-transient reactance 8%
-Temperature rise after over load for 30 minute 800C
-Winding resistance
-Insulation resistance 2 M ohms at deg. C.
-Dielectric strength As per BS 2613

-Insulation class F
-Limits of voltage regulator variation on continuous + 1%
application of 0 to 325 KVA, 0.8 pf load on the
generator
Rev. No. : 02, Oct. 2008
-Maximum voltage dip on application of 120 KW 20%

(Locked rotor current of 1250 A) on base load of 140
KW
-Recovery time to 90% rated voltage on load when 0.5 second
Maximum voltage dip on application of 120 KW
(Locked rotor current of 1250A) on base load of 140
KW
DC motor (frame DC 500/180)
-Rated nominal terminal voltage 258 volts
-Maximum working terminal voltage 300 volts
-Minimum working terminal voltage 200 volts
-Rating 290 KW
-Armature current at rated voltage with alternator 1350A
operating under over load condition for 30 min.
-No load armature current 60A
-Nominal full load speed 1000 rpm
-Temperature rise over 50 degree Celsius after 200C generator has operated for
30 minutes with maximum voltage dip on application of 120 KW (locked rotor
current of 1250A) on base load of 140 KW.
-Insulation class F
-Winding resistance 0.00253 ohms at 25
deg.C
-Dielectric strength AS per BS 2613
-Limits of speed variation on continuous application of+1%
0 to 325 KVA, 0.8 pf load
-Limits of speed regulator variation for transient + 2.5%
application of load as well DC supply variation.
Pony motor (frame LC-2505)
-Rating 37 KW, 1000 rpm
-Rated voltage 415V, 50HZ
-Numbers of starts permissible per hour Three
Tacho generator
-Output 100V at1000 rpm
Neutral grounding resistor
-Value 0.4 ohm
-Rated voltage 1.1 KV
-Current rating 75A continuous or
750A for one minute
-Insulator class 1.1 KV
Rev. No. : 02, Oct. 2008

Chapter-10
Control Inverter Set
1.0 General Description:
60 K VA Inverters are supplied by M/s. KELTRON. All power, control and

protection associated with each inverter is accommodated in one panel only. The
inverters are located in Turbine Building in room No. T1- 118, 119, 120 & 121 at
El-100 M.
The control power supplies and distribution circuits are designed for continuous
operation with utmost degree of reliability under all emergency conditions.
Inverter -1 feeds to 5233-BU-A (Control power supply cell#1), Inverter -2 to
5233-BU-C (Control power supply Cell# 9) and Inverter#3 to 5233-BU-B (Control
Power supply Cell # 4). Output of Inverter is 415V AC, three phases with
neutral. Inverters are designed for voltage regulation  1% & frequency
regulation  1%.
Power is fed from four nos. of Inverter sets to their respective 415V control buses
5233-Bus-Uc,Vc, Wc & Xc. Bus Xc serves as a transfer or hot standby bus. The
Inverter set takes input power from class-I 250V DC bus, which is normally fed
from respective ACVR & battery combination. The ACVRs draw the AC power
from class-III buses and feed Inverters to deliver the uninterrupted power supply
& float on class-I DC buses with their respective batteries.
During class-IV failure and subsequent loss of power supply to the class-III
buses, the DC power for the Inverters are delivered by 250V DC batteries. The
duration of the Inverters running on batteries at full load is limited by the
battery capacity. Subsequent to restoration of class-III supply from DG sets, the
Inverters continue to draw power from ACVRs, which also charge the batteries.
Normally Inverters (INV-1,2,3) are in synchronism with Inverter – 4. In the event
of failure / planned shutdown of any of Inverter (INV-1, 2, or 3), Inverter-4 will be
connected to the affected bus automatically or manually when desired. The
scheme is such that INV-4 can be connected with any one of inverter at a time.
1.1 Equipment Description :
Inverter is a static system, which generates AC supply of stable voltage and

frequency from DC source. It consists of 6 pulse IGBT based converter in bridge
configuration. IGBT (insulated gate bipolar junction transistor) is made of four
PNPN semi conductor layer used extensively as a switching device. . It is a
combination of MOSFETS & BJTS. It is a voltage controlled device as FETs, can
be made ON by simply applying base current pulses & OFF by removing pulses.
Converter bridge comprises three No. of two pulse converter section.
Rev. No. : 02, Oct. 2008

IGBT’s are triggered with pulse width modulation (PWM) based gate pulses at a
displacement of 120 degree. Out put of bridge is fed to delta-star transformer to
achieve 3 Phase, 4 wire AC supply.
Following are the features / advantages of Inverter:

(i) IGBT device is having low conduction losses & easy gate drive.
(ii) PCBs are plug in type & have modular design.
(iii) Static switches with additional isolators for static bypass to facilitate
maintenance.
(iv) Operating parameter & alarm display at local panel.
(v) Inverter components are static, compact & modular size.
(vi) System losses are negligible.
(vii) Since no rotating parts thus less wear and tear.
(viii) Less maintenance.
Inverter Configuration :
Main inverter normally feeds to respective control power supply bus through
inverter mode. In case of failure in main inverter (INV-1/2/3), loads connected to
affected inverter is switched over to INV-4 through static bypass mode operation
of affected main inverter.
Standby inverter-4 is connected to control bus Xc at no load & serves as a hot

standby for changeover. Standby inverter is similar to other Inverters except the
changeover feature, as it is used to replace other three main Inverters, not being
replaced by itself. Standby Inverter-4 is always in synchronism with INV- 1,2,3.
Inverter-4 has no static bypass facility as well as service /manual isolator for
changeover. It has got three nos. of isolators at output side for main Inverters-
1/2 & 3 poised to changeover in the event of any other Inverter failure.
Main inverter (INV-1,2,3) consists two mode of operation –

i) Inverter mode.
ii)Static bypass mode. (standby mode).
Following is the sequence of operation from inverter mode to static bypass mode
in case main inverter (INV-1/2/3) trips on fault.
i) Static switch (SS) of main inverter conducts on sensing tripping of out put
contactor Q-631/632/633 of Inverter-1/2/3 respectively.
ii) Static bypass contactor Q-721/722/723 of inverter –1/2/3 respectively picks-up

within 500 m. sec.
When Inverter trips, its output contactor (Q-631/632/633/634) of inverter (INV-
1,2,3,4) will trip and pulses for IGBT are blocked & inverter will not generate AC
supply. Operation of inverter going out side the operating range of parameter is
known as abnormal condition. In this condition pulses for IGBT is available so
Rev. No. : 02, Oct. 2008

AC supply is still available from inverter but output contactor will trip and
supply will changeover to standby mode.
2.0 System Protections & Annuciations
2.1 TRIP, ABNORMAL CONDITION AND CHANGEOVER PARAMETER : -
(A) TRIP PARAMETERS : - Following trips are provided for inverters.

1. AC over voltage : Set at 264 V ( i.e. 110% of nominal voltage).
2. DC over voltage : Set at 310 V
3. DC under voltage : Set at 200 V
4. IGBT over temp. : >65 Co
5. AC over current : 110% with 10 min time delay.

150% with 1 min. time delay.(full load current is 84A)
6. DC Over current : 360A (i.e. 150% of normal current).
7. Control supply fail
8. Cooling fan supply fail (both MCB Trip). There are two banks of cooling fans.
(B) ABNORMAL PARAMETERS : -

1. AC output abnormal
AC Under Voltage : Set at 216V (i.e. 90% of nominal voltage).
2. Frequency abnormal.
(i) Under frequency : Set at 48 Hz.
(ii) Over frequency : Set at 52 Hz.
(C) CHANGEOVER CONDITION
1. All above-mentioned trip parameters.

2. Frequency abnormal.
(i) Under frequency : 48 Hz.
(ii) Over frequency : 52 Hz.
3. AC Under Voltage : Set at 216V (i.e. 90% of nominal voltage).
In case of AC under voltage and frequency abnormal condition out put contactor
of affected inverter will trip & inverter remains functional, as IGBT gate pulses
are still available.
(D) GENERAL ALARMS :
Following will produce “Inverter –1/2/3 trouble alarm” in control room.

1. All trip parameters.
2. All abnormal conditions.
3. Synchronization faulty (Inverter-1/2/3 is not following Inverter-4).
4. Inverter running on standby mode.
5. Battery operation <240V ( i.e. Battery getting discharge)
6. Inverter-4 fail. (i.e. Supply is not available from Inverter-4)
Rev. No. : 02, Oct. 2008

2.2 ANNUNCIATION:
2.2.1 Annunciation at Inverter panel
S.No. Description Operating Parameters.

AN-1 OUTPUT Abnormal When AC O/P goes abnormal i.e. over
or under voltage
AN-2 DC over voltage DC bus voltage high > 310V
AN-3 Over Temperature Whenever power device heal sink temp.
high . 65oC .
AN-4 Control supply not Whenever internal control supply fails.
OK
AN-5 Inst. Over current Whenever AC over load exceeds.
AN-6 Freq. Abnormal O/P frequency out of range
AN-7 DC under voltage DC bus voltage <200V and battery is
discharged.
AN-8 Input MCCB MCCB is tripped due to over current or
tripped mechanical failure.
Rev. No. : 02, Oct. 2008

2.2.2 Annunciation at Inverter panel
Following annunciations are available in control room for control inverters.
S.No ANN NO./ DESCRIPTI ANN / ALARM GENERATION BY

CRCS ON
1. 440 5233-INV-1 Output contactor of inverter (Q-631)
TRIP tripped
2. 441 5233- INV - Output contactor of inverter (Q-632)
2 TRIP tripped
3 TRIP tripped
4 TRIP tripped
5. 2319 INV-1 General alarm generated by inverter
Trouble
Trouble
Trouble
Trouble
9. ESR-107 5233-BUS- Loss of Potential at bus 5233-BU-Uc
Uc Potential from both inverter mode & standby
lost mode.
10. ESR-109 5233-BUS- Loss of Potential at bus 5233-BU-Vc
Vc Potential from both inverter mode & standby
lost mode.
11. ESR-111 5233-BUS- Loss of Potential at bus 5233-BU-Wc
Wc Potential from both inverter mode & standby
lost mode.
3.0 Panel indications, meters & switches of inverter cubicle.
3.1 Meters
Meter ID Description Purpose

INPUT AMPS. Input DC ammeter. To read DC current
according to O/P AC
load
INPUT VOLTS Input DC voltage To read DC bus
voltage
Rev. No. : 02, Oct. 2008

OUTPUT AMPS-R Output AC ammeter To read R- phase ac

current.
OUTPUT AMPS-Y Output AC ammeter To read Y- phase ac
current.
OUTPUT AMPS-B Output AC ammeter To read B- phase ac
current.
OUTPUT VOLTS Output DC voltage To read AC bus
voltage.
OUTPUT FREQUENCY Input DC frequency To read AC bus
meter frequency.
3.2 Indication provided in Mimic diagram

(a) For main Inverter –1/2/3
Input DC MCCB closed.
Input contactor ON.
Load on inverter –1/2/3
Output AC MCCB closed.
Input filter charge MCB closed.
Load on bypass (standby mode).
Inverter trouble
(b) For standby inverter-4
Input DC MCCB closed.
Input filter charge MCB closed.
Inverter trouble.
Inverter output contactor closed.
Output AC MCCB closed.
Inverter-4 on load (for any inverter-1/2/3).
3.3 Push button / Switches
PB / HS Description Purpose
No.
PB1 Test To test the healthiness of all annunciator
Lamp.
PB2 Accept To acknowledge the fault.
PB3 Reset To reset the system if fault does not persists.
S470 Inverter ON To switch ON the inverter & get AC O/P
S471 Inverter OFF To switch OFF the inverter & get AC O/P
S620 V/M Selector To select phases of voltage
S870 Invert standby To select inverter operation mode i.e. Normal
selector or standby
Q301 Input DC MCCB To switch ON / OFF DC MCCB.
Q751 Output AC MCCB To switch ON / OFF AC output MCCB
Rev. No. : 02, Oct. 2008

4.0 TECHNICAL SPECIFICATION OF INVERTER
SN Equipment particulars Ratings
1. Rated output power of the system 60 KVA
2. Rated input voltage 250V DC
3. DC input at FL 253A
4. Rated output voltage 415V +1%, 3 Phase, 4 Wire
5. Rated output frequency 50 Hz. + 0.5%
6. Type of firings PWM
7. System efficiency at rated load 88%
8. Waveform of the output voltage Sinusoidal
9. Recovery time of voltage from transients

Correction within 1% upto rated voltage 50mS
10. Max overshoot/ undershoot 10%
11. Harmonic at 415V at FL <4%
12. Noise level of Inverter 65dBA at 1.5m
13. Short time current withstand rating of AC 200% for 5msec

output
14. Inverter capable to run at FL without any 15min
cooling
Rev. No. : 02, Oct. 2008

CHAPTER 11
CLASS IV 6.6 KV SWITCH GEAR
(52410)
1.0 SCOPE
This chapter covers the 6.6 KV systems and associated equipment. The system is
shown in single line diagram NAPP-1, 2/52411/6002/ED.
2.0 BRIEF DESCRIPTION OF THE 6.6 KV SYSTEM
The 6.6 KV power supply system is fed from unit transformer and start-up
transformer and caters to class IV, 6.6 KV motors, 6.6 KV/433V auxiliary
transformers (Class IV and III) and 6.6 KV power feed to D2O upgrading plant.
The switchgear consists of two main bus-sections viz. 5241-BU-D&E and 5241-BU-
F&G), the former fed from unit transformer and the later from start-up transformer.
Bus-section breaker 5241-CB-17 interconnects the two bus-sections. A tie
connection has been provided between 6.6 switchgear of unit 1 & unit 2 for diversion
of start-up power from one unit to the other, when one of the start-up transformers is
not available. Tie breakers 5241-CB-1 are provided in both units for this purpose.
Disconnecting links are provided between Bus-D and Bus-E and between Bus-F and
Bus-G to enable isolation of part of the main sections,(BU-D&E & BU-F&G) if
necessary for repairs/maintenance. The scheme has provision to divert the tie
connection between the two units to either of the main bus bars (BU-D&E or BU-
F&G) by operation of isolator 5241-IS-1 and using the disconnecting links in the
under floor bus trunk provided between the two main bus sections. Further details of
these arrangements are covered in (Scheme of Operation).
3.0 DESIGN CRITERION
Details of connected and operating loads on the 6.6 KV system are given in load-
schedule N-1/50000/6003/SCH.
The switchgear is specified for a fault level (3-phase symmetrical) of 500 MVA and
peak making current of the breakers 111.7 KA, based on the fault level of the 6.6 KV
bus. The short time (1 sec.) rating of the bus bars and circuit breaker of 43.8 KA is
also based on the 500 MVA, rupturing capacity specified.
The unit and start-up transformers are rated for a maximum output of 31.5 MVA at
6.9 KV, which corresponds to a full load current of 2635 Amps. Hence, the bus bars,
incoming tie, and bus section breakers are rated for a continuous current of 3000A.
the feeder breakers are rated for 800A, as this is the minimum available for 500
MVA, 6.6 KV circuit breakers. The switchgear is specified for an insulation level
corresponding to 6.6 KV ungrounded system and has an impulse level of 60 KV and
power frequency with stand of 27 KV.
Rev. No. : 02, Oct. 2008

The 800A feeder breakers are of fully draw-out type, whereas the 3000A breakers
are of semi draw-out type requiring manual disconnection of power terminals before
withdrawal. Hence for 3000 A breakers additional draw-out type link cubicles are
provided for isolation of these breakers. These link-cubicles are provided on either
side of the breakers for unit transformers and bus-section breakers and on the bus
side for the start-up transformer breaker and NAPP-1 to NAPP-2 tie breakers. By
drawing out the link cubicles (after tripping the associated breaker) maintenance
access to UT and bus-section breakers is achieved. Maintenance access to SUT-
breaker can be achieved by isolating the 220 KV supply side breaker and drawing
out the 6.6 KV bus side link cubicles. For maintenance access to the tiebreakers,
both the tiebreakers shall be tripped and link cubicles at NAPP-1 & NAPP-2 are
drawn out. Necessary interlocks for safe withdrawal of the breakers and links are
provided.
Air-blast circuit breakers have been preferred to minimize the risk of fire and its
associated damages. Breakers have local air reservoirs to cater to one close open
operation. The air (compressed) supply is through a central compressor system with
automatic starting/stopping facility.
4.0 CONSTRUCTIONAL FEATURES
4.1 GENERAL
The switchgear is of M/S Hindustan Brown Boveri Ltd., and is suitable for indoor
installation. Each breaker/isolator/link/voltage transformer is mounted in one vertical
section. Each cubicle is compartmentalized as breaker compartment, bus bar
compartment and CT & cable box compartment. The cubicles are provided with
lockable doors on the front and ventilation louvers on the rear.
4.2 INSTALLATION
The switchgear is installed in two parallel Bus runs in the switchgear room (T-105) at
EL 100.000 in Turbine building. The relay panels are located in the control
equipment room (EL 111000) in turbine building in two rows with a corridor forming a
duplex panel arrangement. The cable entry is from bottom for the switchgear panels
and top for the relay panels. A cable tray is provided below the switchgear room for
routing and terminating the cables.
4.3 POWER CONNECTIONS
The connection from unit transformer and start-up transformer is by means of 4 nos.
1C X 1000 mm2 XLPE cables, primary coolant pumps by 3C X 240 mm2 copper
XLPE cables, primary feed pumps by 3C X 150 mm2 copper XLPE cables and the
other motor feeders through 3C x 300 mm2 HRPVC cables. The tie between Bus-R
and Bus-H and between Bus-E and Bus- F is by means of Under Floor Bus
Trunking.
Rev. No. : 02, Oct. 2008

4.4 COMPRESSED AIR SYSTEM
The compressed air system for the operation of the breakers is centralized. Two
compressor motors rated 10 HP each maintain a minimum pressure at 27.5-kg/ cm2
in the central plant. The compressed air from the compressors is fed to a parallel
combination of two sets of reservoirs (630 liters and 350 liters). Valve are provide in
a way that any or both compressor can feed to any or both the parallel paths. The
compressed air pressure is reduced to 16 kg/ cm2 by two pressure reducer valves for
further distribution. Any or both the sets of reservoirs can feed the ring distribution
system. The compressed air plant is located in the ground floor at EL 100.000 in the
compressor room along with its control panel and other accessories like pressure
reducers.
The control of the system is so made that if the pressure falls to 27.5 kg/ cm2, one of
the compressor (any of the compressors can be chosen to start first) starts. If there
is a sudden fall in pressure up to or below 25.5 kg/ cm2, both the compressors start
simultaneously and build the pressure up to 30 kg/ cm2, at which the compressor
motors are tripped. A pressure release valve is provided on the central air reservoir
to release the pressure, if it exceeds 32 kg/ cm2. Annunciation if the pressure lies
outside the range of 24.5 kg/ cm2 to 32 kg/ cm2 is provided. Failure of the
compressor is also annunciated. The compressed air distribution is at a pressure of
16 kg/ cm2 through copper pipes of 25 mm dia. The distribution system is provided
with necessary expansion joints and drain plugs to drains condensed water. The
distribution system is ring –type with two feeds and about 37 isolation valves and is
such that if there is any leakage in the distribution system the same can be attended
to, affecting supply to only one breaker at a time.
The local reservoir at the breaker is provided with lockout switches set at 15 kg/ cm2
for tank low pressure alarm, 14.7 kg/ cm2 for closing operation, 14.1 kg/ cm2 for
opening operation and 12.5 kg/ cm2 for low pressure trip. The local reservoir has
adequate capacity to last for one close-open operation.
4.5 CIRCUIT BREAKERS

The 3000A breakers, used for UT, SUT, bus sections and tie, are type DB10q 1000
of M/S BBC, Switzerland. The breaker is wheel mounted and is of semi-draw out
type execution. The breaker can be drawn out after removing bolted connection at
the terminals. To obviate this disadvantage, draw-out type link cubicles are
envisaged as indicated in Para 3.0 when the link trolley(s) is drawn out, the breaker
will be isolated, thereby permitting maintenance of the breaker. Necessary interlocks
are provided between the breaker and link trolley such that the link trolley can be
withdrawn only if the corresponding breaker is open.
Circuit breakers for motor feeders and auxiliary transformers are type DBH 10 m 600
of M/S HBB, Baroda. These are fully draw out type and necessary interlocks are
provided for (i) preventing breaker operation while the breaker truck is in any
intermediate position between service and test positions (ii) preventing withdrawal of
the truck when the breaker is in closed position and (iii) preventing insertion of
breaker truck beyond test position unless the multipoint secondary plug located in
the front potion of cubicle is manually connected for auxiliary supply and preventing
withdrawal of the cubicle beyond test position unless the multipoint plug is
disconnected.
Rev. No. : 02, Oct. 2008
All the motor feeder breakers have special non-linear resistance to limit switching –
over-voltages. The main parts of the circuit breaker are air receiver, main valve, arc
extinction chamber, sequential isolator and control block. The air receiver has got
capacity to store compressed air required for one close-open operation. The
receiver is connected to the arc extinction chambers through main valve. The main
valve takes the tripping command from the control block to allow air from the
reservoir to the arc chamber. The arc extinction chamber houses interrupter, the
contacts of which open only to interrupt the current through the breaker at the time of
tripping. The final isolation is achieved by the main contacts open and after a time
delay, the isolator opens. After the isolator completely opens, the main contacts
close back. During closing operations only the isolator contact will close and the
main contacts will not operate.
The control scheme of the breaker incorporates usual safety features such as anti-
pumping, and under pressure lockout for both closing (14.7 kg/ cm2) and tripping
14.1 kg/ cm2). The breaker is trip-free as per provisions of IEC.
All breakers can be operated from local or remote (control room) position, selecting
the position of a selector-switch located on the switchgear panel.
4.6 ISOLATORS
The isolators are type ADG 12q3 of M/S Brown Boveri rated for 3000A, fully draw-
out and are pneumatically operated. These are of off-load type. The pneumatic
system of the breakers is used for the isolator operation as well.
4.7 BUS-BARS
Bus bars are of copper and are enclosed in a compartment in the rear top portion of
the cubicle. The bus bar compartment is isolated from the breaker. Inter-phase
barriers are also provided between the bus bars.
4.8 UNDER FLOOR BUS TRUNK
A segregated phase bus duct is provided for the connection between BU-R and BU-
H and between BU-E and BU-F. Bus bars of copper rated for 3000A are enclosed in
a steel enclosure and supported in the enclosure on 6.6KV insulators.
4.9 CT LOCATION
The CT’s are located on the outgoing connections from the circuit breakers in the
rear bottom portion of the cubicles. This compartment also houses the cable and
termination.
5.0 INTERLOCKS
5.1 CIRCUITS BREAKERS
All breakers have three-position namely-
-Service position (breaker fully in with power & control circuit connected.
Rev. No. : 02, Oct. 2008
-Disconnected position (Breaker fully withdrawn and power & control circuit
disconnected.
-Test position (breaker fully withdrawn with control circuit connected.
(a) Service Position
In this position, the breaker can be closed or opened. Interlocks are provided to
prevent breaker withdrawal or insertion, if the breaker is closed. If the breaker is in
between service and disconnected position, it cannot be closed. The breaker truck
can be moved between service and disconnected position, only if the breaker is
open.
(b) Disconnected position
The breaker can be withdrawn from service position to disconnected position only if it
is open. In case of feeder breakers, the primary connection gets disconnected
through disengagement of the tulip contacts. The secondary plug also comes out of
the fixed secondary socket. In case of the 3000A breakers, interlocks are provided
to ensure that associated link cubicles are drawn out before the breaker door is
opened. (In case of SUT breaker, which has link cubicle only on the Bus-side,
interlock with 220 KV breaker is provided, such that the breaker door cannot be
opened unless the 220KV breaker is tripped, its respective D.S. is open and the bus-
side link cubicle is withdrawn). The primary and secondary connections have to be
manually removed before fully drawing out the breaker truck.
In the breaker drawn test position the compressed air is kept connected and hence
the breaker can be pneumatically operated through ON and OFF push buttons on
the control block.
(c) Test Position
To withdraw the breaker from disconnected position to test position, the compressed
air connection must be removed. If any testing operation is required, extension
leads for secondary wiring connection and compressed air connection shall be used.
5.2 LINK CUBICLES
All the link cubicles have an interlock to prevent them from being withdrawn or
inserted unless the associated breaker is tripped.
5.3 ISOLATOR
The isolator is blocked from operation if the blocking solenoid ‘B95” is not energized.
This solenoid can be energized by a push-button operation only when all the
breakers (viz. UT, SUT and tie) associated with the isolator and open and the cubicle
door is fully closed.
6.0 SCHEME OF OPERATION
6.1 Normal Operation
Under normal running condition, unit transformer feed BU-D&E and Start-up
transformer feed BU-F&G with the bus-section tie breaker (CB-17) open.
Rev. No. : 02, Oct. 2008

During start-up of the unit, however, all the four buses have to be supplied by start-
up transformer. For this purpose the bus-section breaker CB-17 is closed and all
auxiliaries will be fed from SUT. Once the unit is synchronized with 220 KV and, the
UT breaker (CB-16) is closed after checking for synchronism, with HS-7201 in auto
position, bus-section breaker (CB-17) trips automatically.
If UT is to be taken out of service when in synchronism with 220 KV system, the bus-
section breaker (CB-17) is selected for synchronism, with HS-7201 in SUT position ,
and closed, the UT-breaker (CB-16) trips automatically. Similarly, when SUT is to be
taken out for maintenance, HS-7201 is selected to UT position and bus- section
breaker (CB-17) is closed after checking for synchronism, the SUT breaker (CB-33)
trips automatically.
If SUT has to be restored when UT is supplying entire 6.6 KV systems, then with HS-
7201 in auto position the SUT breaker (CB-33) is closed after checking for
synchronism. The bus-section breaker (CB-17) trips automatically
When either UT or SUT supply is lost, & and protection operated then fast-transfer
scheme initiates closure of the bus- section breaker (CB-17) through respective
breaker (CB-16/33)initiation scheme. It must be noted that under normal operating
conditions HS-7201 shall be in auto position for this.
6.2 ABNORMAL OPERATIONS
If a start-up has to be achieved when BU-G is faulty, opening CB-34, opening the
link between BU-F&G, closing isolator IS-1 and bus-section breaker CB-17 can
achieve the same. For restoring BU-G after fault clearance, unit shutdown would be
required as isolator-1 has to be opened.
If unit has to be started with SUT-1 out service, the same can be achieved by first
transferring SUT-2 load to UT-2. With IS-1 of both units in open position the NAPP-
1, NAPP-2 tie breakers are closed, thereby making SUT-2 supply BU-F&G of NAPP-
1. Now with HS-7201 in SUT position, CB-17 is closed. Once UT-1 is ready for
operation, SUT-2 can be released for Unit-2, by selecting UT-position on Hs-7201
and closing UT-1 breaker(CB-16) after synchroscope check. Tie breaker CB-1 of
unit-1 trips automatically. Unit-2 tie breaker shall then be tripped and SUT-2 loads
can be restored to it. However, if unit-2 is not working SUT-2 can be restrained to
feed BU-F&G of unit-1 even after keeping HS-7201 in SUT position and closing
UT-1 breaker synchronize UT-1. The bus-section breaker (CB-17) automatically
trips. It is also possible to avail SUT-2 supply for UT-1 shut-down (when SUT-1 is
not available). This can be accomplished exactly in the same fashion as in case of
start-up through SUT-2, except that with HS-7201 in SUT-position the synchronism
is done on tie breaker (CB-1).
(For this condition the bus-section breaker CB-17 is already closed, as UT-1 was
supplying the total 6.6 KV system). The UT-1 breaker (CB-16) trips automatically.
When BU-R is faulty, then start-up from SUT-2 is possible by opening link between
BU-R & BU-H and closing isolator (IS-1) with breaker CB-34 between BU-R & BU-G
open. HS-7201 shall now be now in UT-position before closing bus-section breaker
(CB-17). Once the transfer is over, UT-1 can be made operational releasing SUT-2
Rev. No. : 02, Oct. 2008

for unit-2 by synchronizing UT-1 through UT-1 breaker (CB-16)-the tiebreaker (CB-1)
trips now automatically.
Fast transfer to SUT-2 from UT-1 is possible with HS-7201 is auto position. (Note
that SUT-1 is now not available). It may be noted that no interlock prevents either of
the SUT’s feeding both SUT loads. However, such an operation is not envisaged
because in the event of subsequent tripping of the unit and successful fast transfer,
the available SUT will be overloaded. Hence, it should be noted that any SUT can
be released for exclusive use of that other unit.
The SUT, UT Tie and bus-section breakers are permitted to close when the
associated bus is dead and isolated from other sources of supply. The SUT & UT
are not permitted to operate in parallel continuously to limit the fault level on the 6.6
KV within the rupturing capacity of the breakers. Two additional timers 2.1 and 2.2
further ensure this after a time of 0.5 seconds, timer 2.1 tripping bus-section and tie
breakers, when UT, SUT & bus section breakers are in closed position; and timer 2.2
tripping tie breaker (CB-1) and SUT-1 breaker (CB-33) when any one of them is
parallel with UT-1 breaker (CB-16) with isolator (IS-1) on.
7.0 PROTECTIONS
7.1 UNIT TRANSFORMER & START-UP TRANSFORMER BREAKERS
The UT and SUT are provided with the following protection on the 6.6 KV side.
(i) Very inverse time over current relays (51) on each phase with instantaneous
element (50) for fast resetting.
(ii) A definite time over current relay (50A & 50 AX) for transformer, overload
annunciation.
(iii) An IDMT over current relay for earth-fault (51N).
(iv) Separate lock out relay for phase and earth faults (86/86N).
(v) Backup over current protection for both phase and earth faults by means of
timers (51X and 51NX).
(vi) Lockout relay (86B) for (v) above for backup tripping of the source of supply.
7.2 BUS SECTION-1 AND TIE BREAKERS
These are provided with
(i) Phase fault protection by 3 Nos. very inverse times over current relays (51) with
instantaneous element (50) for fast resetting.
(ii) Earth fault protection by an IDMT over current relay (51N) with instantaneous
element (50N) and
(iii) A lock out relay (86) is provided for above Sr. no. i & ii.
The bus section-2 breaker between BU-G and BU-R does not have any protective
trips.
Rev. No. : 02, Oct. 2008

7.3 UNDER VOLTAGE PROTECTION FOR BUS- BARS

Each of the 6.6 KV buses is provided with a 6600 V / 110 V, 400 VA, class
3 3
0.5/3.0 potential transformers for measurement and protection. One set of 2 Nos.
under voltage relays (27Ba and 27 Bb) with a timer (27Bx) provide under-voltage
protection for the bus through lockout relays 27-94A and 27-94B. This protection
trips all motor connected to the bus. PT secondary fuse failure is monitored and
protection trips prevented for under voltage condition on fuse failure.
7.4 MOTOR FEEDERS
All motor feeders are provided with the following protections
(i) One composite thermal overload relay including short circuit protection (46+49+50).
(ii) One definite time over current protection on phases R & B for locked rotor protection
(49S+ 49SX).
(iii) One instantaneous over current relay on phase Y for short circuit protection (50).
(iv) One over load relay 49A connected to Y-phase for alarm only.
(v) One instantaneous over current relay for earth-fault protection connected to core
balance CT.
(vi) A lockout relay 86 for the above protections and bus under voltage protection.
In addition to the above, the primary coolant pump motors are provided with the
following protections.
(i) A motor differential protection (87M)
(ii) Additional locked rotor protection with definite time over current relay
(49SX1+49SX2).
7.5 TRANSFORMER FEEDERS

These are provided with the following protections
(i) Instantaneous over current relay (50) for short circuit protection and very inverse
time over current relay (51) for back up protection on all phases.
(ii) Instantaneous current relay (50N) with an inverse time IDMT over current relay (51N)
for earth faults.
(iii) Lock out trip relay 86 for the above.
(iv) Buchholz protection for transformer.
8.0 ALARM ANNUNCIATIONS AND INDICATING METERS;
8.1 The following window annunciations are provided on the control panel
6.6 KV D2O upgrading plant feeder fault (AN 384)

6.6 KV breaker tank pressure low (AN 385)
6.6 KV breaker low pressure trip (AN 386)
6.6 KV system compressor trouble (AN 387)
6.6 KV breaker control supply fail (AN 391)
6.6 KV system auto transfer blocked (AN 392)
6.6 KV breaker lockout on low pressure (AN 393)
Rev. No. : 02, Oct. 2008
6.6 KV system protection supply fail (AN 394)

6.6 KV BU F/G under voltage (AN395)
6.6 KV BU D/E under voltage (AN396)
5241 CB17 protective relay trip (AN327)
Overload of motor feeder (individually for each set of motors i.e. LPPW, BFP etc.)
8.2 The following CRT annunciations are also provided
Auxiliary transformer trouble (individually for all transformers).

Transformer Gas collection (individually for all transformers).
Protective relay trip (for each set of motors e.g. LPPW protective relay trip etc.)
Bus VT fuse fail.
5241-CB-1 Protective relay trip.,
D2O U/G plant transformer CB protective relay trip.
8.3 The following indicating meters are provided on the control room panel
Voltmeters for BU-D & E, F & G.

Ammeters for UT, SUT, Motor and transformer feeders.
Wattmeters for SUT & UT.
9.0 STANDARDS APPLICABLE
IS 3427 Metal enclosed switchgear

IS 2516 & IEC- 56 AC Circuit breakers
IS 2147 Degree of protection for enclosure
IS 2705 CT’s
IS 3156 PT’s
IS 3231 Relays
10.0 TECHNICAL DATA

10.1 GENERAL
Make M/s Hindustan brown Boveri Ltd., India

Rated/ Maximum Voltage 6.6 KV /7.2 KV ( unearthed system)
Power frequency/impulse with 27 KV ( rms) for 1 min. /60KV peak
stand
Short circuit withstand at rated 43.8 KA ( I sec.)
KV
Clearance provided (insulation barrier provided)
Size of earth bus bar 50 x 6mm copper.
10.2 CIRCUIT BREAKERS
Type Air blast, HBB make ,type DBH 10m600 &

BBC make ,type DBH 10q 1000
Rated current 800A &3000A
Rated system interrupting
current
Rev. No. : 02, Oct. 2008
Making capacity 111.7 KA

Duty cycle 0-3’-CO-3’-CO
Total interruption time 2.5 cycles
Total making time 4.3 cycles
Main contacts
Type Butt
Material Copper (with silver facing of 15 microns)
Insulation
One min. power freq. 27KV (RMS)
Withstand
Impulse withstand 60 KV (Peak)
91.2/50 S)
Type of mechanism Electro pneumatic
Compressed air system
Rated pressure 30 kg/cm2 (central)
No. of close-open 1 CO
operations with Local air
receiver full..
10.3 BUS BARS
Material Copper
Rating 800 A & 3000 A inside the cubicle
Temp. rise 35 deg.C. over 50 deg. C ambient.
10.4 ISOLATORS
Type ADG12q3
Rating 3000A
Mechanism Electro-pneumatic
Power frequency withstand 35 KV (rms) for 1 min.
Impulse withstand 75 KV (peak)
Rated short time current (3 sec.-) 85 KA
10.5 MISCELLANEOUS
CT’s
Standard IS-2705
Insulation 75 KV (peak) impulse & 28 KV (rms) for one
Min. power frq
PT’s 6600 V / 110 V, 400 VA, class 0.5/3.0
3 3
Standard IS-3156
Insulation 60 KV (peak) impulse & 22 KV (rms) for one
Min. power withstand
Rev. No. : 02, Oct. 2008

CHAPTER 12
415V CLASS-IV, CLASS-III AND CLASS-II SWITCHGEARS
(52420, 52310)
1.0 This chapter covers the 415 V system and associated equipment. The system is
shown in single line diagram of 50,000- FS-1.
The breakers used in this system are of English electric make draw out type, air
circuit breakers.
2.0 Categories of breakers continuously rated at 1300A, 2000A & 3750A and
symmetrical capacity of 50 KA are used.
The breakers are of air break, spring charged stored energy type (M-pack cassette
type). The stored energy assures fast closing immaterial of the speed of operator
action. The charging of spring of stored energy mechanism is done on electrically
operated breakers by a 250 V D.C. motor and spring charging of manually operated
breakers is done locally at the breaker panel by breaker handle. When the breaker is
closed the spring for the tripping mechanism is automatically charged. This is kept in
this condition through a latch mechanism. On receiving a trip impulse, this latch
mechanism is unlatched and the trip spring force pulls the trip lever.
The contact separation and arc extinction takes place in medium of air at
atmospheric pressure, as the contacts (fixed and moving contacts) are opened, arc
is drawn between them. The arc is quenched by process of rapidly lengthening
along the arc runners and arc chutes, cooling by heat dissipation in fins and splitting
when the arc can no longer sustain.
2.1 MANUALLY OPERATED BREAKERS
Inserting an operating handle into the operating sector provided and depressing the
operating handle do operation of manually operated breaker. This continuous action
will charge and release the closing spring in one movement closing the breaker at
the correct speed independent of the operator. A direct mechanical coupling gives
indication of ACB “ON” or “OFF”.
On charging spring, the breaker is ready for closing. When a closing impulse is
given by operator from local push button it unlatches the operating mechanism that
close the main contacts of the breakers.
Manual breakers are used at the main buses as supply breakers to the MCC’s.
These are chosen because under voltage tripping or remote control is not needed.
The MCC contactors drop out on under voltage because, their control supply is
energized from their own main.
Rev. No. : 02, Oct. 2008

2.2 ELECTRICALLY OPERATED BREAKERS
This type is similar to the drive used for manually operated breakers, except that a
250V DC electric motor charges the spring for stored energy mechanism.
When the spring is in discharged condition a feed contact closes the circuit and the
motor charges the closing spring. At the end of the charging stroke, the feed contact
opens, causing the motor to stop. The spring condition “charged” is shown through
indicator. Energization of the closing coil through the push button releases the
spring and the breaker closes. Spring energy is now discharged and the motor
charges the spring as described earlier and keeps the breakers ready for next
closing operation.
The breakers are provided with anti-pumping feature. This feature permits and
ensures only one closing of breaker for one closing signal. If for any reason the
breaker trips, it will not recluse if the closing signal is persisting. Further closing of
breaker is possible only after interrupting earlier closing signal and reapplying the
signal. This feature is achieved both electrically and by mechanical linkage.
There are sets of contacts in each phase viz. main contacts and arcing contacts.
Main contact conduct current in closed position of the breaker. They have low
contact resistance and are silver plated. The arcing contacts are hard, and made of
copper alloys. While closing, the arcing contacts close first and then main contacts
close. While opening, main contacts open first and then arcing contacts open
drawing the arc between them. Thus, the cheaper arcing contacts only are subject
to pitting caused by arc (while the costly main contacts are saved) and the arcing
contacts are replaced after inspection during breaker maintenance.
All breakers are fully enclosed in cassettes and can be easily handled during
maintenance. The cassette and doors are finished with stove enamel paint.
The breakers have three distinct positions, SERVICS/TEST/ISOLATED within
cubicle, and is achieved by a racking cam and slide rails operated from the front of
the breaker. Isolated conditions give access to inspection, & from this position circuit
breaker can be completely withdrawn from the housing. The breakers can also be
withdrawn to test and isolating positions with the cassette door closed.
2.3 THE DRAW OUT MECHANISM POSITIONS
Breaker Electrical main Connection Description
position circuit control circuit
Service Connected Connected Normal service position
Test Disconnected Connected for Position for close open
local operation of and control ckt.
breaker only. breaker Operation test
Isolated Disconnected Disconnected Breaker completely
disconnected
The earth connections continue to be connected in all the above breaker positions.
Rev. No. : 02, Oct. 2008

3.0 INDICATORS
Visual indicators showing operation position viz. “ON/OFF” and motor wound stored
charge spring closing (MWS only) “CHARGED/FREE” are provided.
For motor wound stored energy spring closing type of breakers a closing release coil
is provided. This is a solenoid coil operating at 250V D.C.
A positively driven auxiliary switch providing eight contacts for each breakeris
provided. The switch has 4 NO and 4 NC contacts. The Aux. switch contacts are
rated for 11 Amps.
A carriage/ breaker position indicator switch (2NO +1NC) provides electrically
separate ways for test/service interlocks operation.
Spring loaded sliding type moving and fixed contacts are provided with each breaker.
These serve the purpose of external control wiring. Following are the utilities wire
distribution of contacts
MWS MECHANISM 4 WAYS

SHUNT TRIP RELEASE 2 WAYS
UNDER VOLTAGE RELEASE 2 WAYS
AUXILIARY SWITCH 8 WAYS
All ACB’s are fitted with automatic safety shutters for complete operator safety.
These shutters are independent in operation fully shielding the main contacts when
the breaker is withdrawn.
Shunt releases are provided in all electrically operated breakers for remote
operation. All protections are wired to this trip coil so that any protection picking up
will energies this coil and trip the breakers.
A static trip release CTZM type integrally mounted on all circuit breakers for over
current or over current and earth fault protection. This relay has an added
advantage over other relays as it does not require any biasing voltage. The fault
current sensed by CT’s is converted into voltage signal, which serves as operating
energy for this relay. The output of this relay is given to ‘PERA” a sensitive tripping
device (a magnetic latched stored energy trip release), which mechanically pulls the
tripping lever of breaker. A micro switch is provided for trip indication in conjunction
with an armature attracted relay to give flag.
CTZM has following adjustments
Over current pick up 0.5, 0.6, 0.7,0.8,0.9,1.00 times current rating.
Inverse tripping time at 4,8,12,16,20,24 sec. At 6 times of rated current
Short time delay pick up 2,3,4,5,6,8 times current setting.
Short time delay Instantaneous, 0.2,0.4,0.6,0.8,1.0 seconds.
Earth fault pick up 0.1,0.2,0.3,0.4,0.5,0.6, times of rated current.
Earth fault delay Instantaneous 0.1, 0.4, 0.9, seconds,
Rev. No. : 02, Oct. 2008

4.0 INTERLOCKS (MECHANICAL) COMMON FOR ALL 415V BREAKERS
The door of the breaker compartment cannot be opened unless the breaker is
tripped. Access to the draw out sector is only possible when breaker manual trip
lever is pressed and access flap turned. This ensures that breaker cannot be racked
out in closed position.
The breaker cannot be closed in any intermediate position electrically (i.e. between
SERVICE/TEST/ISOLATED position).
5.0 CLASS-IV SUPPLY
The 415 V class-IV power supply system covers all other loads, which may be
interrupted during an outage or disturbance without endangering the plant. The 415
volts class-IV system consists of five class-IV buses, 5242-BU-J, 5242-BU-K, 5242-
BU-L, 5242-BU-M, 5242-BU-K1. Each of these bus bars are fed from 6.6 KV class-
IV supply through 2000KVA aux. transformer BU -J, BU -K1 and BU -K are fed from
6.6KV (unit section) BU-D&E and BU -L and BU -M are fed from 6.6KV (station
section) BU F&G. There is also a provision of stand by 415 Volts BU-J This bus can
be connected to any of the three class-IV buses BU-K, BU-L, BU-M and class-III
buses BU-P and BU-Q (which is shown figure in class-III distribution) in case of non
availability of the transformer associated with these buses. This facility is not
available for BU-K1/L1 (C.W.P.H. supply bus) in view of its remoteness from the
turbine bldg., where all the auxiliary power supplies are located. Motors rated for 90
KW and above are fed directly from these class-IV buses and lower capacity motors
are fed from MCC’s, which in turn are fed from these buses.
Since the buses 5242-BU-K, 5242-BU-L and 5242-BU-M are supplied from 6.6 KV
bus, which have two sources viz. UT and SUT, In each of these buses a set of PT’s
are connected for monitoring availability of supply through indicating voltmeters in
C/R / Local panel and indicating lamps in switchgear, under voltage trip under
voltage annunciation in C/R.
5.1 CLASS-III SUPPLY
The class-III supply system consists of two main buses 5231-BU-P and 5231-BU-Q
In normal plant running condition Bus BU-P is fed from 6.6 KV switchgear (unit
transfer) through a 2000 KVA transformer and BU-Q is fed from start up transformer
through another 2000 KVA transformer. Emergency diesel generators sets (one
each) are available to these class-III buses to restore class-III supply in 30 to 60 sec.
In case of class-IV station supply fail. Provision is also available for the substitution
of any of the class-III transformers by the class-IV reserve transformer connected to
BU-J. Individual loads above 90KW are directly connected to the buses and the
smaller capacity loads are fed from class-III MCCs, which in turn are fed from class-
III buses BU-P and BU-Q. Class-III loads of CWPH system, which is located far
away from turbine bldg. are grouped into two section BU-P1 and BU-Q1 and these in
turn are fed from main buses BU-P and BU-Q from turbine bldg. There is a provision
to tie between two main buses BU-P and BU-Q.
This tie is affected via two breakers in series to take care of the eventuality of failure
of the tie breaker from causing loss of complete class-III system.
Rev. No. : 02, Oct. 2008
5.2 CLASS-II SUPPLY SYSTEM
The class-II power supply system consists of two main buses 5231-BU-S and 5231-
BU-T. Each of these is fed from motor generator set of 325 KVA capacity. The DC
motors of these motors generator sets are fed from separate 250 volts DC buses
5232-BU-U-1 and 5232-BU-V-1, which in turn gets supply from class-III system
through ACVRs. In addition, 2200AH battery banks are available on these DC buses
5232-BU-U-2 and 5232-BU-V-2 to continue DC supply to MG set is motors when
class-III power is lost. The batteries can feed class-II loads for about 30 minutes by
which time class-III power supply must be restored.
6.0 ELECTRICAL INTERLOCKS IN CLASS-IV SWITCHGEAR
In coming supply breakers 5242-CB#1,2,3,4& 39 for BU-J, K, L, M &K1/L 1
 The incoming breakers 5242-CB#1,2,3,4&39 cannot be closed unless the

corresponding 6.6 KV breakers 5241-CB 14,5,21,26&CB#11/19 are closed.
 Incoming breakers will trip whenever corresponding 6.6KV breaker trips due to any
protection.
 The incoming breakers 5242-CB#2,3&4 cannot be closed from C/R unless
respective tie breakers with BU-J 5242-CB# 5/6/7 are opened.
TIE BREAKERS 5242-CB# 5/6/7 (BETWEEN BU-J & BUSES K, L, &M)
These breakers cannot be closed from C/R unless normal supply breakers 5242-CB
#2/3/4 are opened.
NOTE
5242-BU-K-1 is located in CWPH and 5242-CB#39 is feeding to this bus. Provision

of BU-J &K1 interconnection is not existing.
All motor feeder breakers will trip on under voltage initiation of respective buses.
ELECTRICAL INTERLOCKS OF CL-III SWITCHGEAR BREAKER & NORMAL

SUPPLY BREAKERS
Normal supply breakers 5231-CB#1/2 can not be closed from C/R until the
corresponding 6.6 KV breaker 5241-CB#2/32 are closed.
5231-CB #1/2 can be closed after synchronization with other source (refer
emergency transfer operating manual).
5231-CB#1/2 will trip when the corresponding 6.6 KV breaker 5241-CB-2/32 trips or
is opened.
5231-CB-1/2 will trips when emergency transfer is initiated on loss of class-III.
5231-CB#1/2 will trips when an overpower protection is sensed by the respective

diesel generator connected to Bus P/Q.
Rev. No. : 02, Oct. 2008
TIEBREAKERS CONNECTED TO BU-J (5231-CB#3/4)
5231-CB # 3/4 can be closed from control room only after checking for
synchronization.
5231-CB #3/4 can be closed only when 5231-CB#1/5 on Bus-P and CB#2/6 on Bus
Q are OFF.
5231-CB #3/4 will trips when respective diesel generator will senses overpower
protection.
5231-CB#3/4 will trips on initiation of the emergency transfer.
TIE BREAKERS BETWEEN BU-P & Q (5231-CB#5&6)
5231-CB#5&6 will trip on initiation of emergency transfer if they are in closed

position.
Tie breaker 5231-CB#5&6 are closed by emergency transfer after either BU-P or
BU-Q looses the class-IV supply and the associated diesel generator is not available
provided the hand switch HS-7029 in C/R is kept in Auto position.
Hand switch HS-7004 is provided for 5231-CB-5 & HS-7259 for 5231-CB-6 in the
control room for close / trip operation.
INCOMING BKRS OF CWPH BU-P1 & Q1 (5231-CB#49 & 55 AND CB#53 & 60)
Only one hand switch HS-7171 is provided in the control room for simultaneous
operation of 5231-CB#49 & 55 for BU-P1 (CB#55 is in CWPH).
Similarly hand switch HS-7164 is provided in the control room for simultaneous
operation of 5231-CB#53 & 60 (CB#60 is in CWPH).
These breakers will not trip on under voltage but other feeder breakers of BU-P1 &
Q1 will trip on under voltage.
6.4 ELECTRICAL INTERLOCKS IN CL-II SWTICHGEAR
5231-CB #19 & 20 (Tie breakers between CL-III &II buses) will automatically close
on loss of supply to associated class-II bus bars provided the hand switch HS-
7028/HS-7027 is kept on auto position. This will be initiated by the emergency
transfer scheme.
The tie breakers 5231-CB #32 &33 are simultaneously closed or tripped by the
operation of hand switch HS-7008.
Any of the breakers from 5231-CB #19,20,32 &33 can be closed only after checking
for synchronization.
5231-CB#34 & 47 can be closed only when respective DC breakers of
corresponding MG set is closed and trips when the DC breakers trips.
5231-CB#34 & 47 can be closed only after checking for synchronization.
Rev. No. : 02, Oct. 2008
7.0 CONTROL POWER SUPPLIES

250V DC & 48V DC control power supplies are required for breaker operation. 250V
DC control supply is required for spring charging, closing & tripping of the breakers.
This type of supply can be obtained by closing different isolators on 250V DC control
distribution boards as given below
Description MCCB No. DC DB NO.
5242-BU-J, K, L, M & K1/L1 Close Bus 2b1 2 (5232-Bus-X)
5241-BU-J, K, L, M & K1/L1 Trip Bus 6b1 1(5232-Bus-W)
5231-BU-P, S, & P1 Close Bus 8b1 1(5232-Bus-W)
5231- BU-P, S, & P1 Trip Bus 15b1 1(5232-Bus-W)
5231-BU-Q, T, & Q1 Close Bus 11b1 2(5232-Bus-X)
5231-BU-Q, T, & Q1 Trip Bus 7b1 2(5232-Bus-X)
250V DC supply for Breaker control switch is provided individual buses in the MRP in
each bus.
48 V DC control supply is required for remote operation of the breakers and for
annunciation ckt. This supply is obtained from 48V DC control power distribution
panel (CPDP) by closing respective MCB’s. (Refer flow sheet 1-52330-FS-2).
7.1 FAILURE OF CONTROL POWER SUPPLIES.

7.1.1 FAILURE OF 250V DC CONTROL POWER SUPPLIES
As described above the 250V DC control supplies for class-IV, III & II switchgear are
drawn from 250V DC Class-I power supply system. The failure of 250V DC control
supply will be annunciated by window ann. No. 277, 269, 272 & 273 for class-IV, III
&II switch gear respectively. In case of failure of 250V DC control circuit, the
indication lamps built in hand switch in control room panel 6610-PL-1 for affected
breaker or breakers will not glow in control room. On failure of 250V DC (trip or
close) supply, its supervision relay 27T or 27C will de-energized and alarm will
appear in control room.
7.1.2 FAILURE OF 48V DC CONTROL POWER SYSTEM
In the event of failure of 48V DC supply for any breaker, the ‘48V DC MCB trip’, ann.
will appear in Control Room. The hand switch lamp indication will also disappear for
affected electrical breaker, if the same is electrically operated. The tripped MCB
can be identified on MCB trip monitoring system display screen mounted in 65233-
PL (48V DC, CDPD bank No. 2).
8.0 FAILURE OF 415V CLASS-IV SUPPLY
Whenever 415V AC supply fails for the particular bus of Class-IV, III & II SWGR, the
motor feeder breakers will trip on bus under voltage. For class-IV SWGR bus, the
supply can be extended from 5242-BU-J, to affected bus. After charging Bus
normalizes motor feeders in sequence manually. If 415V class-IV electrically
operated breaker O/C trip annunciation appeared in control room, the relay flag for
faulty breaker are to be checked .
For class-III &II SWGR, if check class-IV supply fails, supply will be extended
automatically by emergency transfer scheme (Refer emergency transfer manual).
Rev. No. : 02, Oct. 2008

9.0 FAILURE OF ANNUNCIATION SYSTEM

On failure of annunciation, system the Alarm shall not be available. Immediately
inform CMU to rectify the problem.
10.0 PROTECTIONS
Refer chapter 19 for Class- IV, Class –III and class-II breakers.
11.0 ALARMS AND ANNUNCIATIONS
415, class-IV manually operated breaker O/C trip ANN-274
415 V, class-IV electrically operated breaker O/C trip ANN-275
415V Class-IV control ckt Fail (5242—BU-J, K, L, M & K1) ANN-277
415 class-IV CWPH BU-K1 breaker O/C trip ANN-324
415 Class-IV BU-K, L, M, &K1 potential lost (CRC) ANN- 2210
BU-J, K, L, M & K1 PT fuse fails (CRC) ANN-2233
415V class-III BUP/P1 Control ckt. Fail ANN-272
415V Class-III BU-P&Q Electrically operated Breaker O/C trip ANN-278
415 V class-III BU-P&Q Feeder ground trip ANN-271
415 V class-III BU-Q/Q1 control ckt. Fail ANN-269
415 V class-III BU-P1 & Q1 Feeder ground trip ANN-268
415 V class-III BU-P/P1 potential lost (CRC) ANN-2208
415 V class-III BU-Q/Q1 potential lost (CRC) ANN-2209
415 V class-III BU-P/Q PT fuse fail (CRC) ANN-2232
415 V class-III BU-P1/Q1 PT fuse fail (CRC) ANN-2234
415 V class-II Cont/Prot. Ckt. fail ANN-273
415 V class-II feeder ground trip ANN-276
415 V class-II manually operated breaker O/C trip ANN-289
415 V class-II electrically operated breaker O/C trip ANN-2290
5231-BU-S Potential lost (CRC) ANN-2213
5231-BU-T Potential lost (CRC) ANN-2207
5231-BU-S/T V.T. fuse fail (CRC) ANN-2231
12.0 TECHNICAL DATA

The switchgear confirms to IS-8623, IS-4327. Details of these switchgear is given
below along with number of Panel:
Class IV 35 panels
Class III 25 panels
Class II 20 panels
NUMBER OF ACB’S
Class IV 44 breaker
Class III 46 breaker
Class II 17 breaker
Rev. No. : 02, Oct. 2008

SUPPLY INCOMING ACB’S
Class IV 8
Class III 6
Class II 4
SUPPLY OUTGOING FEEDER ACB’S
Class IV 36
Class III 26
Class II 11
BREAKER SPECIFICATION
(V) 415V isolators One IS-1 in class-III

(VI) Number of phases Three & neutral
(VII) Rated Voltage 415
(VIII) Rated frequency 50 Hz.
(IX) I min. P.F. withstand voltage 2.5 KV
(X) Rated short time current 50 KA for 1 sec.
(XI) Rated current
Incomer 3750A
Outgoing 1300A, 2000A
(XII) Dynamic short time 105 KA peak
(XIII) Current
(XIV) symmetrical breaking 50KA (rms)
capacity
(XV) Equivalent MVA 35 MVA
(XVI) making capacity 105 KA
(XVII) material of bus bar Aluminum
(XVIII) Type of bus bar Air insulated FRP plated for bus bar supports
(XIX) Temperature rise of bus bars 87.5oC
over the specified ambient
temp.
(XX) Ground bus material Copper
Rev. No. : 02, Oct. 2008

CHAPTER 13
415V CLASS-IV, CLASS-III AND CLASS-II MOTOR CONTROL CENTERS
(52422)
This chapter covers a brief description of 415 volts motor control centers (MCC)
feeding various 415 Volts auxiliary loads including controls, protection and indication
of associated 415 volts feeders.
Three phase loads (up to 90KW), 3 phase heater loads and bulk distribution feeders
are fed from these MCCs. These feeders are controlled with switches, fuses,
starters/contactors and bimetal over load relays. Motors above 90KW are fed
directly from 415 V switchgear and are controlled by circuit breakers incorporating
more accurate overload protection by means of thermal overload relays and
separate locked rotor protection. These protections operate shunt trip coil of the
breaker.
415 volts auxiliary loads are classified into three sub-classes viz. class-IV, class-III,
Class II depending upon their importance and availability during normal plant
operation and emergency plant shut down conditions.
Following motor control centers are provided;
S.No. Supply MCC Description Loads

Class
1. Cl-IV MCC-A and MCC-H Service bldg. Auxiliaries
MCC-B, MCC-D & Turbine bldg. Auxiliaries
MCC-J
MCC-C, MCC-E Reactor bldg. Auxiliaries
MCC-F Water treatment plant
MCC-G1 (G2 for CWPH auxiliaries
NAPP-II)
2. Cl-III MCC-K1, MCC-K2 & Turbine and reactor bldg.
MCC-L1 Auxiliaries
MCC-L2 Class-III safety related system
3. Cl-II MCC-M and MCC-N Turbine and reactor bldg. auxiliaries

MCC-Q Class-II safety related loads
MCC-MX E.C.C.S. system related loads
3.0 TYPE OF CIRCUITS
Depending on the variations in controls required and also the range of power ratings,
the MCC feeders are classified into 15 type starting from type A to type S (with E, I,
Rev. No. : 02, Oct. 2008
O, and N excluded). This classification has been based on the practice followed in
the earlier nuclear projects. The manufacturer’s equivalent type are given in the
subsequent description typical schematics for the above mentioned type feeders are
given in drg. No. N-1, 2/52422/6001 to 6008. According to the nature of the loads,
the following groupings are considered.
3.1 DISTRIBUTION FEEDERS
Feeder, which has to supply clubbed loads, which have their own further distribution.
Examples of such loads are elevators, cranes, receptacle etc. These are fed with ‘A’
type feeders. The manufacturer’s equivalent type is type ‘SL’. These feeders
consists of switch and fuse units only. The ‘A’ type feeder capacity ranges from 0-
250 KW.
3.2 HEATER LOADS
Heaters with local control are provided with Type ‘B’ feeders. Manufacturer’s
equivalent is type ‘D1”. These feeder modules incorporate switches, fuses, and
contactor and control transformer. Remote controlled heater feeders are provided
with ‘C’ feeders. Manufacturers type ‘D2’. These have same element as type ‘B’
with an additional interposing relay ‘3C’ for remote control. Very essential remote
controlled heaters are provided with additional power supply supervision by a ‘no
volt’ relay. These are as type ‘D’ (manufacturer’s type ‘D3’). These have same
elements as type ‘C’ with an additional no volt relay.
3.3 VALVE MOTOR LOADS
These require reversible control for closing and opening operation. These are
provided with Type ‘F’ feeder (manufacturer’s type ‘R1’). These feeders incorporate
switch, fuses, two contactors, control transformer, thermal overload relay two
interposing relays ‘3C1’ and ‘3C2’ for remote control and a no volt relay ‘27’ for
supply supervision.
In certain cases, where the operation of two valves are interlinked, a combined
supply feeder is provided for them with type ‘P’ (manufacturer’s type ‘R2). This type
incorporates additional contractors (two numbers), thermal overload relay (one
number) and interposing relay (two numbers) as compared to type ‘F’ feeder.
3.4 PUMPS, FANS OR BLOWER LOADS
Locally controlled pumps, fans or blower motors are provided with type ‘G’, ‘H’, or ‘Q’
feeders (manufacturer type ‘D4’, ‘D8’ and ‘D10’ respectively) depending on following
variations.
- Motor rated below 19KW –type ‘G’ feeder (manufacturer’s type ‘D4’). This
type incorporate, switch, fuses, one contactor, control transformer, thermal
overload relay of manual reset type with a reset push button.
Rev. No. : 02, Oct. 2008

- Motor rated between 19KW and 30KW type ‘H’ feeder (manufacturer’s type
‘D8’). This type incorporates in addition a running time meter as compared to
type ‘G’.
- Motor rated above 30KW are provided with type ‘Q’ feeder (manufacturer’s
type ‘D10’). Type ‘Q’ was initially specified to incorporate additional single-
phase preventor; the same was later deleted, as good quality single-phase
preventor was not available. However type is retained. Thus, this feeder is
identical to type ‘H’ feeder.
Remote controlled pumps, fans or blowers are provided with type ‘J’ , ‘K’ and ‘R’
feeders ( manufacturer’s type ‘D5’, ‘D7’ and ‘D11’respectively) depending on the
following variations
- Motor rated below 19KW-type ‘J’ feeder (manufacturer’s type ‘D5’

incorporates same elements a s type ‘G’, with an additional interposing relay
‘3C’ for remote control.
- Motor rated from 19 to 30 KW type ‘K’ feeder (manufacturer’s type ‘D7’).

Type ‘K’ consists of same elements as type ‘J’ with an additional running time
meter.
- Motor rated above 30 KW type ‘R’ feeder (manufacturer’s type ‘D11’). Type
‘R’ consists of same elements as type ‘K’ feeder with an additional single-
phase preventor. This element was later deleted for reasons mentioned
earlier, however, the type identity is still maintained. Thus, type ‘R’ is identical
to type ‘K’.
Very essential remote controlled pumps, fans or blowers are provided with type ‘L’ ,
‘M’ and ‘S’ feeders (manufacturer’s type ‘D6’, ‘D9’ and ‘D12’ respectively) as per the
following variations
- Motor rated below 19 KW type ‘L’ feeder (manufacturer’s type ‘D6’). Type ‘L’
feeder consists of same elements as type ‘J’ with an additional no volt relay
‘27’ for supply supervision.
- Motor rated between 19KW to 30 KW type ‘M’ feeder (manufacturer’s type

‘D9’). This type consists as same elements as type ‘K’ with an additional no
volt relay ’27 for supply supervision.
- Motor rated above 30KW type ‘S’ feeder (manufacturer’s type ‘D12’). This type
consists of same elements as type ‘R’ feeder but with an additional no volt relay
‘27’ for supply supervision. As in the case of ‘’ type feeder, the
- single-phase preventor has been subsequently deleted but the type are
maintained. Hence, type ‘S’ and type ‘M’ are identical.
For each type of feeder, the module size and the contractor size to be used depends
on feeder power ratings. The prefix number in the type by the manufacturer covers
Rev. No. : 02, Oct. 2008
these variations. An example of deciphering the manufacturer’s type is as follows,

while for further details refer feature manual.
Example type ’ 331D2’
The hundredth digit ‘3’ to prefix refers to the module size (size ¼ in this case). The
other module sizes are 1/8 (number 1), 1/6 (number2), 1/3 (number 4) and ½,
(number 5). The tenth digit ‘3’ of the prefix refers to the contactor size (70A
contactor in this case). The other contactor seizes are 16A (number 1), 30A
(number 2) and 170 A (number 4).
The first (unit) digit number in the prefix ‘1’ refers to the variation in the switch or
bimetal ratings (number 1 or number 2 is used).
4.0 RATINGS OF MODULE ELEMENTS
4.1 Rating of MCC buses are based on estimated load current ratings, which are
standardized as follows
- MCC A, D, G1, H, J, G2, KI, K2, L1, L2, M, N, Q and MX buses are rated for
1000 Amps.
- MCC B, C and E buses are rated for 2000 Amps.
- MCC F bus is rated for 300 Amps.
All the above buses are rated for short time current of 50 KA for one second and a
momentary current of 105 KA peak. The vertical buses on the individual panels are
also rated for the above short time and momentary rating. The MCC’s are provided
with ground bus of 38mm/9.5mm copper.
4.2 SWITCHES
Switch ratings for each circuit is selected on the basis of full load current of the
equipment controlled. The switches used are suitable for the motor circuits with
assigned rating for motor duty. The following switches are used
Switch rating Switch KW rating for motor feeders

16 A K 138 X – 2Z 7.5 KW
63 A K 138 X-6Z UPTO 30 KW
100 A K150 X-16 UPTO 50 KW
200 A LB X III – 200 UPTO 75 KW
250 A LB X III- 250 UPTO 85 KW
630 A LB X III – 600 UPTO 250 KW
The technical literature for above switches can be consulted from either feature
manual or technical leaflet of manufacturer.
4.3 FUSES
In selecting the fuses for the motor loads the starting current time characteristics of
the motors & current time characteristics of the HRC fuses wire taken into account.
For non-motor loads, the load currents were considered. Manufacturer
recommended sizes are generally followed. The following fuses are used
Rev. No. : 02, Oct. 2008

Type Ampere rating

NS (EEC) 4A
3NA10 6, 10,16,20,25,32,50,63 A,
3NA12 32, 50,63,80,100,125,160,200,250,A
3NA14 425, 500, 630 A
The ‘NA’ type HRC fuses are rated for rupturing capacity of 80KA (sym) at 500 volt
AC.
The ‘NS’ type fuses of M/S. English electric make are rated for rupturing capacity of
46 KA (sym) at 440 volts AC.
4.4 CONTACTORS
The contactors used are of M/S. Siemens make, type 3TA, 3TF rated for currents for
16A, 30A, 70A, and 170A. Manufacturer as per their standardization selects the
contactors for different ‘KW’ rating of feeders. The details of contactors used are as
follows
Type (Old) New Ampere rating of Range of KW

415V for AC3 rating for motor
duty feeders
3TA21 12-OAF - 16A 0-5.5 KW
3TA22 10-OAF 3TF 42 30A 5.6-15 KW
3TA22 16-OAF 3TF 47 70A 15.1-30 KW
3TA28 16-OAF 3TF 50, 52 170A 31-75 KW
16A and 30A contactors have 2NO+2NC auxiliary contacts and 70A and 170A
contactors have 3NO+3NC auxiliary contacts. The technical details can be referred
from feature manual.
4.5 Thermal over load relays
Thermal over load protection is provided is generally as per the manufacturer’s

recommendation. The range of the relays provided for the feeders are such that the
full load rating of the feeder is comfortably within the range of the relay, except for
very small motor size where a minimum range of 0.5-1.0A has been provided.
For motor above 45 KW. CT operated thermal over load relaying scheme is
provided to avoid and functioning of thermal overload relay.
4.6 RUNNING TIME METER
Motor feeders rated above 19KW are provided with a running time meter to register
the cumulative hrs, motor was in service condition. The running time meters are of
M/S. kaycee Make, rated for 110 VAC, 50 HZ having four digits register and a reset
knob.
Rev. No. : 02, Oct. 2008

4.7 CONTROL TRANSFORMERS

All feeders except type ‘A’ feeders (manufacturer’s type S1’) are provided with
control transformer for the control of contactors and other auxiliaries such as running
time meter. The control transformer ratings are 100, 150 and 500 VA depending
upon the load of the 110-volt auxiliary circuits associated with that feeder.
4.8 NO VOLT RELAY
Very essential remote controlled motor feeders are provided with ‘no volt relay’ for
supervision of the power supply availability to these auxiliaries. The contacts of the
no volt relay are connected in the 48 volt DC circuits for the remote indicating lamps
of the motor The no volt relays are of English Electric make type ‘VAG11’.
4.9 INTERPOSING RELAYS
The switches for the remote control of the starters of motors are provided in the
control room which operating on 48-volt DC control circuit. The switching commands
from the switches, or other logic interlocks are transmitted to respective starters by
means of interposing relay ‘3C’ (3C1 AND 3C2 for MV’s). These ‘3C elements are
M/S Siemens contactor type ‘3TA67’ with their coils suitable for operation of 48 volts
DC
5.1 GENERAL
The motor control centers are sheet steel enclose, indoor, floor mounting, free
standing, dust and vermin proof modular type. All MCCs except (MCC G1 for NAPP-
1 and MCC-G2 for NAPP-II) are double front type. The MCCs are suitable for
operation in 415 volt, 50Hz, 3 phase, 3-wire supply. MCC’s are of bolted construction
and have a degree of protection IP51 as per IS 2147. The main buses are located
on the top of the panel for MCC ‘B’ & ‘D’ (for which cable entries are from bottom)
and at the bottom of the panel for rest of the MCCs (for which cable entries are at
top). The motor control centers are suitable for extension on both sides depending
upon the availability of space in the rooms where these are located. The dimensions
of the panels are 2350 X 800 X 800 mm except the incoming panels, which are
2350x 500x 800x mm. The MCCs are provided with separate base channels.
The sheet steel used is 2mm or 1.6mm thickness depending on the part of the panel.
Cold rolled sheet steel are used for the external surfaces of the panels i.e. doors and
front covers, for the rest of the panel, including its structure hot rolled sheet steel is
used. Gaskets are provided for all doors and covers for bus bar chamber and cable
chamber.
Each vertical panel is provided with cable alleys on side. The cable alley doors do
not extend on the bus bar chamber at the top or bottom. Each incoming supply panel
is provided with three ammeters. One voltmeter with a selector switch and CTs and
PTs for the ammeters and voltmeter respectively.
Rev. No. : 02, Oct. 2008

The bus bars are made of aluminum of adequate cross section for their rated
current. The bus bars are enclosed in a horizontal compartment such that accidental
contact with live part is eliminated. The feeder modules are fully draw out type
except for type A50 feeder (Siemens type 760 S1) because of its size. The modules
have plug in type terminals, which are independent of the power connections. Earth
buses are copper of 350 sq.mm cross section.
5.2 CHASSIS
The control of individual feeders comprising of components such as switch, fuse,

contactor, over load relay, control transformer etc. are mounted in self-contained
draw out type able chassis. The power connection between elements such as
switches fuses, contactors and outgoing terminals are made of single core cables of
adequate sizes incase of small capacity feeders and by means of tinned copper
strips incase of feeders rated above 10KW. The chassis is complete with all internal
wiring. It is housed in an individual compartment having its own separate door. The
doors are provided with gasket for dust and vermin proofing. The reset push buttons
for overload relays are provided on the door for manual reset type of relays.
The sizes of the different chassis are same in width and depth, but vary in height
depending on the size of the feeder. The minimum size of the chassis is 1/8 which
occupies 1/8 the height of modular compartment space available in the vertical
portion of the panel. The other module sizes are 1/6; ¼, 1/3 and ½ chassis of the
same size are mutually interchangeable.
The main buses are run horizontally at the bottom or top of the MCCs. Each vertical
panel has vertical bus bar for feeder tap off connections. Vertical bus bar are of
aluminium in case of panel with output power less than 10 KW and for higher rating
that are of alstan which is also of aluminium with special tin plating with coats of
bronze, copper, tin. The incoming connections from vertical buses are made through
plug in contacts, which are mounted on the withdraw able chassis. The outgoing
power connections are also plug in type. For modules of rating above 37 KW the
plug in contact are of special type “LYRA” which is totally enclosed spring loaded
contact. The control wires are brought into a separate set of plug in terminals on the
side of the chassis accessible from cable alley.
5.3 MASTER TERMINAL BLOCKS AND RELAY PANEL
To facilitate handling and transportation, MCCs are made up of number of shipping

section each consisting of three standard vertical sections housing the feeder
modules and one vertical section housing master terminal blocks, interposing and no
volt relays.
Individual modules are provided with control terminal blocks to which internal control
wiring is connected. These terminal blocks of modules are connected with master
terminal block for individual feeder control wiring in the master terminal block is also
connected to CDF (Control distribution frame) through multi-pair cables.
Rev. No. : 02, Oct. 2008

5.4 SAFETY FEATURES
The module doors are interlocked so that it can be opened only with the isolator in
‘off’ position. Padlocking facilities are available for locking the switches in ‘ON’
position or ‘OFF’ position.
5.5 MCC Locations
Ideally, the MCCs are to be located at the load centers. However, the actual location
chosen is a compromise of several factors such as bldg. Layout, cable routing facility
etc. accordingly, the MCCs pertaining to turbine bldg. Auxiliaries are located in the
mezzanine floor at EL. 106.6 mtrs. The MCCs G1 and G2 of CWPH are located in
CWPH. MCCS A and H are located in service bldg. Incase or reactor bldg. An
exception is made, since the frequency of entry of maintenance and operation
personnel inside reactor building is not desirable. These MCCs are also located in
the turbine bldg. The safety related MCCs are located in the turbine building and
near PHT bldg. In view of the their diverse routing of cables. The following tabulation
gives location of various MCCs.
MCC LOCATION ROOM NUMBER/ELEVATION

A Service building S-151/EL 100
B Turbine building T-210/EL 106.6
C Turbine building T-206/EL 106.6
D Turbine building T-210/EL 106.6
E Turbine building T-206/EL 106.6
F Turbine building T-101/EL 100
G1 CWPH GRID 7-9/B-C EL 97
G2 CWPH GRID 23/B-C EL 97
H Service building S-217/EL 106
J Turbine building T-206/EL 106.6
K1 Turbine building T-206/EL 106.6
K2 Turbine building T-206/EL 106.6
L1 Turbine building T-206/EL 106.6
L2 PHT building MCC Room/EL 100
M & MX Turbine building T-206/EL 106.6
N Turbine building T-206/EL 106.6
Q PHT building MCC Room/EL 100
5.3 Technical Data MCCs
MCC featureation M system

Manufacturer M/s Siemens India Ltd.
Single front or double front Double except MCC G1 & G2
Modules Fully draw out type
Sheet metal thickness
Front 1.6/2mm
Rear 1.6/2mm
Side 2.0mm
Module partitions 2.0mm
Door 1.6/2.0mm
Rev. No. : 02, Oct. 2008
Clearance in air
Between phases 19mm
Between phase and earth 19mm
Degree or protection IP51
Short time current rating 50 KA for 1 sec.
Dynamic current rating 105 KA peak
Buses
Material Aluminum
Cross section 2000 A-channel 100 x 40x40mm
1000 F-Flat 21/2” x 3/8”
Type of insulation Air insulated
Temperature rise over rated current 35 degrees Celsius over
50 degrees Celsius ambient
Material of buses supports Permali supports
Spacing between supports 800mm
Spacing between buses 145mm min. center to center
Clearance in air
Between phases Min. 65mm for horizontal Buses
Between phase/earth Min. 20mm
Short time rating 50 KA for 1 sec.
Momentary rating More than 105 KA (peak)
Air Break Switches
Make M/s Siemens India Ltd.

Type K138X, K150X, LBXIII
Application standards IS-1822, IS-4047 & IS-4064
Rated current 25,63,100,200,250,600
Motor duty K138X-2Z-7.5 KW/16 A
K38 X-6Z-30 KW/63 A
K150X-16-50KW/100 A
Breaking capacity As per IS-1822 motor duty
As per IS – 4047 for heavy duty
As per IS – 4.64 for normal duty
Contactors
Make Siemens India Ltd.

Type 3TA/3TF
Standards IS-2959 & VDE-0660
Rated current
3TA21 30A FOR AC1 duty
16 A for AC3 duty (7.5KW)
3TA 24 100 A for AC1 Duty
70 A for AC3 Duty
3TA22/3TF 42 45 A FOR AC1 duty
30 A for AC3 duty (37 KW)
Rev. No. : 02, Oct. 2008

3TA28/3TF 50, 3TF 52 220 A for AC1 duty

170 A for AC3 duty (90 KW)
Number of auxiliary contacts 2 NO+2NC
Contactor coil voltage 110 VAC
Limits of operation
Supply voltage variation 85 to 110 %
Supply frequency variation 40 to 60 Hz
Drop out voltage 65 to 45%
Operation time in milliseconds
3TA21 3TA22/ 3TF42 3TA24/3TF47 3TA28/3TF50

Closing 10-40 10-40 15-40 20-50
Opening 3-20 5-25 5-25 10-30
Art duration 10 10 10-15 10-15
Contactor coil consumption in VA
3TA21 3TA22/ 3TF42 3TA24/3TF47 3TA28/3TF50

During closing 65 100 300 900
P.F. during 0.69 0.5 0.6 0.42
closing
When closed 8 18 30 65
P.F. when 0.38 0.33 0.3 0.31
closed
Rev. No. : 02, Oct. 2008

Annexure-1
MCC CONNECTED LOAD IN OPERATING LOAD IN

KW KW
A 408 176
B 569 251
C 790 499
D 318 138
E 757 464
F 53 18
G1 181 117
G2 FOR NAPS-2 76 52
H 796 389
J (NOTE-2) 554 353
K1 731 468
K2 496 233
L1 712 390
L2 172 153
M 216 55
N 156 68
Q 176 8
NOTE
1. All figures are based on load schedule N-1/50000/6003/SCH

2. MCC-J loading does not include MCC-F
3. MCC-M loading includes loads of MCC-MX
Rev. No. : 02, Oct. 2008

CHAPTER - 14
250 VOLTS DC SYSTEM
(52320)
1.0 This chapter covers the description of 250 V DC switchgear, ACVRs and batteries of
electrical system.
The auxiliaries system of NAPP is four tier system designed as class IV, class III,
class II and class I systems. Class IV system feeds loads, the power supply
interruption for which will not effect the safe shut down of the plant. Class III system
feeds the essential auxiliaries of the plant safety but a brief interruption of power
supply to these auxiliaries permissible.
Class II system feeds the most essential auxiliaries requiring uninterrupted power
supply. Class I system feeds essential DC loads of the unit & it is the input source for
the uninterrupted power supply of the class II system. Hence class I system is the
most important auxiliary supply in the plant. This 250 V DC system is sub divided
into 250 V DC Power and 250 V DC control systems.
The 250 V DC Power buses (BU-U and BU-V) are fed from the class III system
through the power ACVRs (automatically controlled voltage rectifiers) and backed up
by 2200 AH batteries for each main bus section. The ACVRs normally supplies the
system with the batteries floating, When class III system fails, the batteries take over
and they are adequately rated to sustain the system for 30 minutes, by which time
the DG sets should restore supply to the class III and the ACVRs take over.
The 250 V DC control bus(BU-W and BU-X) is fed from class III system through
control ACVRs. A battery bank of 400 AH capacity floats on each bus for taking over
when the class III supply fails. There is a provision of a tie between the power and
control system. This tie is normally kept open and can be used to feed the control
bus in the extreme case of non-availability of both ACVRs and DC batteries.
The power and control buses in turn feed to the 415V class II power and control
supply systems through power MG sets and Inverters(or control MG sets). The
power and control ACVRs are capable of equalize charge and boost charge the DC
power and control batteries respectively.In addition two 100 KW standby chargers
(RC-3 and RC-6) are available for boost charging any of the power or control
batteries . The standby chargers have adequate capacity to substitute any one of the
control ACVRs for a short period.
3.0 DESIGN CRITERION OF POWER BOARD
3.1 The 250 volt DC supply consists of two independent bus sections 5232-BU-U, and
5232-BU-V. In normal operation, each section of bus is fed by a power ACVR and a
battery bank. These buses are further sectionalized and the breakers are provided
Rev. No. : 02, Oct. 2008
so that the essential DC motor loads can be transferred from any one-bus section to
the other bus section (Bus U & V)
The load on the class I system is summarized below
Load description BU-U BU-V

(U1, U2 AND U3) (V1, V2 AND V3)
Input to MG 290 KW 290 KW
Input to Inverter/control MG set 63.5 KW 63.5 KW
Motor load (KW/0.9) 43 KW 12 KW
The total load thus on 5232-BU-U is 397 KW and on 5232-BU-V is 365 KW.
Therefore, on any bus, the maximum load is about 397 KW. The power ACVR is
rated for 500 KW to cater to the requirement of the control bus loads as well (when
necessity arises) which is of the order of 60-75 KW in addition to the above i. e. a
total load of about 460 KW. The batteries have a 30 minutes discharge capacity of
2250 A (for end of discharge of 204 volts for the battery bank). This is adequate for
feeding 442 KW for 30 minutes.
The switchgears are rated for 2500 A. The ACVR and MG set breakers are rated for
2500A and are located in a separate board (BU-U1/V1) near the MG set/ACVR
panels. The incoming supply breaker to the power board (for distribution) is also
rated for 2500A. Bus section breakers are rated for 1000A and feeder breaker for
630A. All 2500A breakers are electrically operated type and rest are manually
operated type.
3.2 FAULT CURRENTS ON THE 250 VOLTS DC SYTEM
The 250 volts DC short circuit feeds are indicated below;
Motor generator - 12 KA at 10 millisecond time constant.

Reactoformer - 22 KA at 15 millisecond time constant
Batteries - 25 KA at 3.5 millisecond time constant
Following approximate fault, currents are deduced from the above parameters.
Load description Fault current (In KA) Time constant (In milliseconds)
- Feeder breaker 60 5.0
- Battery breaker 34 and 25 15.0 and 3.5
-Rectifier breaker 37 and 22 5.0 and 15.0
The DC breakers are rated for 55 KA at 10 millisecond time constant, and 31 KA at

15 millisecond time constant, both at 300 volts, 75 KA at 10 millisecond time
constant and 53 KA at 15 millisecond time constant, both at 250 volts DC. Following
are the type test values for current and time constant.
40 KA, 5 Millisecond
33 KA, 16 Millisecond
22.5 KA, 29 Millisecond
Rev. No. : 02, Oct. 2008

4.0 LAYOUT AND TERMINATIONS
The ACVR/ MG set boards and the ACVRs are located in turbine bldg. at elevation
100.000 between grids 12 & 14 (26 & 28) and E & G. The rectifier transformer is
located outside turbine building and connection between transformer secondary and
rectifier cubicle is by means of bus duct.
The incoming from ACVR and in feed to the MG set is connected to the board by
means of three IC X 1000 sq. mm. AL PVC cables per pole. The in feed from the
ACVR/ MG set board to the power distribution board, located in turbine building
between girds 12 & 14 (26 & 28) and C & D at elevation 106600 is also through three
numbers IC X 1000 sq. mm. AL PVC cables per pole. The other feeders from the
distribution board are through IC X 300 sq. mm. AL PVC cables per pole.
The power batteries are located in turbine building at elevation 106.600 between
grids 12 & 14 (26 & 28) and A & C. The connection between the batteries and the
power board is by means of a 2500A bus duct.
5.0 EQUIPMENT DESCRIPTION
5.1 POWER ACVR’S

5.1.1 GENERAL
The power ACVR are of M/S. BHEL's make. The rectifier transformer having six
secondary, each of which feeds one fully controlled six-pulse thyristor rectifier bridge.
The output of 500 KW is achievable, even when any five out of six circuits are
available. Each ACVR consists of three rectifier cubicles, each containing two three-
phase converters along with them AC/DC isolators, a regulation cubicle, protection
and indication cubicle to generate control pulse for the thyristors and one DC filter
cubicle. The connection between the rectifier transformers and the rectifier cubicles
is by means of bus duct. The output from the DC filter cubicle is taken out through
cables.
5.1.2 FUNCTIONS AND CONTROLS
The ACVR can function in auto/manual modes. In 'auto' mode, the ACVR output
voltage is sensed through DC VT connected at the output is compared with the set
reference voltage and the error signal is amplified and fed through a voltage
regulator to a current limiter, while in manual mode, the signal to raise or lower the
voltage is directly fed to the current limiter. The current limiter takes as input the
ACVR output current and battery charging current. The ACVR output current is
sensed by DCCT-1 connected across DC shunt SHB-1 at the output of ACVR and
the battery charging current by DCCT-2 connected across shunt SHB2 near the
battery terminals.
The current limiter allows the error signal to advance the firing angle of the thyristor
through the firing circuit only if the relevant current limits are not exceeded. The
output of the firing circuit is fed to the gate circuits of the thyristor through pulse
transformers.
Rev. No. : 02, Oct. 2008

In the auto mode, the ACVR has been provided with 'soft start' and 'direct step'
facilities. In case of soft start the output of the ACVR rises from 0 to 300 volts (or the
set point reference) in two or three seconds in a ramp. In case of direct step, the
ACVR voltage rises from 0 to 200 volts in step fashion and then ramps up to the set
value.
The ACVR will normally will be in direct-step mode. Soft start can be achieved
through PB-2 and switched off through PB-3. The manual and auto references can
be set through PB-4 and PB-5 and PB-6 and PB-7 respectively.
The ACVR can give its full output even with five bridges (n-1) working. It is permitted
to work with four bridges (n-2) under reduced load conditions. If more than two
bridges fail, the ACVR is tripped. Provision is made in the current feedback circuit
that the sensed feedback current is appropriately measured for n or (n-1) and (n-2)
conditions.
The ACVR is capable of operating in equalizing/normal modes for charging the
batteries. The sensed charging current is appropriately measured for these two
modes. In equalizing mode, the controller allows a higher charging current than in
normal (float charging) conditions.
5.1.3 A bleeder resistance is switched in whenever the ACVR output breaker is open to
facilitate testing.
5.2 SWITCHGEAR
The DC power switchgear is of M/S Voltas (TMG make). All breakers are of the draw
out type. The ACVR breaker and tie breaker between ACVR/MG board and the
power board are electrically operated type, suitable for remote control (i.e. trip and
close), while the other breakers are manually operated type and are suitable for local
closing and opening.
The following DC motor loads are fed from the DC power board
-DC flushing oil pump

-DC seal oil pump
The starters for these motors are provided in separate starter panels, which are in
turn fed from above DC power switchgear.
6.0 INTERLOCKS AND PROTECTION
Each rectifier bridge is provided with an isolator on AC and DC sides for isolating the
same without affecting the others.
The ACVR output breaker can be closed only if the input AC breaker is closed and
any trip on AC breaker trips the DC breaker. The following protections are provided
for the transformer
-Buchholz (Alarm /Trip)

-Oil temperature (two stages) high/ very high
Rev. No. : 02, Oct. 2008
-Winding temperature (two stages) high/ very high
All the thyristor are provided with di/dt and dv /dt protections with series inductance
and parallel RC circuits. There is a device-monitoring unit, which monitors the
converter operation, for each bridge and any abnormality initiates an alarm and pulse
blocking for the bridge. The bridge can then be isolated for testing.
7.0 INDICATIONS AND ANNUNCIATIONS (ACVR PANELS)
7.1 The following lamps indications are provided on the power ACVR panels
-Control supply ON
-Converter ON (individually for all six convertors)
-AC breaker ON
-MG breaker ON
-Battery breaker ON
-Converter breaker ON
-Trip relay healthy
-Converter fuse failure (individually for all six convertors)
-Interlock healthy
-A.C. breaker off
The following annunciations are also provided on the power ACVR panels
-One bridge failed

-Two bridge failed
-Converter OFF (individually for all six convertors)
-Transformer wdg temp. high
-Transformer buchholz gas
-Transformer oil temp. high
-Buchholz surge
-Oil temp.high trip
-Trip relay failed
-Battery discharge
-Transformer oil level low
-Auxiliary 240 volts AC failed
-Surge circuit fuse failed
-Transformer wdg Temp. trip
The following meters are provided on the power ACVR panels.
DC output voltmeter (Vc) 0-400 volts DC

Converter ammeter (Ic) 0-4000 Amp DC
Battery voltmeter (Vb) 0-400 Volts DC
Battery ammeter (Ib) 300-0-3000 Amps DC
AC voltmeter 0-500 Volts AC
AC ammeter 0-1500 Amps DC
KW meter 0-1200 Watts
KVAR meter 0-900 KVAR
PF Meter 0-2700
Rev. No. : 02, Oct. 2008
SWITCHGEAR
The following indications are provided on the M/S Voltas make switchgear panels.
-Breaker closed for all breakers individually

-Breakers open for all breakers individually
The following meters are provided on the DC switchgears panels
Bus voltmeters on U1, U2, V1 and V2 0-400 volts DC

Ammeter for DC ground monitoring 0-5 mA
7.2 CONTROL ROOM INDICATIONS AND ANNUNCIATIONS
5232-RC-1(2) TRIP AN-302 and AN-303

5232-RC-1(2) TROUBLE AN-304 and AN-305
5232-BUS-U2 /V2 volt high/low AN-444 and AN-445
250 V DC CL-1 breaker control supply AN-298
fail
250 V DC breaker O/C trip AN-299
5232-BU-U2/V2 ground AN-300
The following meters are provided on the control panel 6610-PL-1
65232-RC-1 AM-103 0-1250 Amp AC

65232-RC-2 AM-104 0-1250 Amp AC
65232-BAT-1 AM-115 300-0-3000 A DC
65232-BAT-2 AM-116 300-0-3000 A DC
65232-BU-U2 VM-42 0-400 V DC
65232-BU-V2 VM-43 0-400 V DC
8.0 TECHNICAL DATA
Power ACVR make BHEL

Rating 500 KW
Transformer Rating 957 KVA, 6 secondary delta/star
Voltage ratio 415/270 volts
Impedance 6%
Cooling Oil natural
Primary CT details 1500/5A, 30VA
PT for measurement 415/110V
PT for controls 415/380V
Output voltage range 200-300 V DC
Bridge isolating devices
AC isolator rating 600 A
DC isolator rating 500 A
Thyristor details
Make/type AE1, UK/DCR 1004
Rating 500A
Rev. No. : 02, Oct. 2008
Peak inverse voltage 1200 V

Turn off time 215 micro seconds
Smoothing reactor 0.5 mH, 2500A
Switchgear
Bus bar rating 2500/800A
Temperature rise As per IS
Short time rating 60 KA
Circuit breakers
Make/type M/S. TMG/DSAI
Rating 2500 for electrically operated
Breaking capacity 55 KA at 400 volts DC with time constant of
10 millisecond
31 KA at 300 volts for 15 millisecond
Batteries
Make M/S. Standard Batteries
Rating 2200 AH (two of 1100 AH banks)
End of life capacity 70%
Open circuit voltage (fully charged) 246 volts
Recommended Float voltage 262 volts
Equalizing Charge / duration Constant current at rate of 2.5% of AH till
three consecutive readings are constant
provided electrolytic temp. restricted to 45C
Short circuit current 25 KA
1/2 hr. capacity 2250A (2500A for 22 minutes)
Voltage after full discharge 204 volts
Number of cell per bank 120 cells (two numbers banks)
9.0 DESIGN CRITERION FOR CONTROL BOARD
9.1 The control ACVR is rated for 75 KW to cater the control supply loads in addition to the
55 KVA control MG sets. The switchgear is rated for 600 Amp and the incomers from
ACVR, standby battery chargers are rated for 1000 Amps. The batteries are for 400
Amp-Hour capacity, capable of giving 345 Amps for 30 minutes (for an end of discharge
voltage of 204 Volts for the bank).
M/S L&T make breakers are used in DC control switchgear. All breakers are of draw out
type. All breakers here are manually operated type and no remote operation is
envisaged. The outgoing feeders are fed through MCCBs.
9.2 CONTROL SUPPLIES (CLASS II AND CLASS I)
The ratings of control supply systems are given below
Control ACVR 75 KW
Control Batteries 400 AH, 345 A for 30 min.
Control MG set/Inverters 55 KVA/60 KVA
Rev. No. : 02, Oct. 2008
These ratings are adequate for their system requirements.
10.0 LAYOUT AND TERMINATION
The control ACVRs along with transformers are located in turbine bldg. at elevation
106.600 between grids 2&3 (16&17) and B&D. The control switchgear board are
located in the adjoining room i.e. between grids 1&3 (15&17). All the incoming
connections to the control board and the outgoing to the Inverters/control MG set are
by IC X 300 sq.mm Al PVC cables per pole.
The standby battery charger is located in room T1(2)- 216 in turbine bldg. between
grids 12&14 (26&28) and C&D at elevation 106.600. It is connected to each of the
switchgears by means of one number 1C X 300 sq. mm Al PVC cable per pole.
11.0 FUNCTIONS AND CONTROLS OF CONTROL ACVR AND STANDBY BATTERY

CHARGER
These ACVRs (5232-RC-3,4 & 5) are of M/s DUBAS make & RC-6 is Keltron make.
5232-RC- 4 & 5 are of 75 KW each and feed loads of 250V DC control board - 1& 2
(W & X) and float charge 250 V DC control batteries - 3 & 4 respectively. 5232-RC-3
& RC-6 rated 100 KW called standby battery charger (SBC) used to charge any 250
V DC power & control battery bank whenever its respective ACVR is not available.
SBC/ACVRs are IGBT based rectifier units used for charging Lead Acid Batteries.
Battery is always connected in parallel with the charger to feed the loads .These
Chargers are of Constant Voltage and Current limited type. It consists of two similar
bridges, each is capable to deliver rated capacity and hot redundant to each other.
There are main rectifier transformer of 415V/ 137V with two secondary connected in
Delta–Delta, each of which feeds to one fully controlled six pulse IGBT based
rectifier bridge. There are total 24 nos of fans, one set of 12 nos used for cooling of
magnetic components and other 12 nos for IGBT cooling. Fans, transformer, chokes
are located at bottom of cubicle and Bridges & its control circuits at top of rectifier
cubicle. Each bridge consists of dual capacitors filter at output and voltage regulation
is achieved by IGBT based dual bridges which are switched On and OFF using
PWM technique ensures better input power factor under all working conditions
compared to a thyristor controlled rectifiers. This also ensures a very low percentage
of input harmonics current fed to the source and also the input power factor is
maintained about unity from 10% to 100% of rated load. The Converters control
logics & internal operation are fully software oriented & performed by Digital Signal
Processor.
ACVR OPERATING MODES:
The charger consists of three modes of operation namely FLOAT, EQUALISE

and BOOST mode. Normally system works in auto FLOAT mode but other
modes are manually selected according to Battery charge state.
Rev. No. : 02, Oct. 2008

FLOAT MODE
This mode selector switch (MSS) is provided on the front door. When MSS is
positioned on ‘FLOAT’ system is said to be on float charging mode. In auto mode it
will feed the DC loads & float charge the respective battery bank. Charger will
maintain the DC voltage 262V and float indication will come on panel.
EQUALISE MODE
This mode is used to Charge all batteries in a bank to have equal potential, hence
the name Equalise charge. In this mode of operation, the system output voltage is
settable from 265V DC to 300V DC.
BOOST MODE
"Boost Charge" voltage is required to quickly recharge a deep discharged battery. In

this mode, voltage can be set from 265VDC to 325V DC.
SYSTEM WORKING PRINCIPLE

This system mainly comprises of following blocks.
1-Input MCCB
2-Soft start arrangement
3-Input Isolation Transformer
4-Input Filter (Dual)
4-IGBT Bridge (Dual)
5-Output Filter Capacitor (Dual)
6-Isolators
7-Output MCCB / Battery MCCB
8-Battery Discharge MCCB
9-Power Supply Section
10-Main Controls card Section
11-Display/alarm/indication Section
12-Output voltage and Current controllers
13-Sensors
1-Input MCCB (M1)

Input MCCB is provided to connect/disconnect mains to rectifier system. This is along with
a shunt trip coil and an auxiliary contact. The shunt trip coil is operated when the
emergency off push button provided on the front panel is operated during emergency
conditions. The auxiliary contact is used to give the MCCB ON/OFF signal to the DSP
control card (DU2031&33) through the interface card DU2045. Also, necessary signals to
drive the indications for this MCCB position are taken from this auxiliary contact. Once the
input MCCB is switched on an isolation transformer of 2KVA capacity will get the input
supply through a fuse, which is utilized as AC auxiliary supply source for the entire system.
2-Soft Start arrangement (K1 & K2)

Soft start arrangement comprises of two contactors, one-which is rated for full current (main
contactor) and the other-just adequate for start up current (auxiliary contactor), which is
connected in series with resistors. When the input is switched ON for the first time (during
Rev. No. : 02, Oct. 2008
AC power returns) both contactors will be in off condition. The input voltage and input
current feedbacks are fed to the DSP control card and after confirming that input is healthy,
an ON signal is given to the auxiliary contactor from the control card (J29) until the output
dc voltage builds up. The inrush current is controlled in this path because the auxiliary
contactor is connected with series resistor. Once DC voltage builds up with controlled
charging the ON signal is given to the main contactor (J14) and OFF signal will be given to
the auxiliary contactor from the control card DU2031&33. Both contactors will be turned
OFF as they are powered from the input source.
3-Isolation Transformer (TX-1)

Input transformer is provided to isolate source side and load side. Input transformer is a
delta to delta-delta transformer, which provides power to two independent IGBT modules.
The temperature rise of the isolation transformer is monitored through temperature sensing
card DU2062 and the signal is given to the control card PCA1 (through J4 of PCA2&2A),
which in turn trips the entire system.
4-Input Filter (Dual) (C1 & C2 + CH1-CH6)

This filter circuit comprising of AC capacitors and line chokes, which is provided in order to
eliminate harmonics injected back to the source. Two sets of filters are provided which gets
connected to two independent IGBT bridges at their input side. The temperature rise of the
line choke is monitored through temperature sensing card DU2062 and the signal is given
to the control card, which in turn trips the entire system in case of high temperature of this
chokes.
5-IGBT Bridge (Dual) (M1-M6)

Two sets of IGBT bridges which are switched ON and OFF using PWM technique ensures
better input power factor & also ensure a very low percentage of input harmonics in the
current drawn from the source. The control of bridge is made by DSP based controller,
which generates PWM signals and received at driver cards provided for each IGBT. Each
driver has galvanic isolation through optocouplers and provides sufficient gate drive current.
The entire setup is built as module and mounted on heat sinks, which are cooled through
forced air. The PWM signals for IGBT bridge-1 are given from J59 & J60 of main control
card DU 2033+31 and for bridge-2 from J63 & J64 of same control card and it is given to
the IGBT gate through the driver cards DU2025+26+41. In each IGBT Bridges, two IGBTs
per phase are paralleled to increase the reliability of the system. The temperature rise of
the IGBT bridges are monitored through temperature sensing card DU2062 and the signal
is given to the control card (J46), which in turn trips the entire system in case of high
temperature. Also the bridges are protected through snubber capacitors. High temperature
and short circuit whose signal is sensed through driver cards at the DC bus by immediate
shut down of the IGBT.
Filter Capacitor (FC1 & FC2)
Two DC Filter capacitor banks are provided at the output of IGBT bridges to eliminate DC
side ripple and to provide sufficient hold up of energy to take care during the transient
operation.
Isolators (F1 & F2)

These isolators (HRC fuses) are provided to connect /disconnect IGBT bridge from load
side, which shall be used only during maintenance and it is not meant for on-load operation.
Fuse fail indication is sensed and is announced in the window annunciation.
Rev. No. : 02, Oct. 2008
Output / Battery MCCB (M2 & M8-M11)

This is provided to connect/disconnect the load / battery from the rectifier output. In case of
100KW SBC, output MCCB is rated for 630A. This comes along with an auxiliary contact
with contact multiplied, which is used to give the MCCB ON/OFF signal to the DSP control
card (DU2031&33) through the interface card DU2045 and necessary signal for indication
at the mimic/user interface for the MCCB position. In addition to this, there are four Battery
MCCBs each rated for 320A. These MCCBs are along with a under voltage release coil and
an auxiliary contact. The under voltage release coil is operated when there is a DC under
voltage, sensed at the DC bus, preventing any reverse power flow from the battery. Also,
this under voltage coil is operated when the emergency off switch is pressed during
emergency conditions, which is provided in the front panel. The auxiliary contact is to give
MCCB ON signal to mimic indicator.
In case of 75KW ACVRs, the output MCCB is rated for 400A. This MCCB is along with a
under voltage release coil and an auxiliary contact as used in 100KW output MCCB giving
identical function.
Following cards are used in Control ACVRs.
Main controller card DU 2033+2031 PCA 1,2, 2A
Extended card DU 2045 PCA 1,2, 2A
DC – DC control card DU 2040 PCA 4,5, 4A,5A
DC – DC interface card DU 2043 PCA 3, 3A
Filter card DU 2050 PCA 6
Pot. Free contact card DU 2049 PCA 18, 18A, 18B, 18C
Micro controller card DU 2023 PCA 15
Indication card DU 2036 PCA 16
LCD display card DU 2035 PCA 17
Temp. Sensor card DU 2062 PCA 12, 13
Voltage transducer DU 2037 PCA 7,8,9
Relay drive DU 2084 PCA 14
Control fuse card DU 10079 PCA 19, 20
IGBT Drive DU 2025+26B+2041 PCA 10, 10A, 10B, 11A,
11B
The functioning details of each card are as followings
Power Supply Section

Power supply for the control card is derived using an in-house power supply board. Power
supply to this board is derived either from 220V AC auxiliary supply or from output DC bus.
First the input AC is converted into constant DC voltage using AC/DC conversion card. The
output of this card (160 – 425Vdc) is given as input to power supply board. The multi-
outputs of the power supply card are used for main control card, driver cards and display
control cards.
This section consists of two PCA cards
AC/DC conversion card (DU2043) – PCA3 & 3A
DC-DC control card (DU2040R1) – PCA 4, 4A, 5 & 5A
Main controller card:

The DSP (Digital signal processor) control card generates the PWM signals for both IGBT
bridges. It controls and monitors the entire function of the system by taking the voltage and
current feedbacks and various digital signals as input. By using this information it provides
Rev. No. : 02, Oct. 2008
adequate protections for the system. It consists of two inbuilt 2-line,16-bit LCD display. The
DSP1 & DSP2 associated with a CAN module, which communicates between the two DSPs
and generates the digital signals for the front panel display via RS485 communication
cable.
Micro controller card :
The main function of this card is to display the unit parameter in the front panel & gets the
information from DSP control card through RS 485 communication. The received data will
be processed and displayed in front panel display (DU2035). Also it drives LED indications
for healthy and trip status of System. For all fault conditions it displays pop up messages
and gives buzzer
DC – DC control card :
It works on the principle of dc/dc converter. DC voltage is fed to the card from DU2043
AC/DC conversion card & DC is converted in to multiple outputs by forward HI-
FREQUENCY converter switching technology. The outputs of the card are isolated, filtered
and regulated voltage. This card has various protections like Input and output short circuit,
Output over load, Input under voltage and over voltage, Reverse polarity, EMI filters.
Extended card :
It works in combination with DU2031&33 control card & provides an option to
extend five I/O ports. This card has a provision to drive a relay using the given
input signal. Opto-couplers (IC-4N35) are used at input and output for isolation
purpose.
DC – DC interface card :
PCA DU2043 contains a bridge rectifier and filter capacitor. Fuse is provided for the short
circuit protection. Input AC supply for the card is given from 415V/158V AC power sensing
transformer and the DC supply from output DC bus. Output of the card (160V-425Vdc) is
connected to the DC-DC card DU2040R1.
Indication card :
Indication card drives LED indication for various status of the system. It will get the signals
from micro controller card. These signals are converted in to isolated signals using
optocouplers. Isolated signals drive the LED indications and also it is extended to the
combicon connector, which can be used to drive mimic indications, window annunciation or
potential free contacts. This card has a facility to give buzzer for trip
Potential free contact signal card:

This block gets information about input, output and dc bus parameters, system status and
indications from DSP control card through RS-485 communication. Using this information it
controls front panel display, mimic display indications, alarms and potential free contact
signals. To perform all these functions it makes use of Micro controller, Indication, series
Display & Potential free contact signal card.
LCD display card :

This board contains 2-line 16-bit LCD display module with 15 keys. Micro controller initiates
the LCD display and sends the data in ASCII format and displays various parameters. The
15 keys are used to scroll the display modes, to view the different parameters, to scroll
different status and to acknowledge buzzer and fault messages.
Rev. No. : 02, Oct. 2008
Temp. Sensor card :

There are two temperature sensing PCBs used for Bridge 1 &2 which get the signal
through thermostat & thermister mounted on IGBTs & magnetic components. Its output is
in the form of digital to the DSP control card. It consists of LEDs which lit whenever
respective device temperature exceeds the threshold limits. The advantages of this sensor
are excellent accuracy, Very good linearity, low thermal drift, high bandwidth and low
disturbance in common mode.
Voltage transducer :
For voltage measurements, a current proportional to the measured voltage is passed
through an external resistor, which is selected and installed in series with the primary circuit
of the transducer. The advantages of this sensor are excellent accuracy, Very good
linearity, Low thermal drift, high bandwidth and Low disturbance in common mode.
Relay drive :
This PCA card receives the digital signals from the DSP control card DU2031&33. These
signals are used to drive the relay and there by the signals are used to drive the softstart
contactor.
IGBT Driver :
The PWM signals from the control card section are given as IGBT drive pulses using driver
cards. It receives the PWM signals from DU2031& 33 cards. These PWM signals are
electrically isolated using inbuilt opto-coupler & connected to a totem pole driver IGBT pulse
amplifier, which switches the IGBT. The driver cards used here is DU2025&26 in
combination with DU2041 card, which converts the one pulse output to two because two
IGBTs are paralleled in this system. This card has the protection against short circuit.
Potential Free contact card :

This PCA card can provide six potential free contact signals. The required indications,
which are driven from the indication card (DU2036) is given to this card. Using this signal
the relay will be driven (SPDT) and the relay output is available at the output connectors
(J2, J5, J6, J7, J9 & J10). These signals are used for remote indications.
SENSORS:
There are various feedback signals processed from input and output, which are passed to
control card section with isolation. The ACVR output is sensed through DCVT card and
compared with reference set for the respective mode of operation (MSS) and the firing
angle of the IGBTs are advanced or retarded depending on the error signal. However, the
firing angle controller will respond to ensure that total ACVR current and the battery
charging current are within their limits. To sense AC voltages sensing transformers with a
fuse at input, to sense ac current CTs , to sense DC current hall sensors and to sense
temperature cards are used.
There are total six nos. transducers provided to sense the battery current through the
shunt provided at the battery terminals. Two nos. mounted at DC Power board U2 & V2
power Battery path for SBC, other two nos. mounted at Bus-W Control board at Battery-3
path for SBC & Control RC-4 and rest two nos. mounted at Bus-X Control board at Battery-
4 path for SBC & Control RC-5.
Rev. No. : 02, Oct. 2008

12.0 INTERLOCKS AND PROTECTIONS OF CONTROL ACVR

Individual bridge isolation is provided on DC sides.
Output breaker at DCDB can be closed only if AC input & DC output MCCBs are
closed.
DC output MCCBs can not be closed in the followings.
i) System protection operated i.e. DC over voltage, O/P over load, Battery reverse
polarity & System over temperature.
ii) DC under voltage & emergency PB operated.
ACVR PROTECTIONS
(A) ACVR output breaker tripping
Following protections are provided in control ACVRs which in turn trip the
output breaker at 250V DC board.
i DC Over voltage: > 310V
ii. System overload or over current:
110% of FLA with 30 min time delay.
125% of FLA with 10 min time delay.
150% of FLA with no time delay i.e. instantaneous.
iii. System Over temperature: > 65 0C.
iv. Battery Reverse Polarity
(B) ACVR Output MCCB tripping.

Following protection will trip output MCCB.
i. DC under voltage
ii. Emergency trip.
(C) ACVR input contactor tripping and pulse blocking.
Following will trip input (AC) contactor and also cause system tripping:-
i. AC under voltage: < 320V
ii. AC over voltage: > 460V
iii. Abnormal input frequency: < 47Hz or > 53 Hz
iv. DC over voltage: > 310V
v. System overload or over current
: 110% of FLA with 30 min time delay.
:125% of FLA with 10 min time delay.
:150% of FLA with instantaneous
AC under voltage, AC over voltage and abnormal input frequency is grouped
as mains fault for window annunciation.
(D) IGBTS PROTECTIONS
i. Snuber protection
Rev. No. : 02, Oct. 2008
ii Temperature cutoff through thermistor & Thermostat

iii. Output Shortcircuit
Any fault on a bridge initiates an alarm results in pulse blocking for that bridge,
which can then be isolated.
13.0 PROTECTIONS ON SWITCHGEAR
Over current & short circuit protections are provided for all the breakers. Trip
initiations for ACVR faults are provided for the respective ACVR breakers. The DC
bus is provided with a ground detection scheme, which continuously monitors the
insulation of the positive and negative buses with respect to the earth and initiates
alarm in case of ground fault.
14.0 INDICATIONS AND ANNUNCIATIONS
14.1 CONTROL ACVR PANEL

Description of LED Condition for indication generation
Indication Status
ON Input breaker is ON & Input supply is healthy.
(Green) (320V – 460V).
a) Input MCCB OFF
b) Phase Failure of AC supply
Mains OFF c) Input AC voltage out of specified range (<320V
Healthy or >460V)
d) Input frequency out of specified range (< 47Hz
or >53Hz.)
e) Input supply failure
ON System is ON and output voltage is > 150V DC
System (Green)
On OFF a) Mains not healthy
b) Both the Converters are fault.
ON System is ON, MSS selected to float mode and
System on (Green) output voltage is more than 215V
Float OFF MSS not selected to float mode.
ON System is ON, MSS selected to Equalise mode and

System on (Green) the system output voltage is more than 265V DC.
Equalise OFF MSS not selected to equalize mode.
ON System is ON, MSS selected to boost mode and
System on (Yellow) the system output voltage is more than 265V DC
Boost OFF MSS not selected to boost mode.
Rev. No. : 02, Oct. 2008

Control ON Control power supply (+15V) is available provided

Supply ON (Green) ‘Mains Healthy’ LED is ON
OFF Control supply failed
ON(Green) Battery is under charging condition.
Battery on
charge OFF a) Battery is fully charged.
b) Battery current signal failed
Following LEDs will glow on mimic panel :

LED Status 75KW ACVR (RC-4 & 5) 100KW SBC (RC-3)
L1 ON System input MCCB (M1) ON System input MCCB (M1) ON
L3 ON Converter Bridge – 1 ON Converter Bridge – 1 ON
L4 ON Converter Bridge – 2 ON Converter Bridge – 2 ON
L5 ON Output / Battery MCCB (M2) ON Output MCCB (M2) ON
L7 ON - Power Battery – 1 MCCB (M8) ON
L8 ON - Power Battery – 2 MCCB (M9) ON
L9 ON - Control Battery – 3 MCCB (M10) ON
L10 ON - Control Battery – 4 MCCB (M11) ON
(B) WINDOW ANNUNCIATION AT ACVR/SBC PANEL
Description Condition for annunciation generation Whether RC trouble or RC

trip
Fan fail a) MCB (M4 &/or M5) of any one group of RC trouble
fan is in OFF position.
b) More than 4-5 fans in the entire
system is failed.
Battery Battery / DC bus is earthed and more than RC trouble
Earth fault 5mA current is flowing in the earth path.
Battery a) Battery is not connected to DC bus. RC trouble
Current b) Current signal received from battery
signal fail current signal
box /DC shunt is not healthy.
ACVR output ACVR output MCCB is either OFF or RC trouble
MCCB Trip tripped.
Input Input MCCB is either OFF or tripped. RC trouble and trip both.
MCCB Trip
Battery Battery terminals are reverse RC trip.
Reverse Connected (During commissioning only)
Polarity
Output Fuse fail Output fuse of any one IGBT module is RC trouble
open/failed.
Mains fault a) Input MCCB OFF RC trip.
b) Supply Phase Fail
c) Input voltage beyond specified range
(<320V- >460V).
Rev. No. : 02, Oct. 2008

d) Input frequency out of specified range

(<47Hz ->53Hz).
e) Input supply fail.
System i) Main fault – AC under voltage, AC over RC trip.
Fault voltage, Abnormal input
frequency.
ii) DC over voltage
iii) System over load or over current.
iv) System over temperature.
v) Battery reverse polarity.
DC Over System out put voltage >310V. RC trip.
voltage
System 110% with 30 min time delay RC trip.
Over load
125% with 30 min time delay
150% abstentious
System IGBT or system temperature >65 oC RC trip.
Over temperature
DC Under System output voltage is less than 210V, RC trouble
voltage irrespective of mode selected.
Load On Battery is feeding the load with DC bus RC trouble
Battery voltage more than 215VDC.
Metering of ACVR Panel:
The following Display & Panel meters are provided on the ACVR panel
1)- CONTROL PANEL DISPLAY
Mode selection is provided to display key of followings parameters :-
(i) Input parameters i.e. voltage, Current, frequency, power & power factor.
(ii) Output parameters i.e. voltage actual / voltage Set, System current.
(iii) Battery parameters-Press K2 for respective battery current BT1, BT2, BT3,
BT4.
(iv) Load parameters
(v) LED Test
Following keys are provided on LCD meter –
Mode : ‘Mode key’ to select various modes like input, output and battery.
Select : ‘Select key’ not applicable.
ACK : Acknowledge key to silence the buzzer beep.
Enter : Enter key not applicable.

Δ : Increment key this key to be operated in CHARGER STATUS mode to check
status of the CH.
Rev. No. : 02, Oct. 2008
Volt : Volt key to display voltage of the selected mode.
AMP : Current key to display current of the selected mode.
FRE : Freq key to display frequency of the input (selected) mode.
Power : Power key to display power of the input (selected) mode.
 : Decrement key to be operated in charger status mode to check status of Parameters
K1 to k5 : Keys assigned for LED test.
2)- DC Voltmeter -- (0-400 volts)
14.2 CONTROL ROOM INDICATIONS/ANNUNCIATIONS
S. ANNUNCIATIONS IN WA/CRCSANN CONDITIONS /SET POINT

NO CONTROL ROOM. . NO.
1. RC Trouble. i. DC Under voltage.
i) 5232-RC-3 i) DS-2204 ii. Load on battery.
ii) 5232-RC-4 ii) ANN-432 iii. ACVR output MCCB trip.
iii) 5232-RC-5 iii)ANN-433 iv. ACVR input MCCB trip.
v. Output fuse fail.
vi. Cooling fan failed.
vii. Battery earth fault.
viii.Battery current signal fail.
2. RC Trip. i. Main fault – AC under voltage, AC
i) 5232-RC-3 i)DS-2205 over voltage, abnormal input
ii) 5232-RC-4 ii)ANN-435 frequency.
iii) 5232-RC-5 iii)ANN-436 ii. DC over voltage
iii. System over load or over current.
iv. System over temperature.
v) Battery reverse polarity.
3. 250V DC- BUS W/X When leakage current for any bus is
Ground Fault Trouble more than 4 mA.
4. 250V DC- BUS -- When voltage of BU-W/X (DCDB-1/2) is
Voltage High-Low more than 270V or less than 230V.
Trouble
i) BUS-W
ii) BUS-X
5. 250 DC Class-I Control ANN-493 RC breaker, battery breaker or Tie
BKR. Trip. breaker trips on over current protection.
Following meter are provided on the control panel 6610-PL-1.
65232-RC-4-AM-105 0-150 amps AC

65232-RC-5-AM-106 0-150 amps AC
65232-BAT3-AM-117 150-0-500 amps D.C
Rev. No. : 02, Oct. 2008
65232-BAT4-AM-118 150-0-500 amps D.C

65232-BU-W-VM-46 0-400 volts DC
65232-BU-X-VM-47 0-400 volts DC
15.0 TECHNICAL DATA OF ACVRs/SBC
Sl. Equipment Particulars 75KW ACVR 100KW SBC

No
1.0 Type a) IGBT based
a) Thyristor / IGBT based b) PWM technique
b) Type Of control
2.0 Maximum Continuous Output Ratings a) 215-325V a) 215-325V
a. Output Voltage b) 300A @ 250V b) 400A @
b. Output Current c) 75KW 250V
c. KW Rating c) 100KW
3.0 Input
a) Voltage a) 415V, 3ø-3Wire
b) Frequency b) 50Hz, 5%
c) Variation c) +10%, -20%
4.0 Output Voltage Variation 0.5% measured across DC
capacitor terminals.
5.0 Output voltage adjustable range for Float /
Equilise / Boost Operation
a) Float a) 215-265V DC
b) Equilise b) 265-300V DC
c) Boost c) 265-325V DC
d) Type of Mechanism. d) Linear 10T Potentiometers.
6.0 Battery charging current adjustable ranges for
a) Float Operation
b) Equilise Operation a) 10-60A DC a) 20-60A DC
c) Boost Operation b) 20-60A DC b) 20-200A DC
d) Type of mechanism c) 20-200A DC c) 20-300A DC.
d) Linear 10T d) Linear 10T
Potentiometers Potentiometers
7.0 Guaranteed minimum efficiency & input
power factor
a) 100% load – Efficiency and PF a) Better than 90% and 0.9 p.f
b)75% load – Efficiency and PF b) Better than 85% and 0.9 p.f
c) 50% load – Efficiency and PF c) Better than 82% and 0.9 p.f
8.0 Harmonic content at AC input (%) (as defined </= 5 % ( if input voltage THD <5% )
in IS-4540)
Rev. No. : 02, Oct. 2008

Sl. Equipment Particulars 75KW ACVR 100KW SBC

No
9.0 Guaranteed max voltage ripple at output < 1%
(%) Without battery connected.
10.0 Output voltage regulation from 10% - < 2%
100% load
11.0 ACVR / SBC provided with the following:
a) Automatic voltage regulator a) Yes. Built-in
b) Current limiting circuit b) Yes. Built-in
c) Filter circuit at output c) Yes. DC capacitor bank.
d) Walk-in circuit d) Yes.
e) If provided, walk in time e) 10-30Sec
f) Is the walk-in-time adjustable f) Yes
g) Pf correcting equipment requirement g) No. Built-in feature.
at input h) Yes. Capacitor-choke combination.
h) AC harmonic filter at input.
12.0 Maximum short circuit current at output Less than 15 KA
terminals
(KA) (considering the effect of fuses).
13.0 Short time current withstand rating. 3000A for 250mSec.
14.0 a) Overall dimensions (W x D x H) in a) 1200 x 800 x a) 1200 x 800 x
mm 2380 2380
b) No. of panels b) 1 no / system b) 1 no / system
c) Weight (Kg) c) 1400 (approx.) c) 1600 (approx.)
15. Degree of protection as per IS-13947 IP- 31

16. Protection a) MCCB
a) Input side b) MCCB, Electronics circuit for short
b) Output side circuit, DC
Over voltage, over load, over
temperature.
17. Metering a) Integrated multi-page LCD display
meter to monitor input/output/battery
parameters.
b) Analog DC Voltmeter and Ammeter.
15.1 CONTROL SWITCHGEAR
-Make M/S ANDREW YULE

-Bus rating 1000 amps.
-Temperature rise 35 degree Celsius over 50 degrees
Celsius ambient
-Short time rating 65 KA for one second
-Circuit breakers
Make/type M/S L&T
Rev. No. : 02, Oct. 2008

Type CN-CS-1600H
Rating 1600 amps.
Voltage 415v
Rated ultimate SC breaking 65KA
capacity (Icu)
Rated service SC breaking 65KA
capacity (Ics)
Rated short time withstand 65KA for 1sec
current (Icw)
Utilization catg B
Breaking capacity 40 KA at 440 volts and 50 KA at 220
volts DC
Batteries
Make M/S Standard Batteries
Rating 400 AH
End of life capacity 70%
Open circuit voltage 246 volts
(fully charged)
Recommended charge voltage 4.54 KA
1/2 hr. capacity 345A (245A for 60 minutes)
Voltage after full discharge 204 volts
Number of cell per bank 120 cells
Rev. No. : 02, Oct. 2008

5232-RC-6
5232-RC-3
RC-1 5232 5232 RC-2
CB-26 CB-27
5232 5232
CB-2 CB-10 CB-11 CB-8
BUS-U1 CB-3 U2 CB-4 U3 CB-5 V3 CB-6 V2 CB-7 V1
250V DC
5232-BB-1 5232-BB-2
CB-12 CB-13
5232 5232
CB-20 CB-21
5232 MCCB-10b1 MCCB-10b1 5232

CB-22 RC-4 5232 5232 RC-5 CB-23
CB-24 CB-25
CB-16 CB-17
BUS-W BUS-X
5232-CB-18 5232-CB-19
250V DC
5232-BB-3 5232-BB-4
Rev. No. : 02, Oct. 2008

CHAPTER-15
STATION CONTROL POWER SUPPLY & ATS
1.2 GENERAL DESCRIPTION:
The control power supplies and distribution circuits are featured for continuous
operation with utmost degree of reliability under all emergency conditions. In
feed power is fed from three inverters. Earlier Contol Motor Generator were
used in place of Inverter . Because of the non availability of spares of CMG &
CMG is also an obsolete technology, we have adopted Static Inverters. Inverter
has various advantage over CMG like , Inverter is static device though CMG is
rotating device, so low maintenance is required . During failure of any CMG,
manual synchronization is needed to take stand by CMG into service in place of
failure one, but in case of Inverter if any Inverter fails auto changeover takes
place to inverter-4.
In the 48 V DC Control Power Supply System, two full capacity 415 V AC to 48
V DC rectifier units are connected in parallel, each source for rectifier is derived
from different AC in feed. A further security is provided by a 48 V DC battery
back up. 48V DC supply used for Control Room Indication lamps and as logic
supply.
In the case of 240 V AC Control Power Supply System. Supply is derived
directly from inverter. Single phase and three phase loads are distributed
through moulded case circuit breakers. 65233-PL-1, 8 & 15 are fed through
automatic transfer switch (Static Switch) which has capability to transfer on
emergency source within 40 ms. if normal supply falls below 85% of normal
voltage. By this means, power supply is maintained to the 240V AC Control
supply distribution panels. When 90% of normal voltage is resumed, re-transfer
takes place automatically after a time delay of 2 minutes, this time is nullified if
emergency supply falls below 85% of rated voltage during re-transfer.
1.2.1 240 V AC Control Power Supply:
INVERTER of 60 KVA, 415 V AC, 3 phase, 4 wire within + 1% voltage

regulation and + 0.5% frequency regulation feeds Cl-II control power supply in
following manner:
5233- 5233-BU-A ATS-1 65233-
INVERTER-1 (65233-Cell-1) PL # 1
5233- 5233-BU-B ATS-2 65233-
5233- 5233-BU-C ATS-3 65233-

Rev. No. : 02, Oct. 2008

1.2.2 240 V AC Control Power Distribution Panels:
65233-PL-1, 8, 15 is fed through ATS-1, 2, 3 respectively. Each panel consists

of 69 nos. MCB of rating 2 to 15 A with fault interrupting capacity of 10 KA.
Theses panels feeds power to recorders, controllers, indicating alarm meters,
reactor regulation and protection system.
1.2.3 48 V DC Control Power Supply:
Each 48 V DC Control Power Supply bus is supplied by two different RC’s with
a battery Bank on float. The details of arrangement is as follows:
65233-PL-2 to 65233-BU-J 65233-RC-1 (Cell # 2)

65233-PL-4 65233-BU-P 65233-RC-6 (Cell # 11)
& 48 V DC battery bank # 1.
65233-PL11 to 65233-BU-K 65233-RC-2 (Cell # 3)
65233-PL-13 65233-BU-Q 65233-RC-4 (Cell # 6)
& 48 V DC battery bank # 2.
65233-PL-18 to 65233-BU-L 65233-RC-3 (Cell # 5)
65233-PL-20 65233-BU-R 65233-RC-5 (Cell # 10)
& 48V DC battery bank # 3.
Arrangements for AC Power to rectifiers are as follows:
5233- INVERTER -1 65233-RC-1 (BUS-J)

65233-RC-2 (BUS-K)
5233- INVERTER -2 65233-RC-5 (BUS-R)

65233-RC-6 (BUS-P)
65233-RC-8 (BUS-M)
5233- INVERTER -3 65233-RC-3 (BUS-L)

65233-RC-4 (BUS-Q)
65233-RC-7 (BUS-N)
Each paralleled pair of rectifiers is equipped with a load share device, which
maintains the load balance between two rectifiers within 10 percent. The load
share devices are equipped with alarm contacts to annunciate failure of load
share feature.
There are two test supply rectifier units rated at 30 Amps. These buses are
used for detecting ground fault. The arrangement is
5233- 65233-RC-7 65233-BU-M
INVERTER -3 (Cell # 7)
5233- 65233-RC-8 65233-BU-N
INVERTER -2 (Cell-8)
Rev. No. : 02, Oct. 2008

In order to maintain continuity of control power supplies even in remote case of

complete loss of input power to rectifier units, 48 V DC battery back up is
provided. Each battery bank comprises 22 cells and has a rated capacity of
300 AH. Battery banks are capable of supplying loads for 30 minutes.
One standby battery charger provides equalise charge and boost charge after
an emergency discharge or for initial charging. Battery charger output is 50
Amps and capable of varying output voltages from 40 to 60 Volts.
1.2.4 48 V DC Control Power Supply Distribution Panels:
Each main rectifier has adequate capacity to carry the busload. All the six
main rectifier are rated for 100 Amp., 48 V DC.
Main buses 65233-BU-J, K, L and battery buses 65233- BU–P, Q, R and test
buses 65233-BU-M, N are equipped with voltmeter each.
Each main bus feeds power to 18 Nos. of distribution buses i.e. 65233-BU-J1
to J 18. These distribution buses are equipped with 30 A, 50V DC MCB. Each
distribution bus has a transfer hand switch to transfer the distribution bus to
test bus 65233-BU-M or N for ground fault detection or for maintenance. All
distribution buses are provided with under voltage (27) relay. Contact of these
relays are used to display 48 V DC fail in control room. Each distribution bus
can be loaded to maximum continuous current of 20 Amp. Silicon diodes
(Blocking diode) are connected to each branch of main bus and battery bus to
prevent effect of main bus fault on battery bus and vice versa.
Bus J1, K1, L1 supply power to Protective Channels D, E & F. Distribution
buses J2 to J18, K2 to K18 and L2 to L18 provides power through MCB of 5 A,
48V DC. Each of distribution buses except J1, K1 and L1 have 16 Nos. of
MCBs with fault interrupting capacity of 3 KA.
1.2.5 GROUND DETECTION :
Ground fault detector is provided for each main bus 65233-BU-J, K, L. Ground
fault detector 65233-GD-1,2,3, meant for main bus 65233-BU-J, K, L are
mounted in 65233-PL-2, 9 16. Ammeter (AM-19,20,21) which measures
condition of bus insulation and hand switches HS-290, 291, 292 are provided
on main control room panel 6610-PL-1. There is also common ground fault
detector 65233-GD-4 mounted on 65233-PL-3 to test insulation level of main
buses and distribution buses from control equipment room.
Ground detector GD-1,2,3 have three position selector switch in control room
marked 'Auto', Positive ' an 'Negative'. When turned to positive or negative
position ground detector measures directly insulation level of positive or
negative bus with all control circuit. Connected, when turned to Auto ground
detector measures insulation of positive and negative bus alternatively at every
1 minute.Ground detector GD-4 is equipped with hand switch. 226 having five
positions test (+), test (-), off, J+, J-, K+, K-, L+, L-. When control circuits
supplied by a control bus are switched over to the one of test bus and ground
Rev. No. : 02, Oct. 2008

detector is selected to positive or negative position, the insulation level of

positive or negative bus will be indicated by ground detector ammeter.
Ground detector GD-4 can also be used for testing the insulation resistance of
bus-P, Q, R (Battery bus).
1.2.6 MCB trip monitoring system :
The purpose of MCB trip monitoring system is to locate which particular 240 V
AC / 48 V DC MCB had tripped due to some reason.
1.2.6.1 NAPS-1 MCB status monitoring system :
NAPS-1 MCB status monitoring system is of M/s. Situ Electro Instruments Pvt.
Ltd., Mumbai. The scheme uses the distributed data processing and
monitoring technique. The system monitors the status of auxiliary contacts of
MCB. The system consist of 1 control controller unit (CCU), 12 LCM (local
control module) and one remote display unit (RDU). Each LCM can scan 128
Nos. of MCBs and pressed their status at the CCU on the CCU all the datas
regarding MCBs status, No. of LCM connected are logged and displaced on
request.
No. of tripped MCBs, their tag No. and respective panel No. displayed on CCU
and RDU. This log following event :
i) LCM failure - interface card failure, terminal module failure, serial

communications failure.
ii) Tripped MCBs.
iii) RDU failure.
The location of different LCM, CCU and RDU is given below : -
Equipment Location No. of MCB

Connected
LCM-1 65233-PL-1 69
LCM-2 65233-PL-8 69
LCM-3 65233-PL-15 69
LCM-4 65233-PL-4 96
LCM-5 65233-PL-5 96
LCM-6 65233-PL-6 96
LCM-7 65233-PL-11 96
LCM-8 65233-PL-12 96
LCM-9 65233-PL-13 80
LCM-10 65233-PL-18 96
LCM-11 65233-PL-19 96
LCM-12 65233-PL-20 80
CCU PL-6 NA
RDU 6610-PL-9 NA
( Control room)
Rev. No. : 02, Oct. 2008
1.2.6.2 : NAPS-2 MCB status monitoring system :
MCB trip monitoring system is of M/s. APLAB make. The scheme uses the
disturbed data processing and monitoring techniques. The system consists of
one central processing unit (CCU), 12 No. local control monitors (LCM) and
one remote display unit (RDU). The CCU is connected to LCMs via serial
data link. Each LCM can scan up to 96 No. of MCB. RDU gives only status of
tripped MCB in C/R on continuous basis.
The location of CCU, LCM and RDU is given below : -
Equipment Location No. of MCB Connected
LCM-1 65233-PL-1 96
LCM-4 65233-PL-4 96
LCM-5 65233-PL-5 96
LCM-8 65233-PL-8 96
LCM-11 65233-PL-11 96
LCM-12 65233-PL-12 96
LCM-13 65233-PL-13 80
LCM-15 65233-PL-15 69
LCM-18 65233-PL-18 96
LCM-19 65233-PL-19 96
LCM-20 65233-PL-20 80
CCU 65233-PL-6 NA
RDU 6610-PL-9 (C/R) NA
Control power supply for MCB trip monitoring system is 240 V AC. Details of
this is given below : -
S.No. Equipment Equipment 240VACMCBNo.

NAPS#1 NAPS#2
1 LCM-1 LCM-1 MCB-305
4 LCM-4 LCM- 6 MCB-296
5 LCM-6 LCM- 11 MCB-310
6 LCM-7 LCM- 12 MCB-275
7 LCM-8 LCM- 13 MCB-313
8 LCM-9 LCM- 15 MCB-306
9 LCM-10 LCM- 18 MCB-273
10 LCM-11 LCM- 19 MCB-244
11 LCM-12 LCM- 20 MCB-243
12 CCU CCU MCB-296
13 RDU RDU MCB-293
Rev. No. : 02, Oct. 2008

1.3 TECHNICAL DETAILS :

1.3.1 240 V AC Auto Transfer Switch
Input Voltage 415 V, 3 Phase, 50Hz, 4 Wire

Input current 50 Amps
Output voltage 415 V, 3 Phase, 50 Hz, 4 Wire
Output current 50 Amps
Overload rating 125% for 10 min. & 150% for 1 min
Transfer time 40 m sec
Transfer initiation at 85% voltage
Re-transfer time 2 minutes
Re transfer initiation at 90% Voltage
Emergency fails during Delay time is nullified
retransfer
Normal & Emergency fails Loads disconnected
1.3.2 48 V DC Supply Cells
Input 415 V, 3 Phase, 4 Wire

Output 48 V DC,100 Amp (Main rectifier)
48 V DC, 30 Amp (Test rectifier)
Input frequency variation + 5%
Regulation + 1%
Ripple < 5% rms
Voltage dip on sudden 40%
application of Full load
Voltage rise on sudden rejection 40%
of full load
Efficiency > 80% for 100 Amps cells
> 70% for 30 Amps cell
Time for recovery of DC voltage < 500 m sec.
to normal after sudden
application or rejection of load
1.4 LIST OF EQUIPMENT SUB-ASSEMBLIES:
1.4.1 240V AC Supply Cells & ATS:
(i) Controller PCBs:

The ATS (Auto Transfer Switch), which is static switch, consists of 3 controller
cards. PCB-1 senses NORMAL supply, PCB-2 senses EMERGENCY supply
and PCB-3 is installed for LOAD supply sensing.
These controller cards are meant to sense the healthiness of the input supply
and trigger the thyristors with the help of gate pulse card. The controller cards
provide signal to gate pulse card to trigger the Thyristors only if the supply is
healthy. In case the normal supply falls below 85% then PCB1 will give a
signal to PCB-2 to release the gate pulse to trigger Emergency supply
Thyristors. During changeover to Emergency, the triggering pulse to normal
supply thyristors is blocked by PCB-1.
Rev. No. : 02, Oct. 2008
When the Normal supply has reached 90% of the rated voltage, an internal
timer (in Controller IC) is set for 2 minutes. The Normal PCB-1 ensures that
the normal supply is >90% of the rated voltage for 2 minutes. After 2 minutes
fo stabilization the normal supply will be turned ON and Emergency supply will
be turned OFF. In-between this process, if the Emergency supply fails, the
static switch will immediately transfer from Emergency to Normal Supply
without any time delay.
The change over to Emergency Supply occurs during following conditions.
(a) When the Normal Supply is decreased upto or below 85% of the rated
Voltage.
(b) When there is an actuation in Normal Supply Protection.
(c) By forced Transfer using the pushbutton PB-101 provided on the panel
(Forced transfer is carried out only for testing purpose and during no load
Condition to avoid load transient)
(ii) Power supply PCB:

The power supply PCBs are duplicated to have a redundant and reliable
source of supply to the Controllers. AC Supply voltage to the PCBs is
given from the Normal and Emergency supply through step down
transformer. This transformed voltage is then rectified and regulated to
+12V DC. The controller PCBs will transform the +12V to +5V DC
(iii) Gate Pulse Card:

The SCR gate pulse card PCB-6 & PCB-7 at the Normal supply side and
Emergency supply side is used to provide gate pulse for the SCRs of
Normal Emergency side respectively
(iii) Snubber PCB:

The RC-Snubber PCB is provided at each R,Y,B phases for dv/dt
protection at normal Supply and Emergency supply side.
(iv) Miniature Circuit Breaker
(v) AC Voltmeter & Frequency meter
1.4.2 48 V DC, SUPPLY CELLS:
(i) Power Circuit:
It Consists fully insulated two winding, main rectifier transformer and

conservatively rated three diodes and three SCR’s for full wave half
controlled 3-phase rectifier.
(ii) Firing Circuit:
The firing circuit produces a narrow pulse of constant width (1 m sec.)

the phase angle of which can be controlled from 0-180 deg.. by
varying the control voltage from 0 – 10 V DC.
Rev. No. : 02, Oct. 2008
(iii) Control Circuit :
It provides facility for soft start during initial switch ON, checking of OP
- amp operations, regulation adjustment, Anti hunt facility for improved
stability and current limit adjustment.
(iv) Load share and Annunciator Circuit :
It provide facility to control the load share of two cells. When load share
unbalance exceeds 10% an alarm appear in control room. Over voltage
limit is 53 V and under voltage limit is 42 V DC, which is also appears
as alarm in control room when limit is crossed.
(v) Auxiliary Power Supply Circuit :
Generate + 12 V DC for its and bias circuit.
(vi) Fuse Failure Alarm Circuit :
This monitors the status of the capacitor fuses and protection fuses.
When any fuse fails (blows). Alarm contacts operates for display in
window annunciation at DC Supply Cell.
Rev. No. : 02, Oct. 2008

CHAPTER 16
LIGHTING, RECEPTACLE AND SPACE HEATER SYSTEM

(53100)
1.0 SCOPE
This chapter covers the basic features of the lighting system in the Turbine building,
Reactor Building, Service building, Switchyard, Dryer & ECCS Room and emergency
Control Room. Lighting for other areas and outdoor street lighting are not covered in
this chapter.
Also covered in the chapter are the receptacle supply system and the space heater
supply system.
System description
2.1 LIGHTING SYSTEM
The lighting system consists of –
(A) NORMAL LIGHTING
This lighting provides the necessary illumination for enabling the operating and
maintenance personnel to perform their normal duties. This lighting is supplied from
the stations class –IV power supply.
(B) EMERGENCY LIGHTING
This lighting, during loss of normal station lighting, provides the minimum illumination
necessary for the operating personnel to move safely around the plant and perform
the task that may be required to ensure the safety of the station & restores normalcy.
This lighting is supplied from the station’s class-II power supply. In the RB 1&2, TB
1&2, CWPH, service building, main control room and emergency control room
emergency lighting are also provided. Incandescent lamps are provided for
emergency for control room lighting, which is connected to 250V DC class-I supply.
2.2 RECEPTACLES
These are supplied from class-IV power supply and are distributed such that each
cabin, room or enclosed area has at least one 5 Amp or 15 Amp single-phase 240V
AC supplied unit. In large areas, these are distributed evenly at convenient spacing.
415V 3 phases AC units with 60 Amp capacity are also used in machine rooms,
workshops, etc. for connecting portable units like portable sumps pumps, welding
sets, etc.
2.3 SPACE HEATER SYSTEM

Space heating is required for electrical panels, motors, control boards etc. to prevent
moisture condensation when it’s not in service.
Rev. No. : 02, Oct. 2008
For motors up to 30 KW the stator winding may be used for connection to a 240V
single phase 50 Hz AC supply.
For motors rated 30 KW and above space heaters of adequate capacity (depending
on the motor rating) are provided to maintain the motor internal temperature above
the dew point to prevent moisture condensation. These space heaters are generally
rated for 240V, single phase 50 cycle operation.
Space heaters for electrical panels, control boards, etc. are also supplied from 240V
single phase AC supply. These are provided with thermostats to cut off the supply at
a pre-determined temperature.
3.0 FEATURE BASIS
3.1 LIGHTING
3.1.1 SELECTION OF LUMINARIES
While selecting the type of fixture, the following considerations have been adopted.
-Color rendering
-Illumination levels
-Location
-Mounting height
-Effect of voltage fluctuations
3.1.1.1 COLOR RENDERING

The color rendering property of each lamps type is featured by the color-rendering
index. The higher the index the better is the suitability in performing the task of color
identification and matching. Hence, fluorescent fixtures, which have good color
rendering for power consumed, have been used in workshops etc.
3.1.1.2 ILLUMINATION
The approved value of illumination levels for areas in RB, SB, switchyard, etc. are
given in Appendix-1
3.1.1.3 LOCATION
The condition prevailing in a particular area has been taken into account while deciding the
type of fixture to be used.Indoor industrial type fluorescent fixtures (2x40W and 2x65W)
with slotted reflectors have been widely used in most of the areas where normal conditions
exist and good illumination is required.In door totally enclosed weather proof, fixtures
with fluorescent lamps have been used in dusty and excessive moisture laden areas.
Specially conshield type 250 watt HPMV light fittings are used in the fuelling machine
vault and FM service area for achieving more illumination per overall fixture
mounting area.
Rev. No. : 02, Oct. 2008

Indoor decorative recessed type fluorescent fitting (2x40W, 4x20W, 4x40W) with
louvers for areas having false ceiling like office rooms, control room and emergency
control room.
Corrosion proof fittings with fluorescent lamps (2x40W) are used in chemical
laboratories, where degradation of normal types of fixtures could occur due to
corrosive fumes or gases.
‘Bulkhead’ fittings with incandescent lamps for areas where movement of personnel
is restricted and occasional and the area available for fixture mounting is less ex.
cable tunnels.
High bay lighting fixtures with 250W HPMV and 25o watt metal halide light fittings
are used in workshop and maintenance bays.
Substation ‘ lantern’ type lighting fixture with 250W HPMV lamps is used in the
switchyard.
3.1.1.4 MOUNTING HEIGHTS
Fixtures with fluorescent lamps have been used up to a mounting height of about 6
meters. For areas with a ceiling height more than 6 meters High bay type lighting
fixtures with HPMV/metal halide lamps have been used. In some areas like the
spent fuel storage, bay a combination of both fluorescent and high bay 250-Watt
HPMV fixtures have been used.
3.1.1.5 EFFECT OF VOLTAGE FLUCTUATIONS
The lighting fixtures used are suitable for operation on a nominal supply of 240V,
single-phase 50 Hz AC supply with a voltage variation of + 10% (i.e. 216V to 264V).
¯
3.1.2 ILLUMINATION CALCULATION PROCEDURE
The feature process for indoor areas is to obtain uniform general lighting and is
based on the Lumen Method. This gives a specified value of illumination over the
working plane throughout the considered area. The basic formula used is
Illumination = NF x U x M
(In lux) A
Where NF total luminous flux of all lamps (In lumens)
U - Co- efficient of utilization.
M - Maintenance factor
A - Area considered (in sq. m)
The value of ‘U’ is obtained from the manufacturer’s tables by interpolation with the
room index and reflection factors. The maintenance factor takes into consideration
the gradual fall in lumen output of the lamps and dispersion by the luminaries, due to
permanent discoloration of the transmitting and reflecting surfaces caused by aging,
heating, corrosion, etc.
Rev. No. : 02, Oct. 2008
Typical values are

0.75 for clean interiors such as office rooms and laboratories,
0.70 for workshops and other areas
0.65 for heavy-duty machine rooms pump rooms, etc.
( See Annexure-3 of this chapter )
3.1.3 SPACE HEATERS
This is divided into two categories
Motor space heaters

Panel space heaters
3.1.4 SPACE HEATERS FOR MOTORS.
240V single phase, 50Hz AC supply is given to the motor when it is in idle condition.
This supply is switched on automatically by means of a ‘NC’ auxiliary contact of the
circuit breakers/contactor of that motor. This closes the coil circuit of a contactor ‘4’,
which switches on the space heater power supply. (See Annexure-4)
3.1.5 SPACE HEATERS FOR PANELS.
A 240V AC, single phase, 50Hz AC supply is given for these heaters. A plain switch
fuse controlled circuit is used, as there is a separate thermostat controlled heaters
unit with a switch fuse control in the panel to be heated. (See Annexure-4).
4.0 SUPPLY & DISTRIBUTION
4.1 LIGHTING
(A) NORMAL LIGHTING
The stations normal lighting power is provided by two lighting centers from 3-phase,
four wire solidly grounded neutral feeders, one each from 415V class IV busses K
and L. (the lighting centers are featureated as 531-LC-141 and 531-LC-142).
Lighting centers 531-LC-141 is fed from 5242-CB-8 on class IV bus 5242-BU-K,
while lighting center 531-LC-142 is fed from 5242-CB-38 on class IV bus 5242-BU-L.
Each lighting center is connected to its switchgear panel by 7 runs of 1 core 500
mm2 HRPVC aluminum conductor cable. The lighting centers are located in room T-
206 of the turbine building at EL 106 600mm.
(B) EMERGENCY LIGHTING

The emergency lighting centers are featureated as 531-ELC-143 and 531-ELC-144.
They are also located in room T-206 in the turbine building at EL 106 600mm.
These lighting centers are fed from feeder 5R4 of 5231-MCC-M and feeder 4F5 of
5231-MCC-N connected to class II buses 5231-BU-S and 5231-BU-T respectively.
The emergency lighting centers are connected to their respective MCC feeders by 3
core 50 mm2 HRPVC aluminum conductor cables.
Rev. No. : 02, Oct. 2008
Each emergency lighting center is supplied from a 75 KVA, 415/425 Volt, DY11, and
neutral grounded, dry type transformer.
4.1.2 RECEPTACLES
(A) SINGLE PHASE RECEPTACLES
These are rated 5A and 15A and supplied from 240V, single phase 50Hz, AC supply.
These units are metal clad and surface mounting type and weather proof. A 3-pin
type socket (2 pole and earth) is used and the switch provided is a rotary on-off
switch. The 5A and 15A receptacles are featureated as Type A and B respectively.
Only class-IV power is envisaged for these receptacles and it is availed from the
various lighting load (sub) centers in RB, SB and switchyard. A three phase 4 wire
feeder is taken from the lighting center and fed to the receptacle distribution panel
from where single phase supplied are then derived.
(B) THREE PHASE RECEPTACLES
These are featureated as Type-C and are rated for 415V, 60 amps. These units are
also metal clad, surface mounting type and are provided with a 60-amp triple pole
switch. An interlock is provided such that it shall not be possible to insert or remove
the plug when the switch is in ‘ON’ position. Only class-IV power supply is
envisaged from these receptacles. These supplies are taken from the various class-
IV MCCS.
4.1.3 SPACE HEATERS
The class-IV supply required for this is taken from the main lighting boards 531-LC-
141 and 531-LC-142. This is fed to the various space heater supply panels located
in RB, SB, etc. Further single-phase distribution is done from these space heater
panels to the individual loads.
4.2 DISTRIBUTION
4.2.1 NORMAL LIGHTING POWER SUPPLY DISTRIBUTION
The outgoing feeders of lighting center 531-LC-141 are distributed as follows
(a) Turbine building 531-LC-2, 531-LC-3, 531-LC-5.
(b) PHT building PHT building Load Center
(c) Service building 531-LC-145 S136 EL 100000
(d) Reactor building 531 -PLD – 116 (WEST) R 406 EL 100000
531 - PLD – 125 (South) R406 EL 100000
531-PLD-134 R901 EL-126230
(e) Spare Feeder One
The outgoing feeders from 531-LC – 142 are as follows
(a) Turbine building531-LC-1

531-LC-4
(b) Cooling Water 531-LC-50
Pump House
Rev. No. : 02, Oct. 2008
(c) Reactor building 531 -PLD – 137 R 901 EL 126230

531 -PLD – 121 (North) R 401 EL 100000
531 -PLD – 111 (East) R 401 EL 100000
(d) Service building 531-LC-150 S217 EL 106600
(e) Spare Feeder One
4.2.3 EMERGENCY LIGHTING POWER SUPPLY DISTRIBUTION
The outgoing feeders from 531 – ELC –143 are
(a) Turbine Building 531-ELC-6 T206 EL 106600

(b) Reactor Building 531-PLED-117 (West) R406 EL 100000
531-PLED-135 R901 EL 128230
531-PLED-122 (North) R401 EL 100000
(c) PHT Building One (1) feeder
(d) Spare Feeder One
The outgoing feeders from 531-ELC – 144 are as follows
(a) Cooling Water Pump 531-ELC-54

House
(b) Reactor building 531 -PLED – 112 (East) R 401 EL 100000
531 -PLED – 126 (South) R 406 EL 100000
(c) Service building 531-ELC-160 S136 EL 106600
(d) 220 KV Switchyard 531-PLED-106
(e) Spare Feeder Two (2)
4.2.3 RECEPTACLE DISTRIBUTION
(a) Reactor Building 531- PRE-123 in load Center North

531- PRE-127 in load Center South
531- PRE-113 & 531- PRE-114 in load Center East
531- PRE-118 & 531- PRE-119 in load Center West
531- PRE-136 & 531- PRE-138 in Boiler Room
Area
(b) Service Building 531-PRE-149
531-PRE-154
531-PRE-155
(c) Switchyard 531-PRE-104
531-PRE-105
Rev. No. : 02, Oct. 2008

SPACE HEATER DISTRIBUTION
(a) Reactor building 531-PLD-132

531-PLD132-A (for Primary Coolant Pump Motors
only)
(b) Service building 531-PLD-130 (for NAPP-1 motors)
531-PLD-131 (for NAPP-2 motors)
(c) Turbine building 531-PLD-108
(Located in T-206) 531-PLD-109
531-PLD-130
5.0 OPERATION & CONTROL
5.1 REACTOR BUILDING
5.1.1 LOAD CENTRES (EAST AND WEST)
NORMAL OPERATIONAL LIGHTING
Lights are switched on by the operation of contractors energized by manual

operation of switches on their lighting distribution panels. For other areas, where
contactors do not switch lighting, it is switched on by the operation of manual
switches.
EMERGENCY OPERATIONAL LIGHTING
Whenever normal operational lighting fails due to loss of incoming supply or due to
fuse operation in one of the feeder circuits, no-volt relays operate to energize the
contactors so that emergency operational lighting is available for the safe movement
of personnel.
5.1.2 LOAD CENTERS (NORTH AND SOUTH)
This lighting load center provides for lighting in the fuelling machine vault and
adjacent areas.
(a) NORMAL OPERATIONAL LIGHTING
Normal lighting can be switched on either from the control room or from the local
load center by operation of push buttons. The two-position selector switch for
selecting local or remote operation is in the control room.
When the selector switch in the local position, the lights in the FMV can be switched
‘ON’ in two stages by operating the push buttons on the local lighting panel.
When the selector switch is in the remote position, however, all lights in the FMV are
switched ON simultaneously. This stage is required for sufficient illumination
Rev. No. : 02, Oct. 2008
necessary for the observation of the fuelling machine and associated equipment
through the viewing windows in the north and south passages at EL 100000.
(b) EMERGENCY OPERATIONAL LIGHTING
When normal power supply fail the no volt relays drop out to energize the
contractors, which switch on the emergency operational lighting in the FMV area.
SERVICE BUILDING
Normal operational lighting for this building is provided by lighting centers 531-LC-
145 and 531-LC-150. Lighting center 531-LC-145 is located in room S-136 of the
Service Building at EL 100000. Lighting center 531-LC-150 is located in room S217
at EL 106000.
Emergency operational lighting for service building is served by 531-ELC-160, which

is located in, S-136 at EL 100000.Both the normal and emergency operational
lighting are normally switched on. During loss of power supply to the normal lighting
distribution panel or other exigencies, the emergency operational lighting however
remains.
Lighting in the spent fuel storage bay and spent fuel inspection bay at EL 100000
consists of in addition to the room lighting, additional lighting for under-water
movement and inspection of spent fuel. For this special sodium vapor, lamp fixtures
are provided. For further details, refer to drawing NAPP-1, 2/53130/6023/GA.
5.3 SWITCHYARD
Lighting centers 531-PLD-100 & 531-PLD-100 provides normal operational lighting

and both located in the switchyard junction box room in the switchyard on the East
Side.
Lighting center 531-PLD-100 is feed from 5242-CB 9 on class-IV bus 5242-BU-K,

and 531-PLD-101 is fed from 5242-CB20 on class-IV bus 5242-BU-L.
Emergency operational lighting for the switchyard is obtained from lighting

distribution panel 531-PLED-106 which in turn is fed from emergency lighting center
531-ELC-144. The distribution board 531-PLED-106 is also located in the junction
box room in the switchyard.
Normal lighting in the switchyard is provided by 125 W HPMV Substation Lantern

with prismatic glass refractor. Provision for 250 W floodlights have also been made.
Emergency lighting is by 300 W incandescent substation lanterns with prismatic

glass refractor.
The emergency lighting that is supplied from 531-PLED-106 (fed from 531-ELC-
144) is ‘normally’ kept on along with the normal lighting.
Rev. No. : 02, Oct. 2008

5.4 EMERGENCY CONTROL ROOM
Normal operational lighting is supplied from the PHT building lighting board 531-
LDB-1.
Emergency AC lighting supply is taken from 531-ELDB-1. 250V DC emergency

lighting is also provided from a tap off from circuit no # 1 of CP-1, which supplies DC
lighting in the Main Control Room area. The DC supply is fed to two nos. 75W
incandescent lamp fixtures located above the control panel (Ref drawing NAPP-1,
2/53130/6027/GA)
5.5 DRYER ROOM
Normal operational lighting is taken from Service Building Board 531-PLD-147 (531-
PLD-146 for Dryer Room-2).
Emergency lighting supply is taken from Service Building Board 531-PLED-161.
6.0 PROTECTION
The rating of switches, contactors and busses connected with lighting power supply
distribution circuits are equal to or higher than the rating of HRC fuses in the
corresponding circuit.
HRC fuses are provided in each circuit and their ratings are so selected that they are
loaded approximately 75% or less than their rating when all luminaries connected to
the circuit are switched on.
In addition, HRC fuses are also provided for each individual fluorescent and HPMV
fixture.
7.0 POWER FACTOR IMPROVEMENT
All discharge lamps require a means of controlling, or stabilizing, the current passing
through them. The ballast satisfies this requirement. The ballast or choke is placed in
series with the lamp Inherently the power factor of this circuit is low i.e. about 0.5
lagging. The power factor can be increased to 0.85 or greater in a number of ways. A
capacitor connected across the supply terminals is the method adopted.
Rev. No. : 02, Oct. 2008

ANNEXURE-1
A -REACTOR BUILDING
Sr. No. Room No. Room Featureation Type Illumination level as

of approved LUX
Fitting
1. R1-001 Suppression Pool C 100
Chamber
2. R1-101, Moderator circulation B 150
104 Equipment
3. R1- Emergency & main air B 150
410,411 lock
4. R1- Pressure relief chamber A 150-200
501,502 (N&S)
5. R1-601 Feed pump equipment A&B 200-250
room
6. R1-701 Activity monitor room A&B 150-200
R1-702 (N&S), passage & railed
R1-703 fuel monitor room
R1-704
7. R1-705 PHT auxiliary equipment A&B 150-200
room
8. R1-801 PHT equipment room A&B 200-250
9. R1-901 Boiler room A&B 100-150
10 Annular space J 10-20
B- SERVICE BUILDING
Sr. No. Room No. Room Featureation Type Illumination level as

of approved LUX
Fitting
1. S-001&011 Basement Area B 100-150
2. S-101, Entrance hall, passage H&N 100-120
104&110 and portico
3. S-102 Clean clothes B 100-150
distribution center
4. S-103 Lock Room B 100
5. S-104 Security Counter N 100-150

6. S-106&119 Stair Case B 100
7. S-107, Wash Basin, Clock N 50-80
108&113 Room
8. S-111 Health Physics Room N 100-150
9. S-112 EMU Shop B&F 250-300
10 S-114 Change Room N 100-150
Rev. No. : 02, Oct. 2008

11. S-116&117 Work Room & Clock N 50-80

12. S-121&123 B 100
13. S-124 Source Room B 150-200
14. S-124 Protective Equipment B 150-200

Room
15. S-125&118 Passages in S.B. N 100

16. S-126 Electrical, Mechanical B&F 250-300
Maintenance Shop
17. S-127 Stair Case B 100
18. S-128&136 Service Area B&F 250
19. S-129&134 Health Physics Station B 100
No.1 & 2.
20. S-130 Exhaust Ventilation B&C 150
Equipment Room
and Filter Room
21. S-130 D2O Drum Storage B 100
22. S-132 D2O Evaporation and B 100-150
Clean-up Room
23. S-133 New Fuel Storage Room B 100-150
24. S-146 Equipment B 150-200
decontamination center
25. S-137 F/M Maintenance Room B 300-350
26. S-138 Spent Fuel Storage Bay A&F 200-250
27. S-139, SFI Bay No.1 & 2 B 200-250
S-140
S-141
28. S-145 Shipping Flask Loading B&F 150
Bay
29. S-144 Platform at EL 100 M B 100-120
30. S-201 Store B 100-150
31. S-202 Tea Pantry N 100
32. S-203 Passage N 100-120
33. S-204 Library N 300
34. S-205, 206 Office N 300
208,209&
210
35. S-207&212 Toilet N 50 - 80
36. S-211 Clean Clothes Room B 100
37. S-213 Passage N 100
38. S-214 Bio-assembly N 200-250
39. S-215 Counting Room N 200-250
40. S-215 Chemical Control P 300-350
Laboratory
41. S-217&151 Electrical Equipment B 200-250
Room
42. S-218 Relay & Testing B 300-350
Rev. No. : 02, Oct. 2008
Laboratory
43. S-220 Chemical Control P 300-350
Laboratory
44. S-221 Intake Ventilation B, C 150
Equipment Room
45. Passage between B 100
Turbine Building and
Service Building
46. S-109 Showers C 50 - 80
47. Passage between grids N 100-120
7a to 27/F,G at EL
106000
C SWITCHYARD
Sr. No. Room Featureation Type Illumination level as

of approved LUX
Fitting
1. Equipment M 10 - 20
K
2. General L 5 –10
3. (a) Start up transformer pockets near 250 (min)
the middle of HV bushing.
(b) A.B.C.B. at isolator level 18.6 (min)
D.OTHER AREAS
Sr. No. Room Featureation Type Illumination level as

of approved (LUX)
Fitting
1. Dryer Room B 150
2. Emergency Control Room R 300
3. Conference Area R 300
4. Above Panels S, T 450
5. Emergency Airlock Barrel W 50
Rev. No. : 02, Oct. 2008

ANNEXURE-2
TYPE OF FIXTURES
Sr. Room Featureation Type of

No. fitting
1. Indoor Industrial type fluorescent Lighting fixture with A
spotted.
2. Indoor Industrial type fluorescent Lighting fixtures with B
slotted reflector 2 x 40 W.
3. Indoor totally enclosed fixtures 2 x 40 w C
4. Specially fabricated fluorescent fitting suitable to D
accommodate 4 x 65 W
5. Flood light fitting HPL 250w E
6. High bay lighting fitting suitable for 500 W GLS Lamp. G
7. High bay lighting fitting HPL 250 W F
8. Sqare modular ftting 4X20 W fluorescent lamp suitable H
for ceiling mounting.
9. Bulkhead fitting 100W (bajaj type BOHO-P-100 or J
equivalent).
10. Sub-section lantern type lighting fitting with 300W K
incandescent lamp.
11. Substation lantern type lighting fitting 250 HPMV lamps. L
12. Flood lighting fitting HPL-400W M
13. Indoor, decorative, recessed type fluorescent lighting N
fitting for 2X40W lamps.
14. Corrosion proof fitting of fluorescent 2X40 W lamps. P
15. Indoor square shaped recessed modular fluorescent R
lighting fixture with OPAL acrylic diffuser for 4X20 W
lamps.
16. Indoor decorative recessed type modular fluorescent S
Lighting fixture with opal acrylic diffuser for 4x40watt
lamps.
17. Indoor decorative type recessed down lighting luminaries T
with 75 W incandescent lamp. (Philips DBD-10 with
compta lux R-30)
18. Indoor industrial type fluorescent lighting fixture without W
reflector for 2X20 W lamps.
Rev. No. : 02, Oct. 2008

ANNEXURE 3
AVERAGE ILLUMINANCE CALCULATION *
1. GENERAL INFORMATION
AREA IDENTIFICATION A-206

(GIVEN NAME OF AREA AND./OR OFFICE ROOM IN SB
BUILDING
AND ROOM NUMBER)
AVERAGE MAINTAINED ILLUMINANCE 300
FOR FEATURE. E’
(LX)
ROOM LENGTH 9.34
L’ (M)
ROOM WIDTH 6.085
W (M)
ROOM HEIGHT 6.0
H (M)
CEILING REFLECTANCE 50
Qc (%)
WALL REFLECTANCE 50
QW (%)
FLOOR REFLECTANCE 30
QF (%)
THE HEIGHT OF THE WORKING PLANE 3.05
Qf (%)
SUSPENSION LENGTH THE HEIGHT OF ROOM IS WITH FALSE
THE CEILLING CEILLING
ABOVE THE FIXTURES, 3.05
Hs
MOUNTING HEIGHTTHE HEIGHT OF THE 3.05
FIXTURES ABOVE THE WOKING PLANE
Hm (M)
ROOM INDEX, 1.208
Kr=LW / (L+W) HM
FLOOR AREA (m2) a = LW 56,83
2. LAMP AND FIXTURES

LAMP DATA TYPE AND COLOUR FLUORESCENT COOL
LUMINUS FLUX DAYLIGHT (40 w)
F(1m) 2440
Rev. No. : 02, Oct. 2008

FIXTURE DATA TYPE NO RECESSED 2X40W (TYPE-N)

NUMBER OF LAMP PERFIXTURE n
2
COEFFICIENT OF UTILIZATION U U 0.39
MAINTENANCE FACTOR M M 0.75
2. CALCULATIONS
NUMBER OF LAMP CALCULATED

E’A
N= FUM 23.889 = 24
NUMBER OF FIXTURES
N’ 24
N= n 2 = 12
* SAMPLE CACULATION FOR S-206 GIVEN AS A TYPICAL EXAMPLE.
Rev. No. : 02, Oct. 2008

ANNEXURE-4
FUSE FUSE 15A LINK

2A
4
4 COIL OF
CONTACTOR
A SPACE HEATER ON
H
Aux. Contact of circuit breaker/ Motor space Heater
MCC Cell
FEEDER TYPE-A
(FOR MOTOR HEATER)
Rev. No. : 02, Oct. 2008

FUSE LINK
FEEDER TYPE- B
(FOR SPACE HEATER)
Rev. No. : 02, Oct. 2008

CHEPTER 17
GROUNDING SYSTEM
(53200)
1.0 SCOPE
The chapter covers the basic features of installation of grounding and lighting
protection systems for Reactor Building, Service building, Switchyard and
miscellaneous areas and / or equipments.
2.0 OBJECTIVES OF GROUNDING
The flow of high magnitude power frequency current to ground during system fault
conditions raises the station’ s earth potential with respect to the zero potential of the
remote earth. this imposes a potential deference between the metallic frames of
equipment and nearby grounds thus creating dangerous potential gradients for
persons standing in the station area and /or those touching some equipment/
structure associated with station ground . The basic objectives of grounding system
are as follows
A) To ensure freedom from exposure to dangerous electric shock voltages to
persons in the areas;
B) To provide current carrying capacity, both in magnitude and duration,
adequate to accept ground fault currents of the system;
C) To facilitate the operation of relays and protective equipment by providing low
resistance path to earth return currents.
3.0 FEATURE CRITERIA
3.1 SOIL RESISTIVITY
From measurements for soil resistively conducted at site in the dry season the
following data are arrived at for the purpose of feature, average soil resistivity is
taken to be 100 ohm-m.
Depth below surface in Average soil resistivity in ohm-m

meter
0.6 3.5
5.0 33.0
10.0 60.0
3.2 GROUNDING CONDUCTOR
In as much as resistivity of the soil near the surface is very low even in the dry
season, severe corrosion of buried conductor is likely to occur. Accordingly, copper
conductor is recommended for the buried portion of the grounding grid.The
remaining portion of the grounding system can be featured with M.S. conductor, in
the interest of economy. However, as desired by NPS, the entire grounding system
will be featured with copper conductor for the sake of uniformity and as a measure of
Rev. No. : 02, Oct. 2008
safeguard against corrosion at points of inter connection of two dissimilar metal

conductors.
3.3 SELECTION OF GROUND CONDUCTOR SIZES
3.3.1 ASSUMPTIONS
In selecting the ground conductor sizes, the following assumptions have been made
Circuit breaker Fault Current assumed

rating KA (RMS Sym) KA(RMS Sym)
i) 220 KV Systems 26.3 23
ii) 6.6 KV system 44 44
iii) 415 V system 50 50
Fault currents for the 220 KV systems is assumed to be lower than the
corresponding circuit breaker ratings as these values are not likely to be exceeded.
b) Fault clearing time (allowing sufficient 1.0 second

margin for fault clearance on back up
protection)
c) Types of joints Cadweld or Brazed
d) Maximum allowable conductor 450oC
temperature
e) Ambient temperature 40oC
Based on the above assumptions, the following sizes of copper conductors are
obtained
a) 220 KV system (23 KA) 104.5 mm2

b) 6.6 KV system (44 KA) 200 mm2
c) 415 V system (50 KA) 227 mm2
3.3.2 DEPTH OF BURIAL OF CONDUCTOR IN GROUND
(ii) Elsewhere 800 mm

(i) In switchyards 600 mm
3.3.3 FAULT CLEARING TIME FOR ESTIMATION OF 1 SECOND \ TOLERABLE\

TOUCH AND STEP VOLTAGE
3.3.4 COMPUTED VALUES
Based on the above data, the following values are computed
(a) Maximum touch potential 550 V

(b) Maximum step potential
(i) Switchyard 230 V
(ii) Elsewhere
(c) Tolerable touch voltage In switchyards and along
Rev. No. : 02, Oct. 2008
EHV routes with crushed rock surface. 665 V

(d) Tolerable step voltage
(i) In switchyards with crushed rock surface 2165 V
(ii) Elsewhere with natural soil 168.5 V
(e) Overall station ground resistance 0.11 ohms
It is uneconomical to feature the entire grounding system for the highest fault
current of 50 KA. The following conductor sizes are recommended.
(a) 220 KV SWITCHYARD
The grounding grid will be featured with a metric standard 19/2.65 mm conductor
having across section of 105 mm2.
(b) 6.6 KV SYSTEM, 415V SYSTEM AND REST OF THE STATION GROUND
The grounding conductor for the entire station is proposed to be 19/2.65 mm

conductor. In the vicinity of 6.6 KV and 415 V switchgears and transformers the grid
will be suitably re-inforced and each of the two equipment grounding leads will be of
2 X 105 mm2 conductors.
(c) GROUND LEADS FOR MISCELLANEOUS EQUIPMENTS
The recommended equipment ground lead sizes are given in Annexure-1.
3.4 STEP AND TOUCH POTENTIAL AND OVERALL STATION GROUND

RESISTANCE
3.4.1 Assumptions
(a) Average soil resistivity for estimation of ground resistance 100 ohm-m
and touch and step voltages
(b) Surface soil resistivity for estimation of tolerable touch and
step voltages
i) In switchyard and along EHV routes with crushed rock 200 ohm-m
surface
ii) Elsewhere 3.5 ohm-m
3.5 GENERAL RECOMMENDATIONS
3.5.1 Joints
Joints shall be by cadweld process, if import license can be procured, otherwise

brazed joints maybe used.
3.5.2 EARTH PITS
Earth pites, suitably treated, will be provided at locations for discharge of lighting
currents and near transformer neutral grounds.
Rev. No. : 02, Oct. 2008

4.0 LAYOUT OF GROUNDING SYSTEM
4.1 OUTDOOR SYSTEM
i) The grounding loop is copper conductor of size 4/0 AWG (equipment area of 105
mm2) is laid at a distance of 1000 mm around Switchyard, Reactor Building ,
Service Building, Turbine Building, Cooling Water Pump House and Allied Areas.
The depth of conductor buried in each of these areas is in conformity to section
3.3.1. The grounding loop in each area is connected to adjacent grounding loop of
another area by a minimum of two (2) number of copper conductor of size 4/0
AWG.
ii) Rod electrodes of 25 mm diameter copper and of lengths varying from 3 meters to
4.9 meters are located along the run of the grounding loop at intervals varying
from 4 meters (Switchyard) to 7 meters (in other areas).
4.2 INDOOR SYSTEM
The main grounding loop inside the building is also formed by 4/0 AWG copper
conductors at ground floor of the building. This is connected to the grounding loop of
the outdoor system at minimum of two (2) points. Grounding loop at other floor
elevations of the building is formed again by vertical run of 4/0 AWG copper
conductors from the main grounding loop to theses elevations. Horizontal runs of
conductors on the floor is provided by placing the conductor between layers of
reinforced steel with provision of minimum 50 mm cover. In the run along the wall,
column, ceiling etc. the conductors are cleaned along the surface of regular intervals.
Grounding pads, each connected to the main grounding loop by 2/0 AWG tinned
copper conductor, are provided on the floor, wall and ceiling of each area to provide
convenient ground connection point for equipment.
4.3 220 KV SWITCHYARD
Grounding grid inside the switchyard is formed by interconnecting 4/0 AWG tinned
copper conductor at the periphery of the switchyard to 4/0 AWG conductors in the
remaining area and suitably spaced ground electrodes.
Grounding system for each lighting arrester comprises of 4/0 AWG tinned copper
conductor connected to the earthing grid.
Grounding arrangement for each manually operated disconnecting switch includes

grounding grid at the location where the operator is likely to stand for the operation of
the handle.
5.0 EQUIPMENT GROUNDING
Taps from main grounding system and/or grounding pads provided near the
equipment/structure and connected to the grounding terminals of the
equipment/structure.
Rev. No. : 02, Oct. 2008
5.1 GROUNDING OF MOTORS
The frames of all electrical motors are connected to the grounding system by two
distinct paths. The size of the grounding lead specified depending on the motor
rating as given in annexure-1
5.2 ELECTRICAL PANELS
The internal grounding bus of each electrical panel is connected at both ends to the
station ground system by means of conductor of size prescribed in Annexure-1.
5.3 Junction boxes, Instrumentation and Control Equipment all junction boxes enclosing
electrical connections as well as the cases or frames of all instrumentation and
control devices which are not mounted on ground steel support or otherwise safety
grounded, are connected to the station ground system by appropriately sized copper
conductor.
5.4 MISCELLANEOUS STEEL STRUCTURE
All steel structures accessible to personnel as enclosure, Steel stairways etc. are
connected to station ground system.
The metallic sheaths of single conductor power cable carrying alternating current is
grounded at one end only. The rest of the sheath is kept insulated from ground in
order to eliminate circulating currents in the sheath. The metallic sheath of three
phase cable is connected to the station ground bus at both ends.
One 2/0 AWG bare, annealed, tinned, Stranded copper conductor connected to the
station grounding system is run throughout the length of the cable pan and
connected to it at intervals. Tapings are taken from this conductor for grounding the
adjacent trays.
6.0 NEUTRAL GROUNDING
6.1 TURBOGENERATOR
The star connected neutral point is grounded through a single phase distribution
transformer 50KVA, (ON) 16.5 KV/240V, 50Hz. A resistance of 0; .45 ohms is
connected to the secondary of this distribution transformer.
6.2 GENERATOR TRANSFORMER
The GT is delta-connected at he LV side and star-connected on the HV side. The

neutral point of the HV winding is connected solidly to the ground by 2 in parallel
4/0AWG copper conductors at two points.
6.3 UNIT AUXILIARY TYRANSFORMER

The UT is a 22 MVA31.5 MVA 16.5 KV/6.9 KV ONAN/ONAF Vector group Dy 1
transformer. The neutral point of the LV winding is grounded through a neutral
Rev. No. : 02, Oct. 2008
grounding resistor of 3 ohms. The value of the resistor is selected to limit the line to
ground current, in the event of ground fault, to about the full load capacity.
6.4 STARTUP TRANSFORMER
This is a three winding 22 MVA/31.5 MVA, 220 KV/6.6 KV, ONAN/ONAF, Ydyo
transformer in which the HV side star-connection is solidly grounded and the LV side
star connection is grounded through a resistor of 3 ohms. The solid ground
connection is made by 4/0 AWG tinned copper conductor.
6.5 STATION SERVICE TRANSFORMER
Station service transformers 2000 KVA, 6.6 KV/433V, Dy 11, ONAN, are used to
feed power to the 415V auxiliary power busses. The neutral point of the star-
connected winding are solidly grounded by means of two (2) numbers 4/0 AWG
copper conductors.
6.6 STANDBY DIESEL GENRATOR SETS
Stand by diesel generator sets are required to maintain power supply to the essential
auxiliaries. The rating of the generator is 1750 KW, three phase, star connected
winding. The neutral of each generator is connected to the ground through a neutral
grounding resistor of 0.48 ohms to limit the line-to-ground current, in the event of an
earth fault. The earthing of DG sets control panels and excitation panels has been
done at two diagonally opposite sides from two deferent earthing pads.
6.7 MOTOR-GENERATOR SET
The star neutral point of the 325 KVA, 415V generator of the motor generator set is
grounded through a resistor of 0.4 ohms to the limit the ground current, in the event
of a fault.
6.8 INVERTERS/RC/STATIC STATION PANEL
Inverters grounding has done by using 210 AWG ( 2 Nos) earthing conduction
conceded from two different earthing pads.
7.0 LIGHTING PROTECTION SYSTEM
7.1 PURPOSE
Lighting discharges to buildings, equipments and structures result in tremendous

loss. The lighting protection system for buildings and structures is featured for
providing a conducing path between the general mass of earth and the atmosphere
above the building by which the lighting discharges may enter the earth
without producing dangerous potential differences in or near the building and also
without passing through the non-conducting parts of the building.
Rev. No. : 02, Oct. 2008

7.2 FEATURE BASIS
The lighting protection system will be featured generally as per IS-2309-Code of

practice for the Protection of Buildings and Allied Structures against lighting.
Earthing electrodes of the lightning protection system will be interconnected with the
main earthing grid of the plant.
7.3 AIR TERMINATION SYSTEM
(a) Service Building
An air termination system comprising vertically installed rods for the large, flat roof
surface area of the service building, will require a large number of high masts and
will be impracticable uneconomical and unesthetic. As such, an air termination
system comprising of horizontal roof conductors is featured for this building. The roof
conductors are so laid out that not part of the roof will be more than 9 M from the
nearest roof conductor and max. spacing between the roof conductor will not be
more than 18 meters as recommended in IS-2309.
(b) Reactor Building
If the shielding angle is assumed to be 45 degrees for this vital building one 17-M
high mast at the apex of the reactor building dome will protect the building. Such a
high mast will poss feature and installation problems. As such, protection of the
building by using a mast alone is not recommended. Instead, a mast together with
horizontal roof conductors is featured in this case.
(c) 220 KV OUTDOOR SWITCHYARD

Separate masts around the periphery of the switchyard will be very tall and the whole
system will be uneconomical. For the protection of switchyard equipments,
alternatives using (a) masts extending above the gantry towers and (b) shield wires
strung between the gantry towers have been studied. Analysis indicates that for an
internal shielding angle of 60 degrees, the requirement of the system with (a) masts
and (b) shield wires will be as follows
(i) Masts - 12.7 M height above entry top, spacing 30 M
(ii) Shield wires - 5 M height above gantry top, spacing 15 M
The provision of 12.7 M high masts is not advisable due to aesthetic and practical
considerations. As such, shield wires are featured for protection of the switchyard
equipment against lightning.
7.4 DOWN CONDUCTORS
A) Service and Reactor Building
Air termination system will be connected to earthing system by conductors, fixed
along the outer surface of the building. Route, number and spacing between the
down conductors is as per IS -2309. a test joint is provided in the run of down
conductors at approx. 1500 mm above ground level.
Rev. No. : 02, Oct. 2008
B) 220 KV switchyard
Shield wires (which are proposed to be ACSR as against G.S. as a measure of
protection against corrosion) will be connected to the earthing system at each tower.
The down conductor will be cleared along the tower leg.
7.5 Earthing System
Each down conductor will be connected to an earthing electrode installed in a test pit
which in turn will be connected to the plant earthing system.
7.6 Conductor Material and Size
a) Horizontal air termination roof 4/0 AWG tinned copper
conductors and down conductors conductor.
b) Shield wire for switchyard at type Ottar, ACSR
down conductor conductor
c) Vertical air termination at reactor 88.9(3 1/2inch)
building heavy duty copper pipe
d) Earthing electrodes 25mm dia, 3000
mm long copper rod.
7.7 General
All connections between the conductors are brazed type. Metallic pipe, conduit,
structures shall be banned to Lighting protection conductors to prevent the side flesh
over. But no metallic structure, conduit, pipe will be used as air termination conductor
or down conductor.
Rev. No. : 02, Oct. 2008

ANNEXURE –1
RECOMMENDED EQUIPMENT GROUNDING LEAD SIZES
Sr.N Conductor Conductor Area

o. size mm2
a) 220 KV switchyard 19/2.65 105
mm
b) Fences 19/2.65 65.7
mm
c) 6.6 KV and 415V power panels and 19/2.65 2x105
transformers mm
d) 6.6 KV motors 19/2.65 105
mm
e) 415 MCCs, lighting panels (remote 19/2.65 105
from main panels) mm
f) Lighting D. Bs, control boards 19/2.65 65.7
mm
g) Motors
i) 75 KW above 19/2.65 105
mm
ii) 20- 75 KW 19/2.65 65.7
mm
iii) 7.5-20 KW 19/2.65 35
mm
iv) 0-7.5 KW 19/2.65 10
mm
Rev. No. : 02, Oct. 2008

CHAPTER 18
CABLING SYSTEM
(53200)
1.0 Scope
This chapter covers the basic features of the cabling system in the reactor building ,
service building , dryer and Turbine building, emergency control room and
switchyard. Cabling in other areas is not covered in this manual.
2.0 Cabling groups
The plant cabling system consists of the following two basic groups Power cables
Control cables.
2.1 Power cables
2.1.1 Type of power cables
The power cables used are divided as per their voltage grade as follows:
1. 11KV grade grounded neutral system cables capable of continuous

operation at their rated current on 6.6 KV ungrounded neutral system.
2. 6.6 KV grade unearthed cables of continuous operation at their rated
current on 6.6 KV ungrounded neutral system.
3. 1.1 KV grade cable capable of continuous operation at their rated
current on as 415V AC, 3 Phase, 3-wires, 50Hz, solidly grounded/resistance
grounded system.
4. 600/1000V grade silicone rubber insulated cables.
2.1.2 Cables connected of various loads
a) 11 KV cable :- this is a 1000 mm2 single core, aluminum conductors, paper

insulated, MIND screened and sheathed with lead alloy ‘B’ aluminum wire
armored and sheathed PVC sheathed cable used for cable connections of the
following loads
i) Between 6.6 KV switchgear breaker panel & start-up transformer (located in
switchyard) by 12 runs (4 per phase) of the cable laid in trefoil formation. The
cables run through the cable trench/tunnel to the switchyard.
ii) Between 6.6 KV switchgear breaker panel and unit transformer by 12 runs of
the cable (4 runs/ph). The unit transformer is located outside the Turbine
Building on the Western side between grids 9 and 10 for Unit-1 and 23 and 24
for Unit-2.
iii) For the tie connection between 6.6 KV switchgear panels of Unit-1 and Unit-2
Twelve (12) runs of the cable are used for this purpose.
b) 6.6 KV CABLE four sizes of cables have been used in this grade which are as
follows
Rev. No. : 02, Oct. 2008

I. 6.6 KV (UE) three core 300 mm2 cables with Aluminium conductor, PVC insulted,
galvanized steel single round wire armoured and overall PVC sheathed for
connection between 6.6 KV switchgear panels and all loads except as discussed in
clauses ii, iii, iv & v below.
II. 6.6 KV (UE) three core 400 mm2 cables with aluminium conductor, PVC insulated,
galvanized steel single round wire armoured and overall PVC sheathed for
connection to five (5) Nos. 2 MVA Auxiliary transformers.
III. 6.6 KV (UE) three core 150 mm2 cables with copper conductor, XLPE insulated,
unarmoured, CSP overall jacketed cable used for the cable connection between the
switchgear panel and the primary feed pumps located in the Reactor Building at EL
107300.
IV. 6.6 KV (UE) three core 240 mm2 cables with copper conductor, XLPE insulated,
unarmored CSP overall jacketed cable used for cable connection between the
switchgear panel and the primary coolant pumps located in the Reactor Building at
EL 112300.
V. 6.6 KV (UE) three core 300 mm2 cables with aluminium conductor, XLPE insulated,
armoured and PVC overall sheathed cable used for connection between the
switchgear panel in TB and the 6.6 KV switchgear panel at eh D2O upgrading plant.
Two runs of this cable are used for this purpose.
2.1.3 DETAILS OF 150 mm2 & 240 mm2 XLPE CABLES
These three core unarmored cables are of stranded copper conductor with an
extruded semi-conducting insulation shield & overall copper shield taped with flame
retardant CSP overall jacketing, XLPE is also used for the filter material. The
thickness of insulation is 3.6 mm (min) with no negative tolerance. The extruded
insulation shield thickness is 0.7 mm (min), conductor screening is 0.5 mm (min),
non magnetic copper shield tape is 0.075 mm (min) & the outer sheath of CSP is 5.7
mm (min). In an ambient of 50oC. the conductor temperature does not exceed 90oC.
These cables are also featured to carry the same current (under accident conditions)
at a conductor temperature of 130 deg. C (90 deg. C ambient) for 10 mins.
Continuous (four hours cumulative). These cables also have a gamma radiation with
stand capability (XLPE & CSP) of 4.2 X 108 rads. Cumulative dose at the rate of 200
rads. per hour.
2.1.4 DETAILS OF 300 mm2 XLPE CABLE
These three core cables are of stranded aluminum conductor and have PVC overall
jacketing. These cables are armoured with single round galvanized steel wire. The
rest of the particulars are same as above except for the gamma radiation withstand
capability which is not specified in this case as the cables do not enter the reactor
building in the route to the D2O upgrading plant.
(c) 1.1 KV Cable :- Cables used for the 415 V auxiliary system except for the
safety related loads are HRPVC, aluminum conductor, wire-armoured type
confirming to IS 1554(Part-1) 1976. Cables for lighting systems are 3.5 (three and
half) core while for all motor loads cables are 3(three)core type.
Rev. No. : 02, Oct. 2008

For safety related loads in class III, class II switchgear as well as MCC feeders
three-core copper conductor HRPVC insulated cables are used.
For 250V DC feeder loads, 2(Two)core, aluminum conductor, HRPVC insulated

cables are used.
d) 650/1100V Silicon Rubber Insulated (SRI) Cables :-
Due to the higher ambient temperature within the fuelling machine vault, SRI cables
are used for all feeders including lighting supply cables. These cables however
emanate from junction boxes called as ‘transition boxes’ which are mounted above
the blowout panels the North wall of the FMW-North and South wall of FMV-South.
HRPVC cables coming from various supply points are sealed (core sealing) at the
rear end of this box and are terminated on terminal blocks inside the box. SRI cables
take off from here to the various loads inside the vaults.
These cables have tinned, annealed, stranded circular copper conductor, SRI
insulated having colors as red, yellow and blue laid up with asbestos fillers taped
with a layer of glass tape, braided with glass yarns and treated with suitable varnish.
The inner sheath is of black extruded chloro sulphonated polythene (CSP). The
amour is of galvanized steel wire and thus is again covered conductor temperature
of 150C. CSP is as per IS 6380 and is of heat resisting, flame retardant heavy-duty
type.
2.2 Control Cables
Type of control cables
The following types of cables are used for the controls
i) Multicore armored cables

ii) Multipair (twisted) pairs solid conductor cables.
2.2.1 Multicore armored cables
Cables with 7/0 737 mm stranded annealed tinned copper conductor, PVC insulated
single wire armored cables confirming to IS 1554 part I are used for 250V DC
controls CT & PT connections. These cables have the following number of cores and
color codes as given in appendix 1.. 2 core, 4 core, 7 core, 10 core & 24 core multi-
pair cables are used in 48V DC circuits, and 110V AC circuit. These cables from part
of the instrumentation system and will be Covered in the feature manual of
instrumentation system.
3.0 Feature consideration
3.1 Selection of type insulation
Rev. No. : 02, Oct. 2008

The main incoming supply cables for 6.6 KV system have been specified as 11 KV
(E) paper insulated lead covered aluminum Conductor cables taking into account
their better insulation property over PVC cables and their proven reliability.
At the time of ordering cables, PLIC cables were used for main incoming supplies
instead of XLPE cables as the indigenous manufacture of the latter was just
commencing and reliability of the indigenous variety was yet to be proved. Now
XLPE cable reliability also proved & replaced in both SUT & UT out put cable in both
units.
However, considering the economic involved, 6.6 KV (UE system) PVC cables have
been adopted for all other feeders (except primary feed pump and primary coolant
pump).
Generally armored cables have been recommended and used in 6.6 KV and $415
switchgear to prevent the cable from rodent etc. However, for 415 V power cables
with copper conductor unarmored cables have been ordered.
From the experience of MAPP project, where difficulties have been encountered in
routing and terminating armored cables of these large conductor sizes for primary
coolant pump and primary feed pump it was decided to use unarmored cables of
‘XLPE’ insulated and copper conductor.
For the 415V system use of PVC insulated has been accepted practice and HR PVC
insulation has been specified to obtain higher current rating for the same size of the
cable.
3.2 SHORT TIME CURRENT RATING
The following fault levels were considered for the short time rating cables
6.6 KV system – 500 MVA, 44.0 KA

415 V system- 35.5 MVA, 50.0 KA
3.2.2 A fault clearing time of 0.2 seconds has been adopted for all feeder cables
based on the instantaneous operation of the main protection. The transformer
secondary side cables, which are incoming cables to the switchgear, are
featured to withstand short circuits for 1.0 second.
3.2.3 Cables protected by HRC fuses are not specified for any short time rating.
3.2.4 The short time rating of the larger size cables in 6.6 KV and 415V
system are as follows
1.0 sec rating 0.2 sec Rating
(a) 11 KV (E) grade, XLPE insulated1000 70 KA

mm2 A1 cable single core
(b) 6.6 KV (UE) grade PVC insulated
Rev. No. : 02, Oct. 2008
A1 conductor 3 core cables

400 mm2 30.3 KA 67.75 KA
300 mm2 22.7 KA 50.75 KA
(c) KV (E) XLPE insulated copper
conductor 3 core cables
240 mm2 34.6 KA 77.37 KA
150 mm2 21.7 KA 48.52 KA
d) 415V HRPVC insulated A1 conductor
1000 mm2 single core 69.4 KA

400 mm2 3 core 29.80 KA 66.63 KA
300 mm2 3 core 20.64 KA 46.15 KA
e) 415V, HRPVC insulated copper 19.24 43.02
conductor cables 185 mm2 – 3 core
3.2.5 The short time rating of cables used in this project are based on the following initial
and final temperature of conductors.
(A) PIL Cable PVC cable HRPVC cable XLPE cable

Initial temp. 80o 70o 85o 90o
Final temp. 160o 160o 160o 250o
3.3 CONTINUOUS CURRENT RATING
While applying cables to various circuits, the continuous current ratings furnished by
manufacturer for various sizes are considered and appropriate derating factors for
ambient temperature; spacing and grouping were applied to arrive at current rating of
the sizes. The manufacturers’ continuous current ratings are based on the following
temperature limits.
Ambient temperature 40oC

Conductor final temp. 80oC for PILC cable
70oC for PVC cable
85oC for HRPVC cable
90oC for XLPE cable
3.3.1 DERATING FACTORS
Overall derating factors obtained after considering items in 3.3 above are listed
below
(a) 250V DC Power cables 0.6

(b) 415V cables 0.6
(c) 6.6 KV PILC cables 0.703
(d) 6.6 KV XLPE for RB loads 0.86
(e) 6.6 KV KLPE for D2O upgrading plant 0.82
(f) 6.6 KV PVC cables 0.696
Rev. No. : 02, Oct. 2008

3.4 VOLTAGE DROP

The cable sizes are selected to limit the voltage drop in the cable to about 2% when
carrying rated load of the connected equipment. The starting current drops are
generally limited to 10% value. This is the voltage drop between the switchgear/MCC
to the connected equipment, with the bus voltage at rated value. Cable sizes for
loads of rating 90 KW and above are based on the short time rating (The voltage
drops for 6.6 KV motors are low due to this criterion) See Appendix-8.
4.0 CABLE PANS AND ACCESSORIES

4.1 Cable pan layouts have been generally arranged in the following order
Top HV Power cable Pan.
Middle LV Power cable Pan.
Bottom Instrumentation/Control
cable Pan.
4.2 Cable pertaining to safety related equipment is run in separate cable trays
exclusively meant for them. These are generally in the lower most tier of the cable
carrier, to prevent flames from a lower tray (in the event of a fire) affecting this tray.
This is also based on the general requirements stipulated by NPB for cable tray
layouts for safety related loads which states, “wherever the safety related cable tray
crosses with the non safety related trays, safety related tray should cross at lower
elevation”.
4.3 For horizontal runs, ladder type trays are used for power cables and perforated type
trays for control and instrumentation cables. Perforated trays have been used for
control cables to give a neat appearance.
4.4 For continuous vertical runs, ladder type trays are used for all cables.
4.5 In cable carriers where safety related cable trays run along with non-safety related
cable trays the former are provided with solid MS covers.
4.6 Safety related cable trays are identified distinctly by red paint bands of 50mm wide
painted at 2-meter intervals. This band is also present at the points of entry to and
exit from enclosed areas and passages/corridors.
4.7 Cable pans are made of galvanized sheet steel. The load on each cable pan is taken
as an average value of 55 Kg/meter for a 600 mm wide tray. Depending upon the
cable used are 600 mm, 450 mm, 300 mm and 150 mm wide. Standard ease of
erection at site as site fabrication of these would be time consuming and inaccurate.
(Ref. Drgs. NAPP-1, 2/53330/6015, 6016 & 6017/DD).
4.8 The cable pan supports are made of steel channels/angles welded or bolted to the
embedded parts (plates) in the ceiling, wall etc. Supports are located at regular
intervals varying from 1 to 2 meters. These supports are featureed for the seismic
conditions applicable to the respective areas. Δ co-efficient being 0.3g for ground
level and 0.5g for the reactor building SSE (safe shutdown earthquake) conditions
are applied the earthquake coupper most level. For service building and other areas,
Rev. No. : 02, Oct. 2008
OBE (Operation basis earthquake) conditions are applied the earthquake co-efficient
being 0.15g for ground level and 0.3g for uppermost levels. The supports are not dip
galvanized (as per NPB’s requirement) according to IS-2629, 2633 and 4759.
However during installation, whenever it is necessary the supports after welding to
steel members are painted with one coat of vinyl primer and then followed by two
coats of vinyl paint. For supports located in outdoor areas shall be 4 coats of vinyl
paint.
4.9 One 2/0 AWG bare, annealed, tinned, stranded copper conductor connected to the
station grounding system is run along the length of the cable pan in the tier and
connected to it at intervals of 1250 mm. Tapings are taken from this conductor for
grounding trays in the tier. Ref. Drawings NAPP-1, 2/53330/6015 & 6016/DD.
4.10 The bending radii for the various types of cables are given below
Cable type / size Min. bending radius (Times OD)

(a) 11 KV- 1C 1000 A1 (PILC) 20
(b) 6.6 KV- 3C 300 A! (PVC) 15
- 3C 400 A1 (PVC) 15
- 3C 150 Cu (XLPE) 15
- 3C 240 Cu (XLPE) 15
- 3C 300 A1 (XLPE) 20
(c) 1.1 KV- All copper cables 12
- Aluminum cables
95 mm2 and below 12
120 mm2 to 185 mm2 15
300 mm2 and 400 mm2 20
(d) Control Cables 10-12
4.11 For single core cables and control cables, the amour is earthed at the power supply
end and for three core cables; the amour is earthed at both ends.
4.12 Cables in a tray are arranged in two layers touching each other. This has generally
been observed in most areas except in some areas (e.g. RB) where due to space
restrictions more tiers of trays are not possible. In such places the number of layers
per tray may increase.
5.0 INSTALLATION & ROUTING
A brief description of the cable routes/race-ways in the areas covered in this manual
is given below.
5.1 REACTOR BUILDING
Cables entering the reactor building originate from the TB & the PHT building MC
room. These are brought along two cables bridges, one connecting the TB with the
RB on the Eastern side & other connecting the P.H.T. Building and S.B. to T.B.
passes to the RB on the South-west side. (Northwest for RB-2) Vertical cable trays
Rev. No. : 02, Oct. 2008

are present outside the OCW to take these cables to the cables duct openings at
various levels on the OCW & ICW. These trays are supported on a steel framework,
which is in turn welded onto MS angle embedded into the OCW. This whole
enclosure is covered by aluminium sheeting. This has been supplied by M/s Best &
Crompton (Ref. Drawings NAPP-53340 series & M/S. B&C drawings).
Cable entering the reactor building are sealed at both the secondary containment
(OCW) and the primary containment (ICW) (See item 6.0 for details). Routing inside
the RB is on cable trays supported from the ceiling or from the side walls.
FLOOR EI. –93900 AND 95100
Cable entry is through floor openings on floor EL-100000. There are 7 openings, 5 of
which are on the eastern half leading into the moderator area. All these openings
require sealing (Ref item 7.0). For the FMSA, entry is through openings in the ceiling
(i.e. through openings in the floor of FMV) and also through pipe sleeves in the side
walls. These are also to be sealed.
Cable entry is through the IC/OC wall openings both on the TB and PHT side. The
major lighting panels for RB are on this floor, cable pans are located along the IC
wall periphery.
FLOOR EI. – 103700
Cable entry is through floor openings which bring cables from EL-100 m or through
the ceiling i.e. floor EL-107300. These floor openings do not require sealing.
FLOOR EI. – 112300
This is also referred to as the pump room floor. Floor openings are present to route
cables from and into this area from other areas. These openings are mostly along
the periphery but there are also some circular openings to the west of the calendria
hatch. Separate trays running in the East-west direction are provided for carrying the
6.6 KV cables to the primary Coolant Pumps. IC/OC wall openings are present on
both the TB and PHT ends. All cables going to the FMV North and South are routed
through this floor.
FLOOR EI. –126300

This area called as the boiler area forms part of the secondary containment. Cable
entry is only through floor openings located at he TB and PHT cable bridge ends.
These cables do not cross the IC wall. These are directly routed through the annular
space and through the double containment floor slabs. These openings are not
sealed.
ANNULAR SPACE
The major equipment located in this area are the ECCS pumps, Safety relate cables
connecting these motors are passed through the OCW cable duct openings and then
dropped down in the annular space to the terminal boxes.
(Ref. Drawings – NAPP-1,2 /53330/6001 to 6006 & 6027/GA)
Rev. No. : 02, Oct. 2008
5.2 SERVICE BUILDING
Most of the loads in SB are fed from the two MCC’S -A&H, which are located in SB
rooms S-151 (EI. –100 m) and S-217 (EI. –106m) respectively. Some loads, which
require class III supply, are fed from the MCCs located in TB.
The main cable trays in SB are alone the passages on EI.100M and EI.106M (i.e. S-
125 & S-118 on El. 100m and S-224 & S-213 on El. 106m). Cable pans are up to 3
tiers and are either supported directly from the ceiling or below duct/pipe supports or
a combination of both.
The distribution of supplies for loads is based on their locations. MCC-A feeds loads
located between grid 2 and 15 and MCC –H supplies those located between grids 15
to 27.
Cables entering spent fuel area i.e. room S-138 to S-142 are routed through the
main corridor S-125 and then are passed through pipe sleeve located at various
points on the RCC wall along grid F, into the required areas. These pipe sleeves
may be sealed later if required. (Refer drawing nos. NAPP/1,2/53330/6012, 6019,
6024, 6042/GA)
5.3 PASSAGE BETWEEN SB & TB (EL. –106 M)
This main passage, which is about 100 m long, carries the following groups of
cables:
1) Safety related power and control/instrumentation cables going to RB-1 via the
PHT building cable bridge.
2) Safety related power and control/instrumentation cables going to RB-2 via the
PHT building cable bridge.
3) Safety related control/instrumentation cables going to the emergency control
room.
4) All power and control/instrumentation cables going to Dryer and ECCS building of
Unit-1
5) Other cables (mostly from class III Swgr) going to loads located in SB.
6) Incomer cables for MCC-Q and L2 of NAPP-1 & NAPP-2 located in the PHT
building MCC rooms.
7) Incomer cables for MCC-A & H located in SB.
5.4 DRYER ROOM:
Cables are from switchgear located in TB and are routed through the SB-TB
passage, through the cable bridge over the PHT building and are dropped through
the cable enclosure outside the OCW to a trench below. This trench leads to the
Dryer and ECCS building where cables enter through a wall opening and are taken
to the trays supported from the ceiling for routing to various equipment. (Ref. Drg.
NAPP-1,2/ 53330/6044/DD).
Rev. No. : 02, Oct. 2008

5.5 EMERGENCY CONTROL ROOM:

Cables are brought along the SB-TB passage at EL-106 m and dropped through a
wall opening (between grids W1 and X1) along a shaft by the side of the stairway
leading to this room. This then goes through an indoor trench and through three
large pipes into a cable room behind the emergency control room. From here the
cables (mostly control and instrumentation) are taken in trays (one for NAPP-1
cables and one for NAPP-2 cables) to the top of the control panels, where they are
terminated (Ref. Drg. NAPP-1, 2/53330/6043/DD).
5.6 SWITCHYARD:
Cables are routed to and from the switchyard and the turbine building brought a 3m
wide cable trench divided into two halves of 1.5m each with the part towards the
North carrying NAPP-1 cables and the other carrying NAPP-2 cables. This trench
starts from the TB cable vaults and extends upto the SB. At this point (i.e. just after
the SFTD) the trench is replaced by a tunnel which passes below the SB. After
crossing the SB the trench continues till it reaches near the road where it is lowered
and continues as a tunnel. After the road crossing the trench continues and meets
the trench network in the switchyard.
Both these main trenches have 7 tier rack structure of MS angles. Separate racks
are used for 6.6 KV cables, 415V cables and control cables. For the 6.6 KV cables
separate racks are again used for SUT cables and D2O U/G plant feeder cables. The
latter are taken out of the trench near the SUT-2 region and the routed along the side
of the road (directly buried) to the D2O U/G plant. Single core cables going to SUT
are clamped in a ‘trefoil’ formation.
A separate cable pan (perforated) is used for the compressed air piping.
5.7 ROUTING OF CABLES FOR SAFETY RELATED EQUIPMENT:
Cables used for these loads are HRPVC insulated copper conductor unarmoured
cables.
These loads are grouped into two redundant systems and are fed by cables run via
diverse routes to the extent possible in order to minimize the risk of loss of safety
related loads in the event of a fire or some other accident. One group of loads have
cables routed into the reactor building via the main cable bridge between the RB and
TB. Cables for the other group of loads are routed via the passage between service
building over PHT building into the reactor building.
These cables both power and control are provided with a band of 50 mm wide red
paint at a 2 m interval on the outer sheath, before installation.
Two safety related MCCs (one in class II switchgear and one in class III switchgear)
are located in the PHT building MCC room for feeding the second group of safety
related loads.
These loads are given in Appendix-2 for reference.
Rev. No. : 02, Oct. 2008

6.0 CABLE SEALING AT THE CONTAINMENT WALLS OF REACTOR BUILDING:

6.1 INTRODUCTION:
All cables entering the Reactor Building are sealed at the entry points at both the
outer containment wall and the inner containment wall to prevent the leakage of air
borne radioactivity through the isolation of the cables, through the stranded
conductors, armoring etc.
Cable entry into the reactor building is by penetration through the steel plates, which
are welded to the EPs at the cable duct openings. These plates are provided on both
the primary containment wall or inner containment wall and the secondary (outer)
containment wall.
6.2 OPERATING CONDITIONS:
In featuring the penetrations the following containment feature conditions have been
kept as guidelines.
1. Primary containment
Feature pressure 1.25 kg/cm2 (outward)
0.07 kg/cm2 (inward)
Differential pressure 1.44 kg/cm2
Across sealing under
Accident conditions
Temperature 114oC(Steam laden atmosphere)
2. Secondary Containment 0.07 kg/cm2 (outward)
Differential pressure 0.02 kg/cm2 (inward)
Temperature Ambient (50oC)
The sealing arrangement is featured to withstand the temperature of 114oC for a

short time duration in an atmosphere filled with 100% steam. The expected
cumulative dose of radiation is 200 M Rads of Nuclear Gamma radiation.
6.3 SEALING ARRANGEMENT:
Cables coming from the two cable bridges (TB end and PHT building end) enter the
RB through the OC wall. Cable sealing at the outer face of the OC wall is achieved
by means of type ‘B’ mould fastened by means of stainless steel gland/gland-nut
assembly. This mould provides core sealing. Some loads like the ECCS pumps are
located in the space between the OC and IC walls (annular space) and hence the
cables going to these motors do not cross the IC wall. For the rest of the loads
located inside the RB the main sealing for the cable is at the outer face of the IC wall
using type ‘A’ mould. This mould provides strand sealing for power cables. For
instrumentation and control cables, however, type ‘B’ mould is used owing to the
difficulty in strand sealing of the multi pair/multi-core cables. (See Appendix-3, 4 & 5)
The cable is also sealed at the inner face of the IC wall with heat shrinkable sleeves
fitted on to pipe sleeves welded to the sealing plates at the cables duct openings.
Rev. No. : 02, Oct. 2008

This type of a nominal sealing is required for the following reason:

It is necessary to ensure that before the preoperational leak-test on the containment,
all cable penetrations are complete in all respects and that relevant cables are
commissioned so that there is no need for any rework. Hence a local leak testing
facility is better. Before the sealing is done on the interface of IC wall the inner space
between the two seals is pressurized by compressed air and the outer seal is soap
bubble tested.
6.4 TYPES OF CABLES:

The following cable types are involved in the penetration.
6.6 KV grade XLPE insulated, stranded copper conductor power cables.
600/1100 V grade HRPVC insulated aluminum or copper conductor (stranded or
solid) armored / unarmored, PVC outer sheathed power cables.
Control cables and co-axial cables for instrumentation.
6.5 SEALING DETAILS:
6.5.1 Power cables with multi strands in the conductor cores are provided with strand
sealing arrangement at the outer face of ‘IC’ wall using ‘type A’ moulds and again
provided with composite core sealing at outer face of ‘OC’ wall using ‘type B’ moulds.
Power cables with solid conductor, and all other control conductor sealing with type
‘B’ mould both ‘IC’ wall.
Cable seal assembly and seal arrangements are described below:

The seal assembly consists of:
(a) Gland nut Item No.1 of Dwg. NAPP 1&2/53300/6001/DD

(b) Washer Item No.2 --do—
(c) Gasket Item No.3 --do—
(d) Gland Item No.4 --do—
(e) Heat shrinkable
sleeve
(f) Cable seal Type A & B Dwg. NAPP 1&2 /53300/6002 &
moulds
6003/DD
Type PC Dwg. NAPP 1&2/53300/6001/DD
6.5.2 PREPARATION OF CABLE FOR EXPOXY MOULDING:

PVC sheath and insulation (if required), on the portion of the length of the cable
moulding is to be done, is removed carefully without affecting the insulation of the
adjacent portion.
In view of the extra-ordinary adhesion property of the resin , it is essential that the
aluminum mould and joint surfaces should be covered with mould and joint surfaces
should be covered with mould release agent before pouring resin.
Rev. No. : 02, Oct. 2008

6.5.3 CASTING OF THE MOULD:

The aluminum mold is placed over the cable. The resin and harder must be carefully
mixed until hardener is thoroughly distributed in resin. The mixture is then poured
directly into the mould. It take minimum, 24 hours to form hardener casting. Pouring
resin can be carried out up to minimum temperature of 200C.
The mould is removed after epoxy resin has solidified and hardened. On removing
the mould from casting , if bubbles of sizes larger than 2 mm are formed, the
affected part shall be cut off with hack-saw or suitable cutting tool. The casting
should be again placed in the mould and resin poured to fill up the mould and allow
hardening as before. Original casting and newly poured epoxy should form a leak
proof joint.
After removing the mould the rough surfaces of the castings should be removed.
Mould should have suitable seal at ends to confine resin and flow within the mould.
6.5.4 SEALING COMPOUND
Epoxy resin should be used as sealing material. This shall be araldite with hardener
of reputed manufacturer in the prescribed proportion ( M seal compound No. MS-831
and hardener No. MSH 272 or equivalent). Araldite resin MS 831 has the following
features:
a) Excellent mechanical and electrical properties in its solidified condition.

b) Resistant to atmospheric and chemical influences.
c) Stability to aging to good.
d) Colorless, tasteless and completely non-toxic.
6.5.5 FIXING OF THE CASTING TO THE SEALING PLATE
The gland is welded to gland plate as shown in drawing No. NAPP

1&2/53300/6001/DD & NAPP 1&2/53300/6006/DD. Shielded metal arc welding
(SMAW) using electrode E309 is done because the glands are of stainless steel and
the plate of MS. The plate with glands welded to it is then welded to the EPS on the
IC/OC wall openings.
The collar the epoxy casting is then inserted in to the gland with gaskets on either
side. The gland nut is then put with a washer in between and tightened securely.
The gaskets on either side ensure sealing, the nut ensures proper contact of gasket
with the collar face and washer resists tendency of the cable to shift while tightening.
Above the gland nut and gland a further layer of heat shrinkable thermo fit sleeve (of
M/s Ray Chem make ) is provided and shrunk on to them by heating. While heating,
care should be taken to ensure that the adjacent portion of the cable are not
affected. This sleeve should firmly adhere to the cable as well as the gland
assembly.
Rev. No. : 02, Oct. 2008

6.5.6 SEALING WITH HEAT SHRINKABLE SLEEVES:

Heat shrinkable sleeves are of extruded or moulded polymeric material, which is
cross-linked to develop elastic property and shrunk to its unconstrained state by
application of heat. Since this could ensure perfect sealing against pressure leaks at
cable sealing, they are being used for sealing all cables at the inner face of the inner
containment wall of the reactor building.
The sleeves are made of heavy wall and flame retarding variety suitable for
withstanding cumulative dose of 200 M Rads of gamma radiation.
It is proposed to use wrap around sleeves at the outer face of the outer containment
wall where pressure tests for detecting leakage indicate that the sealing provided is
insufficient.
Nucleus grade heat shrinkable sleeves are used on the inner side of IC wall for the
sealing with the pipe sleeve. However, NPS has decided to use non-nuclear grade
wrap around sleeves at the outer face OC wall.
6.6 SEALING OF CORES OF CABLES:
6.6.1 STRAND SEALING OF POWER CABLES:
Outer sheath and insulation of PVC cables is removed in the portion where it has to
be sealed and the conductors are exposed. A copper sleeve is wrapped on the
conductor and crimped so as to close the gaps between strands over which the type
‘A’ moulding is formed.
(refer Drg.No. NAPP 1 &2 /53300/6001/DD).
6.6.2 CORE SEALING OF POWER CABLES:
The outer sheath only is removed. Inserting PVC wedge between them separates
the cores out. This facilitates the resin to flow into the space between cores and fill
the space. Type ‘B’ moulds is used for this.
(Refer Drg No. . NAPP 1 &2 /53300/6001/DD).
6.6.3 CONTROL CABLE SEALING:
Arrangement is similar to 6.62 above. In addition, the outer sheath of the cable is
unbraided and the two ends are bonded by twisting together and soldering.
6.6.4 BUNCH OF CO-AXIAL CABLES:
Two or three cables are grouped together with PVC wedges in between and
moulded in type ‘B’ mould. (Refer Drg No. . NAPP 1 &2 /53300/6001/DD). At the IC
wall inner surface, where sealing is on pipe sleeve with a heat shrinkable sleev,
these cables are passed through a mould type ‘PC’ which is provided to ensure that
no gaps are present between the cables (2 or 3 Nos ) and the heat shrinkable
sleeve. (Refer Drg No. . NAPP 1 &2 /53300/6001/DD).
Rev. No. : 02, Oct. 2008

6.6.5 6.6 KV CABLES:
For 6.6 KV cables (XLPE) entering the RB no core or strand sealing is envisaged.
The cables will pass through the pipe sleeves welded n the sealing plates. The pipe
sleeves are sealed at both ends with heat shrinkable sleeves. These cables are
sealed at the motor terminal box with nuclear grade heat shrinkable sleeves.
6.7 SEALING AND ERTHING OF CABLE ARMOUR:
The amour of power cables is cut at the sealing point and earth separately at the
outer face OC wall and at the inner face of the IC wall. At these places the overall
PVC sheath is removed to expose the armor. Surface of the armour is cleaned.
Earthing clamp is put over the armour and epoxy mould type ‘C’ is prepared over the
clamp as shown in Drg. No.N-1,2/53300/6010/DD, crimped copper plug is connected
to the earthing clamp of the armour. The other end of the earthing conductor is
braced to the copper earth bus.
7.0 CABLE SEALING AT FLOOR CROSSINGS IN REACTOR BUILDING:
7.1 All cables in Reactor Building which in the course of their routing cross the floors at
El-100000 and/or EL 112300 are sealed at the floor crossing points. These are
through cable duct openings which are mostly located close to the IC wall. Some of
these openings located on EL-112300 are circular in shape.
7.2 SEALING DETAILS:
A sealing plate is welded on to the EPs at these duct openings. This plate has drilled
holes into which pipe sleeves are welded. Sealing is by heat shrinkable sleeves
which are fitted on the cable before it is passed through these pipe sleeves.(See
Appendix-6).
In addition to the above, radiation shielding is also provided at these floor crossing
points as per the requirements of NPB. An enclosure is provided, for this the Ep
frame (on the opening ).This is then filled with lead shots upto a height of 150 mm
and covered by a 20 mm thick layer of epoxy cemen or thiocol to prevent
accumulation of water. (Rf. Drg. No. NAPP 1,2 /53300/6009/DD).
8.0 CABLE SEALING AT TRANSITION BOXES IN THE FUELLING MACHINE VAULT

(FMV) :
Due to the higher ambient temperature prevailing is the FMV, only silicone rubber
isolated (SRI) cables are used inside this area. HRPV cables coming from the motor
control Centers in TB and PHT building are terminated at transition boxes to the
various loads. (Rf. Drg. No. NAPP 1,2 /53300/6011/DD).
Rev. No. : 02, Oct. 2008

8.1 SEALGING DETAILS :
HRPVC cables enter the transition box from the rear through the drillings provided.
Stainless steel glands are provided on this rear plate. These glands are the same as
those used on the IC and OC wall sealing plates. Core sealing of these cables is
done in the same way as before and type ‘B’ moulds are used. These cables are
then terminated on terminal blocks located in the transition box. SRI cables are then
taken off from these terminal blocks, through the sides of the transition boxes to the
various loads. These SRI cables are passed through ordinary brass glands fitted on
the two sides. The transition box has a removable cover which is accessible from the
inside of FMV. (Rf. Drg. No. NAPP 1,2 /53300/6013/DD).
APPENDIX-1
COLOUR SEQUENCE FOR 2.5 MM2 CONDUCTOR CABLES
CORE NO BASE COLOUR TRACER COLOUR

1. BLACK(BK) WHITE(W)
2. WHITE(W) BLACK(BK)
3. BLACK(BK) ORANGE(O)
4. ORANGE (O) BLACK(BK)
5. ORANGE (O) WHITE(W)
6. WHITE(W) ORANGE(O)
7. WHITE(W) BROWN(BR)
8. BROWN (BR) WHITE(W)
9. BLACK(BK) GREY(GY)
10. GREY(GY) BLACK(BK)
11. BLUE(BL) ORANGE(O)
12. ORANGE (O) BLUE(BL)
13. GREEN(G) WHITE(W)
14. WHITE(W) GREEN(G)
15. BLUE(BL) BROWN(BR)
16. BROWN (BR) BLUE(BL)
17. BLUE(BL) GREY(GY)
18. GREY(GY) BLUE(BL)
19. BLUE(BL) WHITE(W)
20. WHITE(W) BLUE(BL)
21. ORANGE (O) GREEN(G)
22. GREEN(G) ORANGE(O)
23. RED(R) GREY(GY)
24. GREY(GY) RED(R)
CABLES COLOUR SEQUENCE

2 CORE 1 AND 2 AS ABOVE
4 CORE 1 TO 4 AS ABOVE
Rev. No. : 02, Oct. 2008
APPENDIX-7
A. POWER CABLES
1. 11 KV. (EARTHED)
PILC-1 Core 1000 mm 2 A1-armour (A1)
2. 6.6 KV (Unearthed)
PVC 3 Core 300 mm 2 Al-armoured

2 Core 400 mm 2 Al-armoured
XLPE 3 Core 150 mm 2 Cu-armoured

3 Core 240 mm 2 A1 armoured
3 Core 300 mm 2 A1 armoured
3. 1.1 KV Grade (HRPVC)
3.1 3 core A1 conductor, armored cable sizes 6, 10, 16, 25, 35, 70, 95, 120, 150, 185,
300,400 mm 2
3.2 3 ½ core A1 conductor, armored cable 25,35,50,70,95,120,150,300 and 400mm 2
3.3 4 core A1 conductor armored cable sizes 6,16,35 and 50 mm 2
3.4 3 core Cu conductor, unarmored cable sizes 6, 16, 28 and 185 mm 2
3.5 1 core A1 conductor, A1 wire armored cable sizes 300,500,625,1000 mm 2
3.6 2 core A1 conductor, armored cable size 6,10,25,35 mm 2
4. 650/1100 V Grade (SRI)
4.1 2 core A1 conductor armored cable size 4. mm 2

4.2 3 core cu conductor, armored cable size 4,16,35 and 50 mm 2
B.CONTROL CABLES
1. Copper conductor PVC armored cables (650/1100V)

2 core, 1.5 mm 2
3 core, 1.5 mm 2
4 core, 1.5 mm 2
7 core, 1.5 mm 2
2. Copper conductor PVC unarmored shielded cable
650 /1100V 1 pair, 1.5 mm 2

250/440V 1 pair, 1.5 mm 2
650/1100V 3 pair, 1.5 mm 2
650/1100V 10pair, 1.5 mm2
300V 25pair, 19 AWG
300V 50pair, 19AWG
Rev. No. : 02, Oct. 2008

3. Copper conductor PVC cable (unshielded)
650/1100V 1 core, 2.5 mm 2

650/1100V 2 core, 2.5 mm 2
650/1100V 2 core, 4 mm 2
650/1100V 3 core, 4 mm 2
650/1100V 3 core, 6 mm 2
Rev. No. : 02, Oct. 2008

APPENDIX- 8
VOLTAGE DROP IN CABLES
A 6.6 KV CABLES
S r. Load Cable size& Type Length Voltage drop

No.
1. Primary coolant 3 core 240 XLPE 180m. 181%Running
Pump (Copper) 0.828%Starting
2. Boiler Feed Pump 3 core 300 PVC 55m 0.035%Running

(Aluminum) 0.146%Starting
3. D2O upgrading 2x3core 300XLPE 885m 1.097%Running
Plant (aluminum)
B 415V CABLES
Sr. Load Cable Size& Length Voltage drop

No. Type
1. Moderator circ. Pump (on 2x3 core 185 PVC 290m 0.22% Running
Class III) (copper) 9.37% Starting
2. Moderator circ Pump (on –Do- 140m 1.072% Running
class – IV). 4.29 % Starting
3. PHT standby Cooling 3core 185 PVC 250m 2.51 % Running
Pump (copper) 9.3 % Starting
4. HPPW Pump (NA) (in 3 core 300 PVC 180 m 13.19%*Starting
CWPH) (Aliminium) 2.97%* Running
5. Chilled Water Pump 3core 400 PVC 195m 2.55% Running
(Aliminium) 11.83% Starting
6. ECCS Pump(on class –II) 2x3 core 185 PVC 275m 1.605% Running
(copper) 5.93% Starting
*INCLUDE INCOMER CABLE DROP
Rev. No. : 02, Oct. 2008

CHAPTER 19
PROTECTIVE RELAYING SYSTEM
(65100)
1.0 This chapter covers protective relaying provided for the electrical equipment / system.
Description whenever given for unit 1 is equally applicable for Unit –2.
2.0 EQUIPMENT TO BE PROTECTED
i) Two turbo –generator units 412 –G1 and 412 G-2 rated for 264 MVA, 0.9 PF,
16.5 KV, 3 phase, 50 Hz, 3000 rpm, 3.5Atm. rated hydrogen pressure, sub –
transient reactance 20.9 %, Transient Reactance 28%.
ii) Two main generator transformer 512 – GT1 and 512 –GT2 rated 260 MVA,
0.9PF 235/16.5 KV, 3 phase, 50 cycles, OFWF, Yd -11, with HV OFF load taps, z
=14%.
iii) Two Units transformers (one for each units) 522-UT1 and 522 –UT-2 rated
22/31.5 MVA, ONAN /ONAF, 16.5/6.9KV, Dy-1with on load taps on HV, z =9%,
LV neutral is grounded through a 3.0 Ohm resistor rated for 1350 A for one
minute.
iv) Two START UP transformers 521 –SUT 1 and 521 – SUT 2 rated 22/31.5
MVA, ONAN/ONAF 220/ 6.9 KV, and Yyno with on load taps on HV neutral. HV
side neutral is Solidly grounded. LV neutral is grounded through 3.0 ohm resistor
rated for 1350 A for 1 minute. The transformers have tertiary Winding for 3rd
harmonic and zero sequence current circulation.
v) Three 220 KV bus bars 513 –BU – A, 513 –BU-B 513 –BU- C. BU-B and BU-
C constitute the main buses and BU-A the transfer bus. Bus coupler breaker 513-
CB-1 between BU–B & BU-C, and a transfer bus breaker 513-CB-10 are
provided.
vi) Five transmission lines 514-L1 to 514 - L5 interconnecting the station to

UPSEB grid details as given below
b) Narora – Moradabad single circuit line 77 KM long (514 -L1)

c) Narora –khurja double circuit line 60 KM long. (514 -L3and L4)
d) Narora –Atrauli single circuit line 39 KM long. (514 -L5)
e) Narora – Shimbholi single circuit line 70KM long. (514 -L2).
vii) Each unit has two 6.6 KV sections with further sectionalized to obtain four bus
sections 5241-BU-D, E, F and G. Unit transformer feeds bus sections BU –D and
BU –E and bus sections BU-F and BU-G are fed by start up transformer.
Protection of 6.6 KV systems consists of the following
Rev. No. : 02, Oct. 2008

a) Bus protection for BU-D& E, F& G.

b) Protection for 7 Nos. Auxiliary transformer feeders, five of which feed 415V
class III system.
c) Protection for 4 Nos. Feeders for primary coolant Pump motors rated 2800 KW
and equipped with fly wheels
d) 21 Nos. 6.6 KV motors feeders of various sizes from 373 to
2800 KW.
e) One 6.6 KV feeder to ‘D2O’ upgrading Plant.
viii) 415V service system of the unit comprising of five class IV bus two class-III
and two class II bus . These feed lighting and motor loads above 90 KW.
Breakers are provided with series release. Relay protection is provided for the
following: -
a) Three Nos. diesel generators 5231 –DG1, DG2 and DG3 rated 1450 KW,
425V, 3 phase, and 1000 rpm. The DG sets are normally in stop condition but
are ready for automatic starting. The DG set can operate in parallel with the
grid through class III transformers or in parallel with the other DG sets / PMG
sets.
b) Two Nos. power motor generator sets rated 325 KVA, 0.8 PF, 1500 rpm.
425V, 3 phase, 50 cycles feeding the class II bus sections 5231- BU -S and
BU -T. The MG sets are normally fed by 500 KW ACVRs from class III Supply
and on loss of class III supply they continue to run on 250VDC power
Batteries for about 30 minutes.
c) 415V bus protections.
d) 5 No. 415 V motor feeder feeding 130 KW moderator circulating pumps.
e) Two Nos. 500 KW Power ACVRs, which rectify class III AC supply and feed to
class-I DC supply.
f) 54 Nos. 415 V Feeder Protections. These feeders supply various motors,
MCC supply and emergency lighting.
g) 250 V DC class-I system power and control.
3.0 PROTECTIVE RELAYING –GENERAL FEATURES
3.1 All electromagnetic relays for protections are of draw out type with test
facilities in the draw out position. Static relay wherever provided have built–in
test plugs for testing the relays in the panels itself.
3.2 Breaker controls & protection are done with 250V DC supply. Remote closing,
Tripping and interlocks are in 48 V DC supply with necessary interposing
relays.
3.3 All fault-detecting relays are equipped with hand reset type operation
indicator. In three phase relays with separate elements, each phase has a
separate indicator.
3.4 Annunciations and alarm circuits are to the extent feasible, initiated from open
contacts when any abnormal condition is to be indicated.
Rev. No. : 02, Oct. 2008

3.5 Tripping relays are mainly of hand re-set type. Non-lockout type relays if used
are reset by breaker “No” auxiliary contact in their sealing circuits, or by
separate reset circuits.
3.6 Separate 250 DC supply is provided for closing and tripping. In cases where
single DC supply is used, separate sub circuit fuses are provided for closing
and tripping supply. Protective circuits are provided with DC supply different
from trip circuit supply in 6.6KV and 220KV system
3.7 Trip coils of the circuit breakers are continuously supervised. In 220 KV
system the breakers are provided with two trip coils. All main and back up
protections are connected to trip coil II which is continuously supervised. Also
main & backup protections, pole discrepancy protection and LBB protection
are connected to trip coil-I which is supervised only in breaker closed
condition.
3.8 Trip relays are continuously supervised.
3.9 DC supply for protection, closing and tripping are continuously monitored.
3.10 Trip relays for Generator Protection, transformer protection and bus bar
differential protection trip the association breakers and lock out the closing
circuit from the further closing till the relays are reset. The trip relays of 220
KV lines main protection are self reset type to permit auto reclosure.
3.11 The isolators of 220 KV elements are provided with necessary
interlocks to ensure that they do not make and break any load currents except
charging current of the bus. Interlocks also ensure that on loads transfer of
any 220 KV elements from one bus to the other or to the transfer bus and vice
versa is possible. Similarly the links in the 6.6KV circuits of UT & SUT bus
section are provided with necessary safety interlocks re-closed in / out while
UT/SUT breaker is in “closed” condition
3.12 MAIN OUTPUT SYSTEM PROTECTION PANELS (OR LTG PANEL).
3.12.1 The protection relays of main out put system consisting of protection of all 220 KV
lines, generators, startup transformers and unit transformers are housed in LTG
boards and are located in NAPS#1/2 control equipment room.
3.12.2 LTG Board has a number of relays in the front and rear with a corridor in between in
the form of duplex board arrangements. However, the individual panels do not have
by access on the rear side (that is from the corridor) the relays in the panels are
mounted in a hinged frame inside the panels. This hinged frame can be swung open
to get access to the back connection and terminal connection mounted on the side
and rear of the panels.
3.12.3 LTG-1consists protection of the following elements
S.No. Element Panel No.

a 220 KV Line 1 1A to 1D
b 220 KV Line 2 2A to 2D
c Start up transformer-1 5A & 5B
Rev. No. : 02, Oct. 2008
d Generator-1, UT-1, GT-1 6A to 6D, 7A, 7B

e Bus bar Protection 8A to 8B
f Bus coupler 11
g Bus transfer breaker 12
3.12.4 LTG-2 consists protection of the following elements
FRONT SIDE
S.No. Element Panel No.

a) 220 KV Line 3 1A to 1D
b) 220 KV Line 4 2A to 2D
c) Start up transformer 5A&5B
d) Generator-2, UT-2, GT-2 6A to 6D, 7A, 7B
e) 220 KV Line 5 10A to10D
12.5 Most of the protections associated with Main Output System are with static relays.
These are mounted on the standard 19-rack arrangement in the hinged panels with
connection at the back. M/s ASEA’s standard modular system (combiflex) is
adopted for these.
13.0 RELAY PANEL FOR 6.6 KV SYSTEM
The 6.6 KV systems are provided with a separate relay board. Hindustan Brown
Boveri has supplied a duplex type relay board. Relays pertaining to unit section and
station section located on the opposite sides of the duplex board. The Panels of the
board have back access though the central corridor of the board.
This relay board is located in the control equipment room. The cable entry to the
relay board is from the top. The relay board incorporates marshalling panels in the
center of the board (both on the front and rear). All 48V DC Connection to the CDF
are brought in this marshalling panel and connected to CDF by multipair cable.
3.14 RELAY PANEL FOR 415 V SYSTEM
Due to inadequate space in the 415V switchgear cubicles to accommodate all

protective and auxiliary relays on them, separate relay panels have been provided
for the switchboards.
A duplex type relay panel consisting of three front and three rear panels are provided
to accommodate all relays of class IV switchboards BU-J, K, L&M. This relay board
is located adjacent to the class IV switchgear in room No T1- 210 of turbine building
at EL 106.600m. The marshalling Panel for the 48V DC connection is however
provided in the respective switchgears itself by centrally located panels.
Rev. No. : 02, Oct. 2008

Similarly, class III system is also provided with separate relay panels. These are of
simplex type. The relay board for each of the class III buses P&Q consists of 8
panels in each board. These are located near the switchgears in room No. T-221
respectively at EL 106.6 m in the turbine building. The marshalling Panel for 48V DC
connection is located centrally in these relay boards.
Duplex type relay board consisting of three front panels and three rear panels are
provided for each of the class II switchgear BU-S and BU-T and these are located
adjacent to the respective class II switchgears in room No. T-217 and T-220 at EL
106.6m in the turbine building. Two of the rear panels of these boards are used as
marshalling panels for the 48V DC circuits.
4.0 TURBO-GENERATOR UNITS (412-G1&G2)
4.1 CURRENT TRANSFORMERS FOR PROTECTION & AVR
a) Following CTs are provided in the 16 .5 KV bus ducts on the generator out put
side:
CT-1 - 10,000/5A,Class PS KPV 440 V RCT <1.5Ohm for

differential Protection.
CT-2 - 10,000/5A, 50VA Class 0.2 for low forward power interlocks
and reverse power relay.
CT-3 - 10,000/5A 50VA Class 0.2 for metering.
CT-4 - 10,000/5A,Class 3, 150VA for AVR.
b) CT-5 5000/5A, KPV 300 V, RCT < 1ohm is provided in the parallel winding
connection of each phase, on the neutral end for inter-turn fault protection.
c) Following CTS are provided at the neutral side :-
CT-6 - 10,000/5A, class PS, KPV 400V, RCT < 1.5Ohm for all Protection except
differential protection.
CT-7 - 10,000 /5A,class PS, KPV 400V, RCT < 1.5Ohm for Generator
Differential protection.
CT-8 - 10,000/5A, class PS, KVP 400V, RCT < 1.5Ohm for Generator
Transformer differential protection.
4.2 POTENTIAL TRANSFORMERS
There are two sets of potential transformer connected to 16.5 KV bus ducts
412 PT 2 16.5 KV /110 V, 400 VA class 0.5 /3.0 for protective relaying
3 3
and metering.
412 PT 1 16.5 KV / 110 V, 100 VA, class 3.0 for AVR circuits.
3 3
Rev. No. : 02, Oct. 2008

4.3 NEUTRAL GROUND TRANSFORMER
Neutral grounding equipment for the generator consist of a 50 KVA,

16.5 KV/240V, 50 Hz single-phase transformer and a 0.45 Ohm resistor rated for
306A connected to the secondary of transformer.
4.4 PROTECTION DESCRIPTION
The Protections of both turbo main generator units are similar. This description,
which covers one generator (412-G1) is equally applicable to the other (412-G2).
The Generator protections are divided into four groups as the Main Protections,
backup protections; supplementary start-up protection and excitation system
protection.
4.4.1. MAIN PROTECTIONS

a) Differential Protection (87G)
b) Stator ground fault protection (64A, 64B)
c) Generator interturn -fault protection (87 INT)
d) Loss of excitation Protection (40G)
f) Unbalance current Protection (46)
g) Generator Pole slipping Protection (99G)
h) Reverse power relay (67)
4.4.1.1GENERATOR DIFFERENTIAL PROTECTION (87G))
This is a high-speed differential protection. M/s ASEA’s type ‘RADHA’relay which is a
high impedance restrained type relay is applied for this protection. The high
impedance principle is used for through fault stability even under current transformer
saturation. The Protection has an operating time of about 15 milliseconds and has
very low primary operating value, which is about 2% of CT rating. The protection
covers phase-to-phase faults & three phase faults. It does not cover phase to ground
fault, as the fault current is limited to very low value (10A). The high impedance
relay type ‘RADHA’is provided with a parallel connected non-linear resistance to limit
over voltages during internal faults.
4.4.1.2STATOR GROUND FAULT PROTECTION (64A, 64B)
The stator ground fault protection is provided by voltage relays connected across the
resistance on the secondary side of neutral grounding transformer Relay 64A covers
the full 100% winding of the generator. M/s ASEA Type ‘RAGEA’ relays is applied
for this.
The relay works on the principle that a ground fault anywhere in the protected zone
causes significant change in measured voltage on the machine neutral. For majority
of faults the fundamental (50Hz) frequency component will increases on neutral, but
for faults near 5% of neutral the fundamental frequency voltage does not increase
significantly to make reliable fault determinations. However, faults in this area causes
the third harmonic voltage at neutral to change appreciably, Typically a machine in
Rev. No. : 02, Oct. 2008
service will generate about 1% to 10% third harmonic voltage and about one half of
this will appear on the neutral bus. A fault at the neutral end of the machine will
reduce this voltage to near zero.
The relay consist of three basic components, the first one is a fundamental
frequency voltage relay, which covers the conventional 0-95%of the winding (From
phase terminals). The second one is 3rd harmonic voltage relay which responds to
the drop in neutral voltage (for faults near the machine neutral region) which
measures collapse of 3rd harmonic voltage at the neutral. This relay will appear when
machine is out of service. So to avoid this a third element (which is a voltage relay
connected to generator phase to phase voltage) is provided and its contacts are
wired in series with the contacts of this second element. Both the protections
mentioned above are provided with independent adjustable time delays. Thus, the
REGEA relay is complete protection for the ground fault in the stator winding.
A second relay 64B, which is connected parallel to 64A, measures fundamental

frequency voltage at the neutral and operates for 0-95 % fault. This is a back up to
the ‘64A’ relays 0-95% protection M/s English Electric type ‘VDG14’ relay has been
used for this purpose.
4.4.1.3 GENERATOR INTERTURN FAULT PROTECTION (87 INT)
This protection is by means of a differential current relay connected across cross

connected CTs on the two parallel winding of each of the phases of the generator .
M/s English Electric type ‘CAG34’ relay used for this protection is a high impedance
circulating current type relay with operating speed of about 20-40 msec. A non-linear
resistance connected across the relay limits over voltages during internal faults.
4.4.1.4 GENERATOR LOSS OF EXCITATION PROTECTION (40)
When a loaded synchronous machine loses excitation, it accelerates and runs above
synchronous speed, operating as an induction generator.
Reactive power for its excitation comes from system. The stator end region and parts
of rotor will be overheated if machine is permitted to run for a long time at high slip-
speed. With wound rotor machine it is generally necessary to effect tripping with in
some minute to avoid serious damage to machine. The loss of excitation protection
operate on the principle of measurement of leading reactive power supplied by the
machine and the relay operating Zone is matched with the machine capability in the
leading power factor region. M/s ASEA type ‘RAGPC’ is used for the purpose. This
relay incorporates a directional current element, an under voltage element and over
current element. Moreover a separate under voltage relay type VAGM has been
used later to prevent mal-operation of RAGPC scheme during grid voltage transient.
NC contact of these two under voltage relays have been used in series for trip circuit.
Operation of the directional current element alone initiates only an under excitation
alarm in control room. However, if directional current unit operates in conjunction
Rev. No. : 02, Oct. 2008
with either under voltage (both relays) or over current element, tripping is initiated.
The directional current element has built in time delay feature to prevent mal-
operation during normal power swings.
4.4.1.5 GENERATOR UNBALANCE CURRENT PROTECTION ( 46)
Under abnormal conditions such as unbalanced faults, unsymmetrical loading, the

current in the stator phases will be unbalanced thus causing negative sequence
currents to rise. Due to this negative sequence stator current, double frequency
currents are induced in the metal parts of the rotor and damping winding (if any).
These double frequency induced currents tend to flow in the surface of the solid
forging of the rotor and in the non –magnetic wedges and retaining rings and give
rise to heating of the rotor. If the negative sequence currents are excessive and
persist too long, the rotor will be damaged.
The withstand capacity of the rotor for these negative sequence currents is given by
constant K which is equal to ‘I22t’ where I2 is the per unit negative sequence current
and ‘t’ is the time in second. The value of K for BHEL make 260 MVA machines is
about 7.0. Hence, the negative sequence current protection provided for generator
should have ‘I22t’ characteristics matching with that of the machine.
M/s ASEA type ‘RARIO’ relay has been provided for this purpose. The relay has ‘I22t’
characteristics (K Value) variable between 2 –10 seconds. The minimum pick up
range is 8-30% and the settings are continuously adjustable.
The continuous withstand negative sequence current for the machine is about 0.05 p
u and in order to detect currents higher than this, relay has a separate alarm until
whose pick up can be adjusted between 0.05 –0.20 per unit.
4.4.1.6 GENERATOR POLE SLIPPING PROTECTION (99)
Sudden occurrences in the electrical grid such as rapid load changes, short circuits,
short circuit interruptions, which destroy the equilibrium of energy balances are
usually followed by oscillation.
If the system stability is retained, the stationary operating states will takeover. If the
oscillation is not stable, a loss of the synchronism of one of more machines will
result. Two or more parts of the system are no longer in synchronous running where
the excitation of the synchronous machines is maintained. This states is
characterized by strong oscillations of the reactive and active power.
M/s English Electric type ‘ZTO’ relay is used for this protection. The relay operates
on the principle of measuring impedance course on the R-X diagram and operates to
trip on pole slipping conditions. The scheme consists of 2Nos. angle impedance
relays and a timer to distinguish between pole slipping and power swing blocking
conditions.
Rev. No. : 02, Oct. 2008

4.4.17 REVERSE POWER PROTECTION

Prime mover failure is sensed by this scheme. This protection is basically turbine
protection which prevents motoring action of TG. M/s.ASEA type, RXPE-40 for used
for this.
4.4.2 GENERATOR BACK UP PROTECTION
i) Generator under impedance Protection.

ii) Generator over voltage alarm.
iii) Generator over /under frequency protection.
4.4.2.1 GENERATOR UNDER IMPEDANCE PROTECTION ( 21)
This is a backup protection for interphase faults for faults in the generator
transformer and external system. This will also cover fault in the generator. The
protection is the time delayed to co-ordinate with the 220 KV system main
protections.
M/s ASEA three phase impedance relay type ‘RAKZB’ is applied for this protection.
Generators provided with static excitation have strongly decreasing over current
characteristics as compared to generators with rotating exciters. The back up
protection must be able to operate even when the fault current is lower than the
rated current and likewise in the event of close up faults when the out put voltage
from generator disappears, Relay ‘RAKZB’ measures the impedance and senses
when the quotient V / I alters .Due to its characteristics, ‘RAKZA’ operates at rated
voltage for a certain current. When voltage drops, the relay operates for as lower
current value even if the voltage drops to zero volts, the relay operates for a current
of the order of 20% of the rated current.
4.4.2.2 GENERATOR OVER VOLTAGE ALARM
This protection gives time-delayed alarm for continuous operation of generator at

more than permissible voltage increase because of AVR failure or during manual
control of excitation. M/s ASEA type ‘RXEG2’voltage relay is provided for this
purpose.
4.4.2.3 GENERATOR UNDER /OVER FREQUENCY PROTECTION
M/s ASEA frequency relay type ‘RXFE’ has been applied for under frequency and
M/s.ALSTHOM make ‘MFVUM” for over frequency protection”. It incorporates three
stages of under frequency (81, 81A & 81B ) and one stage of over frequency (8IC).
Three stage of under frequency are :-
First Stage initiate alarm at 48.0Hz, Second stage initiates islanding at 47.7Hz and
third stage initiate house-load operation at 47.5Hz with 1 sec time delay (all five lines
trip). If frequency is still 47.5Hz for 5 sec then unit will operate on house-load
operation with switchyard out.
Stage of over-frequency are :-
Rev. No. : 02, Oct. 2008
Alarm at 51.0Hz and turbine trip at 51.5Hz with 15 sec time delay.
4.4.3 OTHER MISCELLANEOUS PROTECTIONS OF GENERATOR AND TURBO -
GENERATOR UNITS
4.4.3.1 UNDER POWER INTERLOCKS (32A &32B)
It is well recognized that the turbine will have a tendency to over speed if the turbine
stop valve closure impulse and circuit breaker (of the GT) tripping impulse are given
simultaneously. In order to minimize this hazard the protection trippings are
classified into two groups viz those requiring urgent tripping of the complete unit and
those (protections) which can accommodates sequential tripping of turbine first and
the generator breaker later with time delay to ensure that the entrapped steam in the
turbine is fully spent before the turbine is unloaded. These groups are generally
known as class ‘A’ & class ‘B’ groups.
Class A groups protection initiates simultaneous tripping of turbine, generator
transformer breaker, field breaker and unit transformer breaker. This group is served
by trip relays 86G,86GT and 86B.
Class B group initiates tripping of the turbine first, when the turbine governor valves
are closed, the entrapped steam energy is spent out and the power generated
comes down. As this power value goes down to a very small value, a sensitive low
forward power relay senses the low forward power & initiates tripping of the electrical
circuits viz generator transformer breaker, field breaker and unit transformer breaker.
To ensure higher reliability the low forward power relay and its associated timer and
duplicated. The contacts of this protection are wired in series with the class B trips of
the turbine. M/s. EE type WCD-12 relay is used for this protection. Trip relay 86M
initiate turbine trip and 86BU operate on low forward power relay to complete CL-B
trip.
The tripping arrangements of various protections are through the relays
‘86G’,’86GT’,’86B’, & 86M'
4.4.3.2 PHASE BALANCE PROTECTION (60)
This protection compares the voltages at the secondary terminals of the two PTs of
the generator and indicates the PT fuse fail or opening of the MCBs on the PT
secondary circuits. Phase balance relay contact blocks voltage dependent generator
protection and AVR from mal-operating due to PT supply failure conditions.
ASEA’s type ‘RXEG2’ under voltage relays are provided for this protection. The
scheme compares voltage conditions corresponding phases of the two PTs and
identifies the PT circuit, which has lost the voltage.
4.4.3.3 GENERATOR UNDER CURRENT RELAY (50UI)
An under current relay is provided for interlock in the Stator water cooling scheme
M/s. ASEA’s type ‘RXIG2’ current relay is provided for this purpose.
Rev. No. : 02, Oct. 2008

4.4.3.4 GENERATOR UNDER POWER REALY (32C)
ASEA’s directional power relay type’RXPE40’ is provided for interlocks in the speeder
gear circuits.
4.4.4. SUPPLEMENTARY PROTECTION OF THE GENERATOR FOR STARTUP

CONDITIONS
i) Phase over current protections ( 50S and 50ST)

ii) Ground fault protection (64C)
The generator is normally expected to be run up to its rated speed before excitation
power is applied by closing the breaker. However, the residual magnetism in the field
circuit may provide small voltage build up even when the machine is run up to its
rated speed. At this stage faults if any in the generator stator circuits may not be
detected by regular protection as most of the relays are frequency dependent or
tuned to 50 Hz frequencies. Hence, separate phase and ground fault protection are
provided.
4.4.4.1 PHASE OVERCURRENT PROTECTION ( 50S & 50 ST)
M/s ASEA type RXIG-2 current relay is used for this purpose. The CT current is
rectified by a built is in rectifier and level detector senses the level of the Rectified
current. The protection is interlocked with the auxiliary relay for the generator
transformer breaker and unit transformer breaker closed position to ensure that the
protection is inoperative when the machine is synchronised with the 220 KV bus bar.
4.4.4.2 GROUND FAULT PROTECTION (64C)
M/s ASEA type RXIK voltage relay is used for this protection. The generator neutral
potential as measured across the resistance on the secondary of the neutral earthing
transformer is fed to this relay. The AC voltage is rectified and the level detector
measures rectified DC voltage. The protection is also inter locked with GT breaker
position relay to isolate the trip circuit as soon as the generator is synchronized with
the 220 KV bus bar.
4.4.5 EXCITATION SYSTEM PROTECTION
The generator is provided with a static excitation system, which obtains the
necessary excitation power from the terminal connected, excitation transformer,
which rectifies the AC power through controlled thyristor, rectifies and feed the DC
current to the generator circuits. M/S BHEL supplied the complete excitation system
along with its protection and control as a package system along with the turbo-
generator. The tap off bus duct for the excitation system transformer incorporates the
CT required for protection of excitation transformer. CT details are as below: -
Ratio - 200/1A
Burden - 15A
Class - 5P20
Rev. No. : 02, Oct. 2008

4.4.5.1 EXCITATION TRANSFORMER OVERCURRENT PROTECTION
Time delayed over current protection with instantaneous high set units is provided for
the short circuit protection transformer. M/s Brown Boveri‘s type ISX-147 relays are
used for this purpose in N-2 and EE type CTU-62 relay is used in N-1.
4.4.5.2 ROTOR Ist GROUND FAULT PROTECTION
The scheme consists of external 48V DC supply injection into the rotor circuits. One
point of the supply grounded .on the appearance of Ist ground fault the AC circuit
gets completed and current flow in the field ground detector relay to initiate alarm.
ABB type RXNB-4 relay is used for this purpose.
4.4.5.3 ROTOR 2nd EARTH FAULT PROTECTION
While the machine can be continued in service with one rotor earth fault, appearance
of 2nd rotor earth fault will severely affect the magnetic balance in the air gap and
result in rotor distortion and severe damage. Hence it is advisable that the machine
is taken out of service as early as possible after appearance of Ist ground fault
alarm. However to take care of the situation of 2nd earth fault appearing immediately
after the Ist fault before machine is taken out BHEL have recommended provision of
2nd rotor earth fault protection. A separate relay has been provided.
The protection scheme normally disconnected from the field circuit and has to be
switched on when the Ist earth fault appears. The scheme consists of a bridge
circuit, which has to be balanced manually with the first rotor earth fault in the
machine. This balance is disturbed when the second fault appears and the bridge
null detector initiates tripping M/s English Electric type CAEM relay is used for this
protection.
4.4.5.4 ROTOR OVERVOLTAGE PROTECTION
This protection is envisaged to limit voltages occurring in the field circuit during
excitation of the field (field suppression). An air gap arrester with a series resistor is
connected across the field. On over voltage the air gap flashes over and the arrester
connects the resistor directly across the field.
4.5 TRIPPING LOGICS
The various protections associated with the generator, generator transformer and
unit transformers are connected to trip the unit through trip relay 86G, 86GT, 86B
and 86M trip relays. Block diagram given in Annexure give the various protections
operating on this trip relays.
The protective trips of Generator are generally classified into three groups, class A,
class B and class C. Protections which require high speed clearance are grouped
under class ‘A’ these are routed through trip relay 86G, 86GT, and 86B. They trip
generator transformer breaker, generator field breaker, breaker of unit auxiliary
transformer and the turbine simultaneously. Certain protection such as loss of
excitation, negative sequence current protection, over fluxing protection etc. can
Rev. No. : 02, Oct. 2008
tolerate a sequential tripping of the turbine followed by the generator such that the
energy of the entrapped steam in the turbine is fully spent before the generator is
tripped. This arrangement reduces the risk of over speeding of the turbine.
These protections are classified as class ‘B’. These are connected to operate on trip
relay ‘86 M’. This relay initiates tripping of turbine (closure of governor valve) and
breaker of Unite Auxiliary transformer (UAT). The later is done to initiate fast
transfer of 6.6 KV unit systems to start up transformer. After the turbine governor
valves are closed and the energy of the entrapped steam is spent, the output power
of the generator will come down. This is sensed by the under power interlocks 32A
and 32B. This would initiate trip relay ’86 BU’ which is wired to trip the generator
transformer breaker, Generator field breaker and Unit Auxiliary transformer breaker,
for obtaining better security the under power interlock circuits are duplicated.
Certain protection such as bus bar differential protection, Generator under

frequency, GT OTI/WTI, Gen. backup impedance stage-I etc. require tripping only of
the 220 KV side breaker of Generator transformer to isolate the external fault, or
load. These are classified as class ‘C’.
These protections are wired to trip relay ‘86S’ which initiates only tripping of
generator transformer to isolate the external fault, or load. These are classified as
class ‘C’.
The under frequency operation of generator can result only due to excessive load on
the system. These should corrected by adequate load shedding measures at the
receiving ends of transmission. However, since generator under frequency limit
should not be exceeded incase of inadequate load shedding. The under frequency
protection of generator is provided with separate trip relay 86-81 relay so that
flexibility of choosing elements to be tripped at various stages of under frequency is
available. If frequency does not improve than GT breaker is tripped through 86S
relay.
5.0 GENERATOR TRANSFORMER PROTECTION (512-GT1, GT2)
The current transformer in 220KV switchyard bay for the Generator transformer is
provided with the following cores (CTS are provided in all three phases).
Core 1 :1200-800-600/1A (used ratio is underlined)

Class : PS
KPV > 2000-1350-1000V
RCT<6-4-3 ohm
This core is used for overall differential protection
Core 2: 1200-800-600/1A
Rev. No. : 02, Oct. 2008

Class : PS
KPV > 2000-1350-1000V
RCT < 6-4-3 ohm
This core is used for back up over current protections and breaker back-up
protection (BFR).
Core 3: 1200-800-600 /1A

30VA class 0.2 at 800/1 ratios
This core is used for metering.
Core 4: 2000-1000/1A
Class: PS
KVP > 2000-1000V
RCT < 10-5ohm
I exe = 30 mA at 500V for 1000/1 ratio
This core is used for bus bar differential protection.
Core 5 : 2000-1000/1A
Class: PS
KVP > 2000-1000V
RCT < 10-5ohm

I exe = 30 mA at 500V for 1000/1 ratio
This core is spare and kept shorted.
The following CT’s are provided in the transformer line terminal bushings (220KV
side).
Core 1: 800/1A
Class : PS
KPV > 200V
RCT<4ohm
I exct =0.1A at 100V
This core is used for restricted protection and is provided IN all three bushings.
Core 2: 800/1.5 A
30VA class 0.5
This used for winding temp. Indicator.
This core is provided in ‘R’ phase only.
Core 3: 800 /1.5 A
30VA, class 0.5
This core is provided in ‘Y’ phase and kept as spare for winding temperature
indicator.
TRANSFORMER NEUTRAL BUSHING CT’S (220KV side)
Following cores provided
Core 1: 800 / 1A
15 VA, class 5P10
Rev. No. : 02, Oct. 2008

This is used for back up ground fault protection.

Core 2 : 800 / 1A
Class : PS
KPV>200V
RCT <4 ohm and Ie = 0.1A at 100V
This core issued for restricted earth fault protection.

5.2 PROTECTION DESCRIPTION:
The protection for both the generator transformers are similar. This discussion
covers the protection GT1 and is applicable for GT2.
5.2.1 OVERALL DIFFERENTIAL PROTECTION (87 GT)
This protection, which is used as the differential protection of the transformer, also
covers the generator and the 16.5 KV bus duct up to tap off connections to the UT.
10,000/5 CT’s are provided on the neutral side of the generator and the bus duct in
the tap off connections to the UAT for this purpose.
A high speed, biased differential relay with harmonic restraint feature is provided for
this purpose. M/s ASEA type ‘RADSE’ relay is used. An auxiliary CT of 0.8/2.67 A
ratio is used on the HV side for ratio matching.
Type ‘RADSE’ is a high speed relay with operating time of the order of 30
milliseconds. The bias setting is variable between 20 to 50%. The relay incorporates
second and fifth harmonic restraints and a high set unit in the differential circuit for
fast tripping incase of severe internal faults.
5.2.2 BACKUP OVERCURRENT PROTECITON FOR PHASE FAULTS (51GT)
The protection consists of IDMT over current relay type ‘CDG31’ of M/s English
Electric the protection is provided on all three phases. This will operate as back up
protection for transformers faults due to the fault current flowing from system side.
This may also serve limited back up protection function for faults external to the
transformer.
This protection is provided on HV side ( 220KV) of transformer.
5.2.3 RESTRICTED EARTHFAULT PROTECTION (64 GT)
In the addition to the overall differential protection, a restricted earth fault protection
covering the transformer HV winding only is provided. The zone of the protection
extends from 800 /1A CT provided on the transformer neutral end to 800 /1A CTs
provided on the transformer bushings. The protection covers ground fault only.
M/s ASEA type RADHD is used for this purpose. The relay is high impedance type
and has high speed operation. A non-linear resistance is connected across relay
terminals to limit the voltage developed during severe internal fault conditions
Rev. No. : 02, Oct. 2008

5.2.4 BACK UP GROUND OVERCURRENT PROTECTION (51 N)
This is a simple IDMT over current relay connected to 800/1 CT in the transformer
neutral. The relay provides back up protection for faults both internal and external to
the transformer. M/s English Electrical type CDG-11 relay is used for this purpose.
5.2.5 GAS PROTECTION (63 G)
A vibration proof gas operated relay (pitot relay) is provided in the transformer in
place of normal Buchholz relay. This relay has two contacts, one for alarm on slow
gas formation and a second contact for tripping on sudden surge oil into relay.
5.2.6 PRESSURE RELIEF DEVICE
GT-1 is equipped with 2 Nos. pressure relief devices (PRD). Actuation of any one
PRD will generate alarm in C/R. If both PRD’s operate, class –A trip is initiated
through trip lockout relay 86GT.
5.2.7 OVERFLUXING PROTECTION (59F1, 59F2)
The generator transformer is specified to withstand 110%of over fluxing continuously

.The manufacturer has furnished the over fluxing with stand characteristics of
transformer as below
120% over fluxing for 2 minutes

135% over fluxing for 1 minute.
140% over fluxing for 5 sec.
In order to protect the transformer from over fluxing during abnormal operation (such
as start up & shutdown of the unit). Two stage over fluxing protection is provided .the
first stage with a lower setting (112%)initiate the following
a) Alarm ( 8 sec)
b) Running down of the AVR if machine is off the busbar (30sec).
c) Tripping the unit in class B mode if the machine still remains connected to the
bus bars (2 min)
The second stage with a higher setting ( 120%) initiate tripping the unit in class A
mode after a delay of 5 sec.
M/s ASEA’s type ‘RUTUA’ relay has been used for this; the relay has two stages of
over fluxing level detection and operation in conjunction with external timers and
auxiliary relay to achieve the above.
5.2.8 INTERLOCK FOR STARTING OF TRANSFORMER OIL PUMPS (59S)
A voltage relay connected to generator PT initiate starting of oil pumps of the

transformer cooling system when the generator starts building up voltage and
Rev. No. : 02, Oct. 2008
reaches to about 40%. In addition to this interlock, one interlock from generator field
breaker auxiliary relay (GFB-52AX) is also incorporated to ensure that any one of
above two interlocks will initiate auto starting of the transformers oil pumps before
the generator breaker is closed.
M/s ASEA type ‘RXEG2’voltage relay has been provided for this purpose. This has a
setting range of 20-60V.
5.2.9 OVERLOAD MONITORING (WTI / OTI)
The load of generator transformer is indirectly monitored by measurement of oil

temperature and winding temperature. The oil and winding temperature indicator are
provided with contacts for initiating alarm as a first stage and tripping of GT breaker
at the second stage whenever the oil and winding temperature limits are exceeded.
The OTI and WTI trips are routed through trip relay ‘86S’. The setting for WTI and
OTI is given below
OTI: 750C for alarm , 850C for Trip

WTI: 850C for alarm and 950C for Trip
6.0 PROTECTION OF UNIT AUXILIARY TRANSFORMERS
(522-UAT1&UAT2)
There is one unit auxiliary transformer for each, unit. The description given below
covers the protection of UAT-1 and is equally applicable for UAT-2
The following current transformers are provided in the 16.5 K.V tap of bus duct
for the UAT.
CT- 9 : 1250/5A
Class: PS
KPV > 260V
RCT < 0.6 ohm
This core is used for UAT differential protection.
CT 10 1250 /5A
30 VA
Class 5P20
This core is used for backup over current protection
CT-11 10,000/5A
Class: PS
Rev. No. : 02, Oct. 2008

KPV>400V
RCT<1.5 ohm
This core is used for overall differential protection.
The following current transformers are provided in the H.V leads of transformer.
CT-1: 700 / 5 A
20 VA 5P10
This is used for OLTC protection, current transformers is provided on ‘R’ phase only.
CT-2 : 636/2. 65-2, 2.9A
10VA, class 5
The CT is used for winding temperature indicator.
The following CT cores are mounted on the LV phase terminal :-
Core 1-3000 / 1A
Class : PS
KPV > 600V
RCT < 12 ohm
I exct =15 mA at 300V
This is used for restricted fault protection of the 6.6 KV windings.
Core 2 : 2635/5A
10VA class 5.0
This is used for line drop compensator of the on load voltage regulation. The CT is
provided on ‘B’ phase only.
Following CT cores are provided in LV neutral :-
Core 1 3000/1A
Class : PS
KPV>600V
RCT<12ohm
I exct = 25 mA at 300V
This is used for restricted earth fault protection 6.6 KV windings.
Core 2 100/1A
30 VA
Class 5P20
This is used for stand by ground fault protection on the LV side
Rev. No. : 02, Oct. 2008

6.2 PROTECTION DESCRIPTION “
6.2.1 TRANSFORMER DIFFERENTIAL PROTECTION (87 UT)
M/s ASEA type ‘RADSE’ relay has been provided for this protection. It is a high
speed , biased differential with 2nd and 5th harmonic restraints for the magnetic in
rush currents of the transformer and has a high instantaneous unit for faster
operation during severe internal faults.
6.2.2 BACK UP OVERCURRENT PROTECTION FOR PHASE FAULTS (51)
This is a simple very inverse time over current relay connected in HV side. M/s
English Electric type, ‘CDG33’ relay is used. The relay has three current elements
one for each phase.
The Protection serves backup protection for external faults on the LV side and for
internal faults in the transformer. Only phase faults are covered in this protection as
the 16.5 KV and 6.6 are high resistance earthed. This protection is provided on HV
side.
6.2.3 RESTRICTED EARTH FAULT PROTECTION FOR LV SIDE (64)
As the neutral of the 6.6 KV side of the transformer is earthed with a resistance to
limit ground fault currents in the order of 1300A,a separate restricted earth fault
protection is envisaged for the 6.6 KV winding. M/s ASEA type ‘RADHD’ high
impedance, high-speed over current relay is provided for this protection.
Non-linear resistances connected across relay terminals to limit the over voltages in
the CT secondary circuits in case of severe internal faults.
6.2.4 STANDBY EARTH FAULT PROTECTION
This is a simple IDMT overcorrect relay type ‘CDG12’ of M/s English Electric and
serves as back up to the ground fault protection of the 6.6 KV system (cable & bus)
and ground faults in the transformer windings. This also serves as a protection for
the neutral grounding resistance which is short time rated.
6.2.5 TRANSFORMER GAS PROTECTION (63P)
A Buchholz relay is provided for this. The relay has two contacts one closes on slow
gas formation and initiates alarm. The second contact closes on sudden bush of oil
flow incase of severe internal faults and this contact is connected for tripping of the
unit. The on load tap changer of unit transformer is provided with an oil surge relay
similar to second stage of the buchholz relay of the main transformer. This is also
connected to trip the unit.
Rev. No. : 02, Oct. 2008

6.2.6 OVERLOAD MONITORING
The loading conditions on the transformer are indirectly monitored through the
measurement of oil and winding temperature measurement. These indicators are
provided with contacts for initiation of alarm as first stage and trip at the second
stage whenever the oil and winding temperature exceed permissible limits. The
setting of OTI and WTI is given below :-
OTI : 750C for alarm and 850C for trip

WTI : 850C for alarm and 950C for trip.
6.2.7 PROTECTION FOR ON-LOAD TAP CHANGER
An over current relay is provided to inhibit automatic tap changing operations when
the transformer current exceeds the rated current.
7.0 START UP TRANSFORMER (521-SUT-1, SUT-2)
7.1 GENERAL
The protection of the two startup transformers are similar this. This description
covers protection for SUT-1 and is applicable for SUT-2.
The following cores are provided on the 220KV CT for SUT.
Core 1: 150-100/1A (The used ratio is underlined)
Class : PS : KPV > 750V-500V
RCT<1.5-1.0 ohm
The core is used for transformer differential protections.
Core 2 150-100/1A
30VA
Class 5P20
This core is used for back up over current protection and breaker back up Protection.
Core 3 150-100/1A
30VA
Class 0.5
Core 4 : 2000-1000/1A
KPV>2000-1000V
RCT<10-5 ohm
I exct. =30 mA at KPV/2 Volts
This is used for bus bar differential protection.
Core 5 : Similar to Core 4
This is a spare core and is kept shorted.
Rev. No. : 02, Oct. 2008

TRANSFORMER BUSHING CTS
HV BUSHING
Core1 100/1A
15VA CL.1.0
This is provided on ‘y’ phase only and kept shorted as spare core.
Core 2 100/1A
Class PS
KPV>200 V
RCT<1 ohm
This core is used for restricted for fault protection of HV winding.
HV NEUTRAL BUSHING
Core 1 100/1A
30 VA
Class 5P20
This is a space core kept shorted.
Core 2 100/1A
Class PS
KPV>200V
RCT<1ohm
I exct =100 MA at KPV volts
This core is used restricted earth fault protection of HV windings.
L.V. PHASE BUSHING
3000/1A
Class PS
KPV>600V
RCT<12ohm
I ext=25 mA at KPV volts
2
This core is used for restricted earth fault protection of LV winding.
LV NEUTRAL BUSHING
Core 1 100/1A
30VA
Class 5P20
this core is used for standby earth fault protection on the LV side and also for backup
ground fault protection 6.6 KV bus connected to UAT.
Core 2 3000/1A
Rev. No. : 02, Oct. 2008
Class PS
KPV> 600 V
RCT< 12 ohm
I ext = 25mA at KPV volts
2
This is core is used for restricted earth fault protection of LV windings.
Potential supply for the directional over current relay phase & ground faults are
availed from 220 KV bus PT’s 513VT-1 (BU-C) and 513-VT-2 (BU-B). There is a
provision for changing over from one VT to another by manual selection through
selector switch.
The VT fuses are monitored by a fuse failure relay whose contacts are connected in
series with the trip contact of the directional over current relays. An auxiliary VT of
voltage for polarization of ground fault directional relay.
7.4 TRANSFORMER DIFFERENTIAL PROTECTION (521-SUT-87)
M/s ASEA’s type ‘RADSE’ relay has been provided for this. It is a high speed,
percentage biased differential relay with 2nd and fifth harmonic restraints for
magnetizing inrush current. An auxiliary ct of 0.862 / 2.886A ratio has been provided
for the HV side CT connection for ratio matching. Similarly another auxiliary CT of
2.4 /2.886A ratio has been provided on the LV side where a 5500 /5A CT core is
available. The auxiliary CTs are star /delta. Protected zone extends from the 220KV
HV CT’s (513-CT-3) side to the 6.6 KV CT’s located in the switchgear.
7.5 RESTRICTED EARTH FAULT PROTECTION (512-SUT1-64A)
The stat connected HV windings of the transformer are provided with a restricted
earth fault protection zone, which extends from neutral end CT to the terminal
bushing CTs. M/s ASEA’s type ‘RADHD’ high impedance circulating current relay
has been used for this fault stability is achieved by high impedance principle. The
relay pick up voltage setting is selected to be more than CT secondary voltage
developed during though fault current flow taking into account CT saturation as the
worst-case. Anon- linear resistance is connected across relay terminals to limit the
CT secondary voltages during severe internal faults.
7.6 RESTRICTED EARTH FAULT PROTECTION OF LV SIDE

(521-SUT1-64B)
This protection is similar to the HV side restricted earth fault protection .The zone of
protection extends from LV neutral CTs to the LB terminal bushing CTs. M/s ASEA
type ’RADHD’ relay is used for this purpose.
Rev. No. : 02, Oct. 2008

7.7 BACKUP PHASE OVERCURRENT PROTECTION (521-SUT1-67)
The protection consists of directional very inverse over current relays one for each
phase. M/s English Electric type ‘CDD23 ‘ relays are used. The directional featured
prevents relay response to 220 KV system ground faults when the SUT will be
supplying zero sequence currents to the 220 KV systems. (Due to the presence of
tertiary delta windings).
7.8 BACKUP GROUND FAULT OVERCURRENT PROTECTION

(521-SUT1-67A)
This is a directional IDMT over current relay connected to the zero sequence current
and polarized by zero sequence voltage. The directional feature is for the same
reasons stated in 7.7 above. M/s English ELECTRIC TYPE “CDD21’ relay is used.
7.9 STANDBY EARTH FAULT PROTECTION ON THE LV SIDE

(521-SUT1-51SN)
This protection is similar to the stand by earth fault protection of UAT described in
item 6.6 above. This acts as backup to 6.6 KV system (bus & cable) and transformer
LV ground faults and also protects and the neutral grounding resistor, which is short
time, rated M/s English Electric type ‘CDG12’ relay is used.
7.10 TRANSFORMER GAS PROTECTION (512-SUT-63P)
A Vibration proof gas operated relay (pitot relay) has been supplied by transformer
manufacturers. On slow gas formation the Ist contact of the relay operates to give
alarm. Oil flow caused by sudden pressure rise initiates the operation of the second
contact, which is wired for trip.
The on load tap changer (OLTC) of transformer is provided with an oil surge –relay
operates to trip the transformer.
7.11 OVERLOAD MONITORING (521-SUT-WTX/OTX)
Oil and winding temperature indicators are provided to monitor the transformer over
loading conditions these indicators are provided with contacts for initiation of alarm at
first stage and trip at the second stage, whenever the oil and winding temperature
exceed permissible limits. The manufacture is operating instructions manual shall be
referred to the recommended settings for the alarm and trip stages.
7.12 TRIPPING ARRANGEMENT

The main protection 87, 64HV, 64LV, 63PX operates main lockout –relay ‘86M‘. The
backup protection 67R,Y, B, 67N and WTX/OTX operates second trip lock-relay
‘86B’. Both the trip relays are continuously supervised.
Operation of any one of two trip relays 86 M& 86B operates both the tip coil II and tip
coil I of the breaker, Trip coil-II is continuously supervised, whereas trip coil II is
supervised only after closing of CB. The trip from breaker back up protection
operates trip coil I directly. Both the Trip relays ‘86 M and 86B’ have additional
contacts to trip LV breakers and the bus transfer breaker when the latter substitutes
the ‘SUT’ breaker.
Rev. No. : 02, Oct. 2008
8.0 220 KV LINES
The current transformers for lines are provided in switchyard. These are provided in
all the three phases.
Core 1 1200 –800-600/1A (used ratio is underlined)
Class PS
KPV> 2000-1350-1000V
RCT<6-4-3 ohms
This core is used for distance protection.

Core 2 1200-800-600A
Class PS
KPV>2000-1350-1000V
RCT<6-4-3ohms
This core is used for backup o/c protection and breaker backup protection.
Core 3 1200-800-600/1A
Class 0.2 at 800/1 ratios

Core 4 2000-1000/1A
KPV > 2000-1000 Volts
RCT<10-5 Ohms
I ext = 30 mA at KPV volts
2
This is used for bus bar differential protection.
Core 5 Identical to core 4
This is a spare and kept shorted.
8.2 Narora –Moradabad line (514-L1)
8.2.1 Main Protection (514-L1-21/21G)
The main protection is a high speed, 3zone non-switched ‘mho’ distance protection.
M/s English Electric ‘MM3T’ distance scheme has been adopted.
The ‘MM3T’ scheme consists of two ‘YTG1’ relays one for phase and the other
ground fault protection. Each of these relays has three measuring units and three
starting units. In the phase fault relay one measuring unit and one starting unit are
associated with each pair of phase viz AB, BC, CA. in the ground fault unit one
measuring unit and one stating unit is associated with each phase viz. A, B & C. the
measuring units have off-set ‘mho’ characteristics and are used for zone-1 and zone-
2 measurements. The stating unit has offset ‘mho’ characteristics and is used for
starting the timers for zone-2 and zone-3 and the measurement for zone-3.
Rev. No. : 02, Oct. 2008

A brief description of the sequence of operation of the scheme is as follows
Faults anywhere with in the reach of the relay (up to zone 3) cause the starting unit
to operate which triggers the zone 2 and zone 3 timers.
If the fault is in zone 1, the measuring unit operates and clears the fault.
If the fault is not in zone 1, the zone 2 timer at the end of its set time extends the
reach of the measuring elements to zone-2. If the fault is in zone-2, the measuring
element will now operate and clear the fault.
If the fault is beyond Zone 2, the zone 3 timer at the end of its time setting will initiate
tripping and clear the fault.
The relay has provision for independent flag indications to identify the faulty phase
(or Phases) and the zone (1,2or 3 as the case may be)
The scheme has the following additional features
(1) Blocking for VT fuse failure,

Line VT fuse failure resulting in loss of voltage input to the relay may be seen
as a fault. An in having action against this condition is provided by a high
speed fuse failure detection relay VTP which switches off the power supply to
the distances protection.
(2) Blocking for power swings
A system power swing may also be seen as line fault if the power locus enters the
starting and measuring unit characteristics. A separate power swing-blocking relay
‘YTO’ is included in the scheme to block relay operation during power swings.
(3) Inter trip facility
The distance protection acts in conjunction with line carrier for high-speed clearance
of faults any where in the line. Permissive under reach inter tripping scheme is
adopted.
(4) The scheme has built in trip relays one for 3 phase trip (86T) and three
numbers for single phase trip (86A, B& C). These are self-reset type relays
permitting auto enclosure of the line.
8..2.2 BACKUP DIRECTIONAL OVERCURRENT PROTECTION

(6514-L1-67/67N)
The main protection has three zones of measurement. The third zone serving the
backup function for faults in the line and in the adjacent section. However additional
directional IDMT over current relays and provided for both phase and ground fault
and serve as backup when distance protection is taken out for maintenance or
repairs. The time setting of the backup protection is adjusted to permit the Ist and 2nd
Zone operation of distance relay first, to ensure proper discrimination. M/s English
Electric type ‘CDD 26’ relay are used. The phase backup directional over current
protection (67) is provided in R&B phases only.
Rev. No. : 02, Oct. 2008

8.2.3 POTENTIAL SUPPLY FOR MAIN & BACKUP PROTETIONS
The distance protection and the backup directional over current protections are fed
from individual lines CVT’s. An auxiliary VT with star /broken delta connection is
provided for obtaining zero sequence voltage for polarization of the directional over
current relay for the ground faults.
8.2.4 POLE DISCREPANCY PROTECTION
All Lines breakers and transfer breaker are provided with pole discrepancy
protection. A timer ‘62’ gets energized whenever there is discrepancy in the breaker
position of the three poles and initiates tripping command to the trip coil I.
8.2.5 AUTO RECLOSING OF THE LINES
The control scheme provides for single phase and three-phase auto re-closing
feature. The line circuits breakers are provided with separate trip coil and closing coil
for each. Trip relay 86A give trip command for phase ‘A’ only. Trip arrangement for
other phases is on the same line. 3-phase trip relay ’86 ’ gives simultaneously trip
command for all three phases. The three closing coils are connected in parallel and
single closing command is given from auto re-closer scheme however this command
will be effective only on the tripped phase due to interlock of breaker auxiliary contact
’52NC’in the closing coil circuit.
The trip relay 86T, 86A, 86B & 86C initiates auto-closing scheme there is a pressure
switch interlock to ensure that breaker tank has adequate air pressure performing
the re-closer. A selector switch has been provided for selection of the single or 3-
phase auto re-closure. The switch has the following position
 Single phase auto re-closing

 Single and three phase auto re-closing
 Three phase auto re-closing
 Non-auto re-closing
The circuit when selected for single-phase auto re-closing ‘trip and recloses the
faulty phase only a zone 1 ground fault. The auto re-closer is locked out for zone 2
and zone 3 ground faults and for all multiphase faults.
The circuits when selected for single and three phase auto re-closer trips and
recluses the faulty phase one zone 1 ground fault and also trip and auto re closes
the all the phases for zone 1 multiphase faults. For all other faults single or
multiphase in zone 2 or zone 3 the auto enclosure is locked out. In the case of 3-
phase re-closer, facilities are available for deadline and synchronizing check re-
closer at the other end.
The circuit when selected for three phase auto re-closertrips and recluses all the
three phases for zone 1, single phase and multiphase faults and lockout for other
cases.
Rev. No. : 02, Oct. 2008

With the selector switch in Non-auto re-closer m, position all re-closer are locked out.
The exact type of re-closers to be adopted for the lines depends on The UPSEB
system stability requirements and has to decide in consultation with UPSEB.
The scheme provides for separately adjustable dead times for single phase and
three phase re-closer and adjustable time setting for the re-close time.
M/s English Electric type ‘VARMA III ‘ re-closing relay is used. Further details of the
re-closing scheme operation are available in the manufacturer’s technical literature.
8.2.6 DEADLINE CHARGING SYNCHRONISING CHECK FACILITY
This function is achieved through voltage comparison of the bus and line voltage
measured through bus PT’s and line CVT’s. The voltage of the bus to connect to the
line is selected for comparison through respective main bus isolator auxiliary
contactor. Two under voltage relay 27BVT, and 27 LVT monitor the bus and lines
voltage respectively. Any one of these relay dropping off, thus indicates either a
dead line hence allows auto re-closer when both the bus and line are live
synchronizing check relay SKD takes care of proper synchronism before permitting
re-closer.
8.3 NARORA –KHURJA LINES

(514-L-3-and 514-L-4)
These are double circuit lines from Narora to Khurja in the UPPCL. The protection is
auto re-closer features of these lines are identical to that of Narora Moradabad line
(514-L1).
8.4 NARORA –ATRAULI LINE

(514-L-5)
The protections and auto re-closer scheme for this also identical to that of Narora –
Moradabad line (514- L1)
8.4 NARORA –SHIMBOLI LINE

(514-L-2)
The protection and auto re-closer scheme for this is also identical to that of Narora –
Moradabad line except for the type of distance relay used. M/s English Electric
‘Micro mho distance protection with ‘mho’ characteristics.
The scheme has three independent Zones of protection zone 1 to zone 3 . Zone 1
and zone 2 have circular mho characteristics where as zone 3 has offset mho
characteristics their separate comparators for each type of phase and earth fault.
The micro mho scheme is provided with integral microprocessors based logic, which
provides five basic operating schemes selected means of thumb wheel switches.
These are
a) Basic 3-zone distance

b) Zone 1 extension
Rev. No. : 02, Oct. 2008
c) Permissive under reaching

d) Permissive over reaching
e) Blocking scheme
The choice of the three phases or single phase tripping is available for each of the
above option.
The scheme provides for instantaneous clearance of 3 phases close up faults, which
might be produce when circuit breaker is closed on to a line with earth connection.
The scheme also incorporates power swing blocking feature for any zone (zone 1 to
zone 3). There is supervision for VT for blocking the protection in case of VT failures
All other aspects of line protection and auto re-closer is similar to other lines.
8.0 BUSBAR DIFFERENTIAL PROTECTION
The two 220 KV main bus bars 513-BU-B and 513-BU-C are provided with high-
speed bus bar differential protection. The protection is arranged in two zones to
cover each bus bar. Each 220 KV elements have a 2000-1000/1A CT core for bus
differential protection and the coupler has two such cores one of each zone. The
transfer bus is included in the main bus Zones itself; however there is a high speed
directional current protection for transfer bus (as a part of the bus differential
scheme) which ensure selective disconnection of two bus alone in case of fault in it.
As any 220 KV elements can be connected to Bus ‘B’ or Bus ‘C’ there is a provision
for switching the CT of each relays, which are actuated by Isolator auxiliary contacts.
The relay has one operating coil and the resetting operation requires energisation of
reset coil.
This feature ensures that the CT connections are not opened during failure of 250V
control supply. The auxiliary contacts (‘NO’ & ’NC’) of the isolator, which are used to
switch the changeover relays, have to be such that the ‘NO’ contact closes earlier to
the main power contact and the ‘NC’ contact opens later than the power contact.
During transfer of any element from one bus to another, the two zones are
automatically paralleled. During the period when the two main bus isolation of any
element is remaining closed, the bus coupler CTs are automatically shorted and one
of the differential relays is disconnected. The remaining differential relay caters to the
one complete zone the details of these circuits are shown in M/S.ASEA schematics
drawing No. XIN 72103028(NAPP/65100/3928/ED).
M/s ASEA type ‘RADSS’ bus bar differential protection is used. This is a high-speed
differential relay using the principle of percentage restraints as well as high
impedance. The relay has an operating speed of 5-10 milliseconds has full stability
for through faults involving complete saturation of line CTs. the relay has in addition
a simple over current elements in the differential circuit as a check feature also as an
alarm relay is included in the differential circuit and is set to operate conditions. The
alarm relay disconnects the main tripping relay after a time delay of about 5 seconds.
Rev. No. : 02, Oct. 2008

10.0 220 KV BREAKER BACK UP PROTECTION
The 220 KV elements of NAPS are provided with breaker back up protection to take
care of breaker failure to trip after receipt of protective trip signal. This protection
consist of over current detectors with a built in time delay relay. The main and back
up protection of the element initiates breaker backup protection. The protection gives
out tripping impulse in two stages. In the first stage, the tripping impulse is given to
second trip coil (Trip coil –I) of the same breaker without any time delay, so that in
case of failure of the main trip coil (Trip coil –II), the breaker can trip thorough this
second trip coil. If this is also not successful then in the second stage, the breaker
backup protection initiates trip of all elements electrically connected to the element in
which the breaker has failed. The trip relays of bus bar differential protection are
used for this purpose. The breaker backup protection is connected to the CT core in
which the other backup protections of the element are connected. M/s ASEA’s
‘RAICA’ relay is used for this purpose.
11.0 220 KV TRANSFER BUS PROTECTION
The CT of the transfer bus is provided with 5 cores as in the case of lines. One core
2000-1000/1A is used for the high speed directional over current relay for the bus
bar high speed directional over current relay ensures selective isolation of transfer
bus. In case of fault in the transfer bus core No 2 with 2000 –1000 /1A is used for
over current relay & breaker backup protection of the transfer bus. The other three
cores are spare and kept shorted.
The CT details are given below; -
Core 1 2000-1000/1
Class PS
KPV >=2000-1000V
RCT <=10-5 ohm
I ex <= 30 mA at KPV
2
Core 2 2000-1000/1A
Class 5P20
30VA
This is used for breaker back –up protection.
Core 3 2000- 1000/1A

30 VA, class 0.2 at 2000/1A
Class 0.5 at 1000/1A
This core is spare and kept shorted
Rev. No. : 02, Oct. 2008

Core 4 Details as same as core 1
This core is also spare and kept shorted.
Core 5 2000-1000/1A
Class PS
KPV >2000-1000 V
RCT<=10-5 Ohm
I ex <= 30 mA at Vk/2
This core is used for bus bar differential protection.
Since the transfer bus breaker has to act as substitute for any element breaker (such
as lines or generator), additional contacts from the trip relays and these individuals
elements are wired in the trip circuits of the transfer breaker. These trips are selected
through auxiliary contacts of the transfer isolators of the respective element.
The 48V DC closing circuits of transfer circuit has inter locks to ensure that
Only one element can be transferred at a time.
Once an element is on the transfer bus, the transfer isolator & any other element can
not be operated
The breaker backup protection of the transfer bus operates through isolator auxiliary
contact interlocks selected tripping of only those elements to which the transfer bus
is connected.
Provision of auto re-closer and dead line charging / check synchronizing features are
provided for the transfer bus bar breaker when it substitutes one of the line breaker.
12.0 220 KV BUS COUPLER PROTECTION
The 220 KV bus coupler CT has fives cores, out of which only two are used one for
the bus differential protection of BU-B and the other for the Bus differential shorted.
The CT details are as follows; -
Core 1 2000-1000/1A
Class PS
KPV>=2000-1000V
RCT <=10-5 ohm
I ex <=30 mA at Vk/2
This core is used for bus-bar differential protection of BU-B
Core 2 2000-1000/1A
30VA, class 5P20
This core is spare kept shorted
Core 3 2000-1000 /1A

Rev. No. : 02, Oct. 2008
30VA,class 0.2 at 2000/1A

Class 0.5 at 1000/1A
Core 4 2000-1000/1A
Class PS
KPV>=2000-1000v
RCT<=10-5 ohm
I ex <=30mA at Vk/2
This core is also spare and kept shorted
Core 5 2000-1000/1A
Class PS
KPV >= 2000-1000 V
RCT <= 10-5ohm
I ex <= 30 mA at VK/2
This core is used for bus-bar differential protection of BU-C.
The location of the CT is at main bus I (BU-C) end while the bus coupler breaker is
at main II (BU-B) end i.e. both the cores used for bus differential protection are
provided on one side of the breaker. Hence to take care of a fault between the CT
and bus coupler breaker, the CT connections are made a way that the core
protection and the core towards breaker BU-B end is connected for BU-B end is
connected for BU-C differential Protection.
Since the only protection of the bus coupler is bus differential protection, which
initiates tripping of all elements in the bus zone, a separate breaker backup element
of the bus zone will also be tripped through interlock in the bus differential scheme.
13.0 6.6 KV BUS PROTECTIONS

(5241-BUS –D&E and 5241-BUS –F&G)
13.1 GENERAL
The bus selection 5241 –BU-D & 5241 BU-E are interconnected by a link to form one
continuous bus section. The link serves only the purpose of partials isolation of. The
bus incase of bus fault requiring maintenance & repair work. Single bus fed from unit
Auxiliary transformer. The incoming breaker is connected to BU-E. Similarly BU-F
&G constitute a second bus fed from start up transformer. The incoming breaker is
connected to BU-R, which in turn connected to BU-G through bus section breaker.
The two bars BU-F and BU-E are interconnected through a bus section breaker.
13.2 CURRENT TRANSFORMER
The following CT’s are located the 6.6 KV Switchgear Panels and are provided on all
three phases.
Rev. No. : 02, Oct. 2008

13.2.1 Incoming from UAT is provided with three cores.
Core 1 3000/5A
30VA
Class 10 P20
This core is used for back up over current protection.

Core 2 3000/5A
50 VA
Class 0.5

Core 3 5200/5A
Class PS
VK >750V
RCT <3ohm
This core is used for differential protections.

13.2.2 Incoming from SUT is provided with 3 cores.
Core 3000/5A
30VA
Class 10p20
This core is used for backup O/C protection.

Core 2 3000/5A
50VA
Class 0.5

Core 3 5500/5A
Class PS
VK > 750V
RCT <3 ohm
This core is used for SUT differential protections.
13.2.3 The bus section has 2 CT, core of 5000/5A. 50VA, 10p20. These CTs are parallel
connected to achieve 2500/5A ratio and are used for backup current protection.
13.2.4 The bus tie breaker CT has three cores the details of which are as follows
Core 1 3000/5A
50VA, class 0.5
Core 3 5500 /5A
Class PS ,
VK > 750 V
RCT<3 ohm
Rev. No. : 02, Oct. 2008
13.2.5 BACKUP OVER CURRENT PROTECTION OF BU-D& E
The incoming breaker is provided with very inverse times over current relays type
‘CDG33’ for phase faults in bus bar and as backup phase over current protection for
feeder faults. The relay has three elements one for each phase three instantaneous
over current relay are provided whose contacts are wired in series with the trip
contact of the above relays to ensures fast resetting of the scheme.
One IDMT over current relay type CDG11 is connected to the transformer neutral CT
for ground fault protection for faults in the 6.6 KV Bus and as backup ground fault
protection for feeder faults.
These protections are provided with an additional time stage by means of external
timer to initiates tripping of the complete unit.
A definite time over current relay is provided to initiate alarm on sustained
overloading of the unit auxiliary transformer.
13.2.6 BACKUP OVERCURRENT PROTECTION OF BU-F&G
The protection is similar to that of BU-D & E descried above. The additional time
stage through external timers initiates tripping of the HT breaker of the SUT in this
case.
13.2.7 BUS SECTION BREAKER PROTECTION
The bus sections breaker has backup over current protection for phase fault and
ground fault. Similar to that of incoming breaker of ‘SUT’ & ‘UAT’. These are time
coordinate with the latter ensure selective tripping of affected bus section (D&E OR
F&G). The ground fault protection (51N) of the bus section breaker is connected to
the residual connection of the phase CT’s to obtain Zero sequence current.
13.2.7 BUS UNDER VOLTAGE PROTECTION
Each of the bus sections (BU-D, E, F & G) are provided with one set of PT’s of
6600/110V, 400 VA class 0.5/3.0 under voltage relays Bu-27,Ba, 27 Bb (Set at 40% )
connected to these PTs, operate with small time delay (0.7 Sec) to trip all motor
feeders connected to the bus section. This under voltage protection prevents
simultaneous starting of all motor when the 6.6 KV supply is restored. The time delay
provided is sufficient to allow fast transfer to take place with out tripping of the
motors on under voltage. A second set of under voltage protection set at about 70%
with a time delay of about 5 seconds initiates a common under voltage alarm
annunciation.
14.0 6.6KV FEEDER PROTECTION
Each feeder except PCP motors feeders has a set for current transformers with two
cores, one for metering and other for protection. The parameters of these vary from
Rev. No. : 02, Oct. 2008

feeder to feeder depending on the feeder rating and these are shown on
manufacturer’s single line diagram.
The measuring core CT’s are connected to Amp transducers for remote indications
of feeder current. The protective cores are connected to comprehensive motor
protection relay for motor feeders. The feeders for primary coolant pumps are
provided with two additional cores, one for differential protection and the other for
feeding under power relay for the ‘PCP’ motors.
Each feeder is provided with a separate core balance CT of 40/1A ratio for ground
fault protection.
14.2 PROTECTION OF MOTOR FEEDERS EXCEPT FOR PCP MOTORS
14.2.1 GENERAL
These motors are provided with comprehensive motors relay which covers thermal
overload, symmetrical and unsymmetrical faults in the motor. In addition to the
above, certain additional protections are provided and these are covered in 14.23.
14.2.2 COMPREHENSIVE MOTOR PROTECTION
The comprehensive motor protection used is of M/s English Electric type ‘CTM’ or
M/s HBB type ‘ITX’ and consists of the following features.
a) Approximately inverse time thermal overload protection, the characteristics of

which is coordinated with the thermal overload characteristics of the protected
motor.
b) Instantaneous overcorrect protection for short circuits. This is in the form of a

positive sequence current relay in the English Electric type ‘CTM’ and over
current relay in M/s HBB’s ‘ITX’ relay.
c) Negative sequence current protections. This is in the form of instantaneous

current relay set at about 200% in the English Electric type ‘CTM’ relay. In
HBB’s ‘ITX’ relay, the negative sequence current relay has lower setting in the
range of 25 –50% but has a fixed time delay of 4 seconds.
d) Built in definite time over current protection locked rotor. This feature is
available only in the ‘ITX’ relay of M/s HBB.
e) Built instantaneous current relay for ground faults. This feature is also only
available in the ‘ITX’ relay of M/s HBB.
The HBB relay type ‘ITX’ is used for condenser cooling water pump, while
other motor feeders are provided with ’CTM ’relays.
Rev. No. : 02, Oct. 2008

14.2.3 ADDITIONAL PROTECTION
a) Instantaneous over current relay for short circuits. This is provided on Y phase
CT as the comprehensive motor protection is connected to ‘R&B’ phase CTS
only this will be an additional protection for short circuits over and above the
instantaneous short circuit protections built in the comprehensive motor
protection relay mentioned above M/s ECC type ‘CAG17’relay are used.
b) Definite time over current relay for overload alarm. This protection initiates
alarm annunciation after a set time delay but prior to operation of thermal
element of the comprehensive motor protection relay. M/s ECC type ‘CTU’-
12’. Relay has been used for this purpose.
c) Locked rotor protections
A separate definite time over current relay has been provided for locked rotor
condition of the motor. The time setting of this relay is chosen to be less than
the locked rotor with stand time of the motors.
d) Instantaneous current relay for earth faults
This earth faults in the motor feeders is detected by this instantaneous current relay
connected to the core balance CTs. M/s English Electric type ‘CAG12’ relays are
used for this.
14.3 PROTECTION OF PRIMARY COOLANT PUMP
The following protection are provided
(a) Comprehensive motor protection for thermal overloads and short circuits.
(b) Two stages of locked rotor protections
(c) Instantaneous O/C in ‘B’ phase for short circuits.
(d) Overload alarm by definite time over current relay.
(e) Instantaneous earth fault protection.
(f) Under power protection
Item (c), (d) & (e) are similar to the protection described in 14.2.3 (a), (b) and (d) .
M/s Universal Electrical motor protection relay type ‘TMP’ has been used for item
(a)in NAPS-2 and M/s ABB Type-RAMDE in NAPS-1
This includes thermal overload protection and instantaneous short circuit protection
for symmetrical and unsymmetrical faults on the same lines English Electric relay
type ‘CTM’ described in 14.2.2 above.
Rev. No. : 02, Oct. 2008
The locked rotor protection for the motor consists of the two stages of definite time
over current relays. This has become necessary as the locked rotor withstand time of
the motor is is less than starting time of the motor under reduced voltage conditions.
State ‘1’ of the protection is set about 350% current and 9 seconds delay (Motor
starting time at 100% voltage is around 6 seconds and safe stall time under hot
conditions is 7 seconds). This protection takes care of locked rotor conditions under
normal voltage.
The second stage of protection is set for 175 % current and 15 seconds delay to
permit starting time 14 seconds under reduced voltage conditions. The starting
current under this condition also less such that first stage protection will not operate
for this (350% current and 6 seconds delay).
The under power relays of items (f) were initially provided for this purpose of isolating
the ‘PCP’ motors from 6.6KV bus on loss of 6.6 KV supply in order to conserve the
stored energy in the flywheels for running the motors for some more time. However,
on the basis of the experience of RAPS & MAPS it was decided later to delete the
tripping function. Hence, the trip circuits of under power protection are to be kept
open at the links provided for this purpose.
In addition to the above, the PCP motors are provided with differential protection. For
this purpose all the six terminals of the motors brought out 400/1A KPV >200V, RCT
<2.0 ohm CT’s are provided for this protection in the phase and neutral. The phase
CT’s are provided in the 6.6KV switchgear while the neutral CT’s are located in the
motor terminal box. Relay type CAG –34 is used for this purpose.
15.0 PROTECTION OF 6.6 KV/433V AUXILIARY TRANSFORMERS
15.1 PHASE FAULT PROTECTION
Transformer phase fault protection is provided by very inverse time over current
relay type CDG-63 connected to all the three phase CT cores. IT has additional high
set instantaneous over current for high short circuit currents.
Core 1 200/1A20VA class 10P20, this core is used for phase fault protection.
Core 2 200/1A, 10VA, class 1.0, this is used for metering.
15.2 GROUND FAULT PROTECTION
This protection consists of ‘IDMT’ over current relay with lower setting and longer
time delay and instantaneous over-current relay is M/S EE type CAG-12. Both the
relays are connected to a 40/1A, class PS core balance CT.
16.0 PROTECTION OF D20 UPGRADING PLANT FEEDER
16.1 PHASE FAULT PROTECTION
Rev. No. : 02, Oct. 2008

This type provided by a very inverse time over current relay type CDG-61 connected
to all the three phase CT cores. This has additional high s4et instantaneous over
current for high short circuit current the CT details are given below
Core 1 750/1A, 20VA class 5P20

For protection
Core 2 750/1A, 10 VA, class 1.0 for metering.
16.2 GROUND FAULT PROTECTION
This protection consists of ‘IDMT’ over current relay with lower setting and long time
delay and instantaneous over current relay with higher setting and with a separate fix
time delay. This time delay has been introduced to permit tripping of CB at upgrading
plant first. The ‘IDMT’ relay is M/s EE TYPE CDG11 the instantaneous over current
relay is CAG –12 OF M/s EE. Both the relays are connected to a 40/1A, class PS
core balance CT.
17.0 DIESEL GENERATORS
There are two Diesel Generator sets for each unit. The applicable for other sets also.
The following CTs cores are provided in the 415V circuit breaker Diesel Generator.
Core 1 3500/5A
Class PS
KPV > 80V
RCT<O.7ohms
I excts < = 60 mA at ½ KPV, this CT is used for differential protection
Core 2 3500/5A
50 VA Class 1, this CT is used for metering
The following CTs are provided in the neutral side of the Generator.
Core 1 3500/5A
Class PS
KPV>80V
RCT<O.7ohms
I exct < = 60 mA at ½ KPV, this core is used for differential protection
Core 2 3500/5A
30VA
Class 5P10, this core is used for back o/c protection, negative sequence current
protection overpower and reverse power relays.
Neutral CT 500/5A
10VA
Rev. No. : 02, Oct. 2008
Class 5P10, this is used for back ground fault protection >
The metering provided in diesel control panel is fed from a separate metering CT
core provided at the machine terminal.
One set of pts of 418 / 110V class 0.5/3, 200VA are provided on the
3 3
incoming side of the DG breaker for feeding the potential supply for DG relays.
17.3 PROTECTION
The following protection are provided:-
a) Differential protection (87)

b) Negative sequence current protection (46)
c) Reverse power protection (67)
d) Excess load protection (32)
e) Backup over current protection for earth faults. (51R,Y,B)
f) Back up over current protection for earth faults (51BN).
g) Under frequency protection (81)
17.3.1 DIFFERENTIAL PROTECTION
This is provided by a high speed, high impedance circulating current type differential
protection M/s English Electric type CAG-34 relay has been used for this purpose.
The relay current coil are shunted by non-linear resistor to limit excessive over
voltage incase of internal faults.
17.3.2 NEGATIVE SEQUENCE CURRENT PROTECTION
This protection consists of an inverse time current relay of M/S EE

type CTN. The relay has in built negative sequence current filter and operates on
negative sequence current component of the generator current. The time current
characteristics of the relay have to be co-ordinate with the I2t characteristics of the
machine.
17.3.3 REVERSE POWER PROTECTION
This is provided by a single-phase directional power relay which has a built in time
feature. M/s English Elect4ric type ‘WDG11 ‘ has been applied for this. The
protection operates to trip the DG incase of motoring the conditions due to loss of
motive power from the engine.
Rev. No. : 02, Oct. 2008

17.3.4 EXCESS POWER PROTECTION
This is provided by a single-phase directional power relay with an external timer. M/s
English Electric type ‘ WDG12’relay is used. The protection initiates load shedding to
reduce the load on the generator.
17.3.5 BACKUP OVERCURRENT PROTECTION (51,R, Y and B)
This consists of voltage controlled IDMT over current relays one for each phase. The
relays are connected to the CTs in the neutral end of the generator. M/s English
Electric type CDV22, relays are used for, external faults involving moderate dip in the
voltage the relay operates on its normal time characteristics.
However for close up or internal faults when the voltage dip is considerable the
voltage control feature increases the torque on the relay disc and relay operates with
shorter timer characteristics. In order to prevent PT fuse fail conditions shifting the
characteristics, the contacts of DG PT and buts PT are wired in series in the shading
coil circuits of the relay.
17.3.6 BACKUP GROUND FAULT PROTECTION (51BN)
This protection is provided by an IDMT over current relay (type CDG11 of M/s EEC.)
this protection in conjunction with two additional times stages operates as a three
stages protection as described below
The first stage trip the class III ties breakers CB-5 &6 and the class II tiebreakers if
class II is interconnected to class III bus of the concerned DG set. The second stage
(through timer ‘ 94 X’ initiates tripping of class III to class II tie breakers the third
stage initiates (through ’94 NY‘) tripping of the DG breaker.
17.3.7 UNDER FREQUENCY PROTECTION (81)
Protection is provided by under frequency relay (Type FTG11) of M/s ECC and a
time (81Y). The first stage of under frequency protection initiates load shedding by
disconnection for class III tie and isolates the DG set on its own busload. The second
stage imitates load shedding schemes.
18.0 MOTOR GENERATOR SETS

There are two motors generator sets for each unit the protection of all the four MG
sets are identical to the protection for one set is described below and is applicable
for other sets also.
The following CT cores are provided on the 415V breaker of the MG set.
Core 2 600/5A
Class PS
VK >75V
Rev. No. : 02, Oct. 2008

RCT<0.35 ohms
I exct <60 mA, this core is used for restricted earth fault protection.
Core3 600 /5A
15 VA
Class 5P20, this core is used for instantaneous O/C relays for short circuit protection
Core 4 600/5
50VA
Class 1, this core is used for metering.
The following core is provided at the neutral end of the phase winding of the
generator.
Core 1 600/5
30VA
Class 5P20, this core is used for back up O/C protection.
NEUTRAL CT
Ratio 600/5A
Class PS
VK>75V
RCT<0.35
I exct <60mA AT1/2 KPV, this core is used for restricted earth fault protection.
18.2 POTENTIAL TRANSFORMER
One set of PT’s with ratio of 418/110 V, class 0.5 /3, 100 VA is provided on the
incoming side of the breaker for the Generator.
18.3 PROTECTION FOR THE ALTERNATOR
The alternator of the MG set is provided with the following protection
a) Restricted earth fault protection.
b) Instantaneous over current protection for machine short circuits.
c) Backup over current protection of phase faults.
d) Backup over current protection for ground faults.
e) Reverse power protection.
f) Under voltage protection.
18.3.1 RESTRICTED EARTH FAULT PORTECTION

Protection is provided by means of high-speed high impedance circulating current
type differential relay (Type CAG14 of M/s EEC). The residual connection of the CTs
on the phase side is matched with the neutral connection to obtain the zero
sequence differential current for restricted earth fault. Relay operation is similar to
the differential protection of DG set.
18.3.2 INSTANTANEOUS OVERCURENT PROTECTION
An instantaneous high set overcorrect relay is provided on each phase. The setting
of the relays selected to higher than the maximum short circuit current supplied by
the alternator. Hence this protection will be operative only when the machine is
paralleled to the DG set, during faults in the alternator will be adequate enough to
operate the relay.
Rev. No. : 02, Oct. 2008
18.3.3 BACKUP OVERCURRENT PROTECTION FOR PAHSE FAULTS
The back up over current protection phase fault is similar to the back up over current
protection for DG set covered in 17.3.5 M/s English Electric type ’CDV22’ relay have
been used for this purpose.
8.3.4 BACKUP GROUND FAULT PROTECTION (51N)
An IDMT over current relay (M/s. EE type CDG11) has been provided for this. The
protection operates to trip alternator breaker though trip relay ‘94B’.
18.3.5 REVERSE POWER PROTECTION (32)
Protection is provided by means of a single-phase power directional relay and a

timer the protection operates when the alternator runs into motoring region due to
loss of prime mover power. This is feasible only when the MG set runs in Parallel.
With the DG, set or another MG set.
18.3.6 UNDER VOLTAGE PROTECTION (27)
A time delayed under voltage protection is provided to trip when the alternator incase
of sustained under voltage to trip the alternator incase of sustained under voltage in
the class II system.
18.4 UNDER VOLTAGE PROTECTION OF DC MOTOR OF THE MG SET
The DC motor of the alternator is provided with the following protection
a) Thermal overload protection.

b) Short circuit protection by means of magnetic release in the breaker
c) Field under current protection.
d) Over voltage protection.
e) Overspend protection.
f) Under/over frequency protection.
19.0 415V SWITCHGEAR
The 415V Circuit breakers are provided with a CT operated static series trip device,
which provides overload and short circuit protection. The range available on these
releases is indicated in the manufacturer’s single line diagram for relevant
switchboards. This series trip device operates directly on a second trip coil of the
breaker.
19.1 INCOMING FEEDERS FROM TRANSFORMERS
Rev. No. : 02, Oct. 2008

The following protections are provided

Restricted earth fault protection for the LV side of the transformer by means of high
impedance circulating current differential relay type ‘CAG14’. The protection
operates to trip the ‘HV’ breaker.
Inverse definite minimum time over current (IDMT) protection for phase and ground
faults by means of static series trip device mentioned in 19.0 above.
19.2 MOTOR FEEDERS
The following protections are provided in addition to the series trip device mentioned
in 19.0 above.
a) A composite motor protection relay type ‘CTM’ of M/s EE comprising of thermal
overload instantaneous over sequence, components of the fault current and
instantaneous over current relay for ground faults.
b) Definite time over current protection on two phases locked rotor protection.
c) Incase of class III feeders the ground fault protection is provided by means of
core balance CT a separate instantaneous over current relay type CAG12.
Hence, the ground fault protection feature of (a) above is not provided.
d) In case of class II feeders in view of the low fault Level at class II bus the series
trip device mentioned in 19.0 above is not provided. The short circuit protection
consists of only the instantaneous over current features in (a) above. In addition
to this an instantaneous over current relay is added in the ‘Y’ phase (Motor
protection relay is connected to R&B phase only.
19.3 PROTECTION FOR POWER ACVR FEEDER
In addition to the series trip device mentioned in 19.0above, the following protection
is provided for the power ACVR feeders.
a) Inverse time over current protection (51R,Y, B) and Instantaneous over current
protection (50R,Y, B) with a relay type CDG-61.
b) Inverse time ground over current protection (51N) through a CDG 11 relay
connected in the residual circuit of the phase CTs.
The ACVR itself is provided with its own protections for its transformer and the
rectifier. These protections include buchholz (2 stage), Oil temp (two stage) and
winding temp (two stage) for transformer, di/dt, dv/dt for thyristor, and over current
protection.
Rev. No. : 02, Oct. 2008

19.4 PROTECTION OF MCC FEEDERS
The following protections are provided static series trip device,mentioned in 19.0
above for class IV & Class III feeders. For Cl-III feeders a separate inverse time
minimum time type relay (EE make-CDG) is used for ground fault protection. For
class II feeder’s definite minimum time over current protection is provided for phase
and ground fault in lieu of the series trip devices. In case of class III & II feeders,
separate instantaneous ground fault protection is provided by means of a core
balance CT and an instantaneous over current relay type ‘CAG12’
19.5 TIE BREAKERS
Tiebreakers are provided with only series trip devices mentioned in 19.0 above.
19.6 UNDER VOLTAGE PROTECTION
The under voltage protection scheme for motor feeders are similar to that of the 6.6
KV system described earlier. This protection ensures that on loss of supply all motor
feeders are disconnected so that when the supply is restored, the transformer is not
subjected to the cumulative starting currents of all feeders.
20.0 250V DC SYSTEM
All the feeder breakers in this system are provided with instantaneous series
releases for short circuit protection while the incomers are provided with time-
delayed releases. The ACVR breaker board, are electrically operated type. The
motor loads that are fed from this system are
i) DC flushing oil pump motor
ii) DC seal oil pump motor
The starters for these motors are provided in separate starter panels in which bi-
metallic overload relays are provided for the motor overload protection.
The DC bus is provided with a ground detection scheme, which continuously
monitors the insulation of the positive and negative bus bars with respect to the earth
and initiates alarm n case of ground fault. For details of this scheme, refer feature
manual on 250 V DC system (NAPP-52320)
21.0 415V CLASS II CONTROL SYSTEM
Inverters sets connected to 250 V DC power and control buses, feed 415V class II
control system (Cell-1 to 9). This system in turns feeds the 240 V class- II control
power supply distribution panels. The out going feeders of the 415V class II control
system is protected by MCCB.
Rev. No. : 02, Oct. 2008

CHAPTER 20
AUTO AND EMERGENCY TRANSFER, SYNCHRONISING AND LOAD SHEDDING
(65230)
1.0 Narora atomic power plant consists of 2 units of 220MW capacity each. Power
Supply arrangements for both the units are identical. The description of the auto &
emergency transfer and synchronising schemes of unit 1 are described below . The
schemes are identical for unit –2 . The station service load requirement are divided
into four class as follow :-
Class 1V Loads
Majority of electrical loads, which may be interrupted permanently on loss of normal

supplies.
CLASS III LOADS
Loads which are needed for emergency operation of the plant but may be interrupted
for a short time during the switching of the power supplies in case of loss of the
power supplies. In case of loss of 1V supply , these loads are supplied by diesel
generator units.
CLASS II LOADS
The most essential loads which must not be interrupted. The class II systems are
further divided into class II power supply bus bars which are normally fed by DC –AC
motor generator sets of 325 KVA for the power supply bus bars and 60 KVA inverter
sets for the control power supply. These motors generator sets take power supply
normally from the class III system via power and control ACVRS and the respective
class-I DC bus bars. During interruption of Class III supply, they draw DC power from
the power and control batteries connected to these DC bus bars.
CLASS I LOADS
All loads which require DC power. This system is further divided into class power
and class I control supply bus bars.
These are supplied from 250 V DC power and control bus bars respectively. These
DC bus bars are fed from class III system through power and control ACVRS under
normal conditions.
The Power and control batteries connected to these bus bars supply DC power
supply when the class III power source is interrupted.
Rev. No. : 02, Oct. 2008

1.1 SYSTEM CRITERIA
A. The 6.6 KV automatic transfers has been feature to maintain class IV power in
the event of one of the two sources of the class IV supply (Viz from unit
transformer and from the startup transformer) is lost. The automatic transfer
is achieved by closing the tiebreaker between the unit and station section of
the 6.6 KV supply system.
B. In order to obtain successful automatic transfer the tiebreaker should be

closed in less than 200 milliseconds, (say 160 milliseconds). This fast
transfer would limit the transient current and voltage dips within safe limits and
also ensures smooth and quick re-acceleration of all motors connected to the
affected bus.
C. The 415 V emergency transfer (EMTR) has been featured to:-
a) Restore Class III supplies in short time from standby diesel generator
units.
b) Take necessary steps to ensure maintenance of uninterrupted supply

to essential class II loads and class I loads.
c) Restore supply in short time to the loads which can withstand a short
interruption.
D The scheme incorporate synchronizing facilities for the 220 KV lines,

generators, and other auxiliary system breaker involved in the emergency
transfer scheme.
E. Automatic load shedding circuit is also including in the emergency transfer

system as the load shedding process is to be initiated by the EMTR scheme.
2.0 DISPOSITION OF BUSES :-
Under normal operating conditions, two sources supply the station loads:
i.Main generator 412-G1 via unit transformer 522-UT1.
ii.220 KV systems via start-up transformer 521-SUT-1. (These transformers feed four
6.6 KV buses which in turn feed various loads including seven 415 volt buses
supplied via 2 MVA transformers). Normally the feed to each bus and to each
load is radial. However, there are alternate supply routes depending upon the
available power sources. Therefore, the following power distribution schemes
may be considered.
a) Normal power distribution :- All power sources and switching equipment are
available.
Rev. No. : 02, Oct. 2008

b) Startup and shutdown power distribution:- All power sources and switching
equipment are available except the main generator.
c) Emergency Power Distribution Normal power distribution is not possible
because of outage or failure of some equipment.
All-important auxiliaries are arranged in 2x100% or 3x100% units, which are

normally supplied from separate sources. Therefore, loss of single source would
result in partial loss of essential loads.
Emergency 415 V AC power supply is made available by three 1450 KW diesel

units. These have a short time rating of 1750 KW for two hours and 1650 KW for
eight hours. Two motor generators sets of 325 KVA each serve to supply
continuously class-II power supply from Class III power supply via Power ACVR
backed up by 250 V DC batteries in the class I power bus bar. During class III
supply loss, the MG sets continue to supply class II power by drawing power 250 DC
power batteries.
class II control supply bus bars are fed from 3 Nos, inverter sets of 60 KVA capacity
each. A fourth 60 KVA inverter set is provided as standby for the three sets. these
inverter sets also draw normal power from class III system via control ACVR backed
by 250 V DC control batteries. In the event of the class III power failure, they
continue to feed class II control supply by drawing power from 250 V DC Control
batteries.
The three diesel units, one being standby, are capable supplying essential service
load continuously in the event of loss of normal supply. However, one diesel unit by
itself has insufficient capacity to continuously supply all the essential class II and III
loads and thus under these conditions, load shedding of less essential loads will be
initiated. The 250 V DC power batteries have capacity of feed class II busloads
through inverter sets for 30 minutes. This allows sufficient margins for some manual
switching if the emergency transfer equipment is not available or is unable to
complete restoration of all essential loads.
Features of the system is such that the two main supply sources are not to be
running parallel at 6.6 KV or 415 Volt level to keep the fault levels below the
equipment interruption ratings. However, a diesel unit may be run in parallel with the
other sources (transformer, PMG) and is so used when necessary, to effect a
smooth uninterrupted transfer without paralleling of main sources at 6.6 KV or 415 V
levels. Paralleling of main sources at 6.6 KV for a few mili-seconds is accepted when
either of main sources is to be taken out of service and is being manually restored to
service. Under these conditions, the circuitary automatically checks that both the 220
KV and 16.5 KV generator systems were interconnected and are in synchronism
before thy are paralleled for a few cycles at 6.6 KV.
The various classes of power are as follow
Class IV :- Least essential loads
Rev. No. : 02, Oct. 2008

(a) 6.6KV buses 5241-BU-D, E, F and G

(b) 415 Volts buses 5242 –BU-K, L, M, J and K1 (L1 for NAPP-2)
Class III :-
Loads which may be interrupted for a start-time automatically restored through
EMTR in case of normal supply failure. Supply 415 Volts buses 5231 –BU-P-Q, P1,
Q1
Class II :- Loads which must not be inturrpted 415 Volt buses 5231-BU-S,T
5233-BU- Uc, Vc, Wc and Xc
Class I :-
5232-BU-U1, U2, U3, V1, V2, V3, & 5232-BU-W and X For normal operating
condition s the buses are supplied as follows (Reference drg. 50000-FS-1)
1. Main generator is connected to 220 KB bus (i.e. 513 –CB2 closed). One or more
line breaker (513 CB-4, 6, 7, 8 and 11), the bus coupler breaker (513-CB-1)
closed.
2. Class IV power is supplied to 6.6 KV buses 52441 –BU-D, BU-E and BU –F, BU-
G by unit start-up transformer (i.e. 5241 –CB –16, CB –33 and 34) the tie breaker
5214 –CB –17 isolator 5241 –DS –1 and tie breaker to unit 1/2 5241-CB-1
normally open. The 415 volt class IV buses5242- BU-K, BU-L, BU-M and BUK1
(L1) are supplied from 6.6 KV buses each with a 2 MVA transformer (i.e.5241-
CB-5, CB-21, CB-26, CB-11& 5242 –CB-2, CB-3, CB-4 and CB-39 (CWPH)
closed. the transfer (reserved) bus 5242-BU-J is energized from 6.6 KV bus 5241
–BU-E via its own 2 MVA transformer (i.e. 5241-CB-14and 5242 –CB-1 closed)
but it is not supplying any load (i.e 5242-CB-5, CB-6, CB-7 and 5231-CB-3, CB-4
are open).
3. Class III buses 5231-BU-P, BU-Q are supplied from their respective 6.6KV class
IV buses (i.e.5241 –CB-2, CB-32, and 5231-CB-1, CB-2Closed) and are not tied
together (i.e. 5231 –CB-5, CB-6 Open). The diesel units are not in operation (i.e.
5231-CB-7, CB 31, CB-70). Tie isolator to unit –2 is open and isolator 5231-DS-2
closed.
4. Class II buses 5231- BU-S , BU-T are supplied form class II buses P and Q
respectively via ACVR 5232 –RC-1 & 2 and motor generator sets 5231-MG-
1,MG2 ( i.e. 5231-CB-9 , CB – 29 closed ,5232 –CB –1 CB-2,CB-3, CB-7, CB-8 ,
CB-9 closed , 52331-CB –34 , CB-46 closed ) and are not tied together( i.e.5231
–CB-19 , CB-20 , CB 32, CB –33 open).
5. Class I power buses 5232 Bu-U1, U2, U3, V1, V2, V3, are supplied from 250 V
DC batteries (5232 –BAT –1,2) as well as power ACVR’S (5232-RC1,2) with
5232 –CB-3,4,6,7,2,8 closed and tie breaker (5232-CB –5 ) open Class-I control
buses 5232-BU-W,X are supplied from 250 V DC batteries (5232 –BAT –3,4)as
well as control ACVRs (5232-RC-4,5) (5232 –CB- 18,19,24,25closed ) and tie
breaker –CB –16,17 and, Power bus to control bus tie breaker 5232-CB-20, 21
are open .
Rev. No. : 02, Oct. 2008
The stand by batteries charger (5232-RC-3&6) breakers 5232 –CB 10, 11, 22, 23
are normally kept open and another standby charger (5232-RC-6) MCCB’s are
kept open.
3.0 6.6 KV AUTOMATIC TRANSFER
There are four 6.6KV buses; two each have it own Transformer supply. 5241 –BU-
D, BU-BU-E is fed from unit transformer and 5241 –BU-F and 5241 –BU-G are fed
from startup transformer with 5241 –CB 16,CB- 33 & 34 closed and tie breaker 5241-
CB-17 open. In case of loss of supply to one set of buses, these buses will be
transferred automatically to the other set of buses by closing the tiebreaker CB-17.
The most important 6.6KV loads are the four primary coolant pumps. Each pumps
equipped with a fly–wheel. In case of a total loss of station service power. Pumps are
driven by the flywheels to provide the necessary cooling during the reactor shutdown
period.
In order to obtain a successful automatic transfer, the breaker must be closed in less
than 200 milliseconds, (say 160 milliseconds). The fast transfer is obtained by
energizing simultaneously the trip circuit of the incoming transformer breaker and the
closing circuit of the tiebreaker.
The total closing time for the 6.6 KV breakers is 120 –130milliseconds and the total
tripping time about 80 milliseconds. This provides a dead time about 40 to 50
milliseconds. Because of this fast transfer there is no danger of out of phase
condition of the system and bus residual voltage at the moment of closing of the tie
breaker.
3.1 METHOD OF INITIATION
The state of power system from 220 KV to 6.6KV is indicated by a 48 V DC model of

the system. This is known as a matrix, with various relays indicating the state of any
one system or bus, the matrix consists of protection relay contacts and breaker
auxiliary contacts (Refer Drawings NAPP/65230/6003,6005/ED).
There are three electrically separated identical matrices. Two out of three matrices
must operate to initiate auto transfer in order to prevent an incorrect transfer caused
by a fault in matrix.
The 6.6KV automatic transfer control initiating the closing of the tiebreaker 5241-CB-
17 is by relays ‘Ex’ or Fx’. Closing is permitted only if:
a) Both 220 KV and 16.5 KV sources were inter -connected to ensure synchronism
(i.e. relay S1and S 1-X energized)
b) The tie breaker 5241-CB –17 control in AUTO (i.e. HS 7201 in AUTO) and
Rev. No. : 02, Oct. 2008

c) The bus was healthy prior to the loss of incoming supply and bus voltage has not
fallen below 70% (i.e. relay 27 –BY)
d) Closing is provided only the first 200 milliseconds.
Various protective are relays and contacts of circuit breakers applicable to the
following equipment will initiate a 6.6KV auto transfer.
Main generator412-G1, Relays 86G, 86M, and 86 GT
Start up transformer 521 –SUT –1. Relay 86M, 81-86(U/F), bus bar differential relay,
SUT 220KV CB Aux. Contact.
Backup protection initiating unit or SUT trip are not allowed to initiate fast transfer
since the bus voltage might have fallen in magnitude as well as out of phase during
the delay of backup protection.
3.2 MANNUAL CONTROL
The Tie breaker 5241 –CB-17 may also be closed manually, and the associated
incoming breakertrips automatically as soon as the tie breaker has closed, without
interrupting the power supply to 6.6 KV buses.
This is selected by a three-position hand switch located in the control room (HS-
7201). This hand switch can be set in UT1/AUTO /SUT1. When the HS 7201 is kept
in position SUT –1 and the tie breaker5241-CB-17 is closed, the incoming breaker
from unit transformer is tripped provided the incoming breaker from start –up-
transformer is closed. Similarly, when HS-7201 is in UT –1 position, the SUT 1
breaker is tripped provided both tiebreaker and incoming breaker from unit
transformer are closed.
On manual closing of the tie breaker the 6.6 KV tie between the two sources is made
only for a few cycles before the selected incoming is tripped the closing of all three
breakers are through synchronizing check is manual mode.
4.0 RESTORATION
The automatic transfer is a one-way transfer. There is no automatic transfer back to

normal supply when both sources are again available.
This is done manually by closing the incoming transformer breaker. The hand switch
HS –7201 is to be kept in auto. The closing of incoming supply is inter locked and
permits closing of the breaker only both sources are in synchronism. On closing the
incoming transformer breaker, the tiebreaker is automatically tripped. The two
sources are paralleled for a few cycles.
Rev. No. : 02, Oct. 2008

4.1 415 VOLT EMERGENCY TRANSFER
The main purpose of this transfer is to re-establish power supply to class III buses
and maintain continuity of class II power supply, during Class IV power failure to the
class III buses.
The EMTR scheme controls the diesel generator sets and breakers in 415-volt class
III and II switchgear. The power motor generator (PMG)sets are normally connected
to class II bus on AC side and to CL-I bus on DC side. The power to PMG set is
normally from CL-III bus through power ACVRs. This mode of connection prevents
the transmittance of class IV disturbances to the class II power supply.
Incase power supply to the class III bus is lost, the PMG takes power from class I
batteries and supplies to class II. The class I battery bank is having the capacity to
feed the class II bus for 30 minutes. In this period, the emergency transfer has to
reestablish a permanent supply to the class II bus from class III bus via the power
ACVRs.
The EMTR scheme operates the following switchgear
a) Trip and close 5231-CB-5& CB-6 Class III, tie breaker

5231-CB-7 DG-1 Supply breaker
5231-CB-31 DG-2 Supply breaker
5231-CB-19 Supply class III bus P to class II bus S
5231-CB-20 Supplies class III bus P to class II bus
When power supply restored by DG-3, CB-5 & CB-6 serve as tiebreaker if power
supply not restored by affected bus DG1 or DG2.
b) Trip only 5231-CB-1 Class IV supply to Bus P (Normal)

5231-CB-2 Class IV supply to Bus Q (Normal)
5231-CB-3 Class IV supply to Bus P (Transfer)
5231-CB-4 Class IV supply to Bus Q (Transfer)
c) Close only 5231-CB-8 PHT standby cooling pump 1
5231-CB-10 Air Compressors 3
5231-CB-11 Moderator circulating pump 1
5231-CB-13 HPPW pump 1 (Active)
5231-CB-63 IDCT Fan-3
5231-CB-64 IDCT FAN-4
5231-CB-56 NAHP-2
5231-CB-61 NAHP-1
5231-CB-57 NAHP-3
5231-CB-51 Modp P-3
5231-CB-62 PW cooling water P-3
5231-CB-23 Aux. BFP pump 8
5231-CB-24 Moderator circulating pump 5
5231-CB-27 Air Compressors
Rev. No. : 02, Oct. 2008

5231-CB-30 PHT standby cooling pump 2
5231-CB-48 Aux. BFP pump 1
5231-CB-26 HPPW pump 3(Active)
5231-CB-54 HPPW pump (Active)
The function of 415-volt emergency transfer system is to restore class III bus and
loads by any of the following routes
i. If supply from class IV 6.6KV system is restored with 0.5 seconds(The time
delay for U/V tripping of bus loads & initiation of DG start), the normal supply
arrangement will be restored.
ii. If 6.6 KV class IV supply is not restored all three diesel units are started. If the
diesel units associated with the affected bus starts up and closes in
successfully, class III loads are sequentially restored.
iii. If diesel generator associated with the affected bus fails to start or its output
CB fails to close, DG-3 associated breaker closes, if third DG also fails, the
class II tie breakers (CB –5 &CB –6 ) are closed provided that unaffected
class III bus is being supplied by its diesel or normal class IV supply . Class III
loads are then sequentially restored.
iv. Establish class II supply through class III to close II tie incase of loss of class
II supply.
4.1 METHOD OF INITIATION
a) Loss of class IV supply to the class III buses.

Class III under voltage lockout relays BU-P-27-94 or BU-Q-27-94 senses
this condition.
b) Loss of supply to class II Bus:- Tripping of Motor Generator sets (PMG).

This sensed by class II under voltage lockout relays BU –S –27 –94 or BU –T –
27-94.
c) Tripping of power ACVR’ s input CB.

This will result in loss of supply to class II bus after 30 minutes when class –1
battery gets discharged completely. This is sensed by input breaker of ACVR
provided that tie-breaker between CL-III & CL-II is open.
4.2 TRANSFER EVENT
Refers Drawing result NAPP-65230 /6007Sh1 and 2, NAPP- 65230 6008 Sh1 and 2
and NAPP /65231/6009 /ED. the 415 Volt emergency transfer has two separate
circuits one for bus P the other for bus Q. Both transfers may be carried out at the
Rev. No. : 02, Oct. 2008
same time. However in this case the breaker between two systems 5231 –CB-5 or
CB –6 and CB –70 closed until one side DG has permanent supply the following
describes the bus P&S system bus Q&T system is similar.
When transfer is initiated, the relay 1P1 will energies and seal in contacts of this
relay initiates all transfer circuits, thus when relay 1P1 is de -energized the
emergency transfer are de-energized. This can be isolated from hand switch HS –
7301 located in the control room panel 6610 –PL –2. The hand switch HS –7031 can
be set in “ EMERGENCY TRANSGER ON /EMERGENCY TRANSFER OFF”. In
case the transfer event are not completed in four minutes. These are lockout relay
(2XP) will be energise and seal in and reset complete events and prevents further
automatic transfer. The seal of this lock out relay may broken by HS –7031 turning it
to “EMERGENCY TRANSFER OFF” or by push button PB - 7031 in EMTR Panel.
4.2.1 CLASS III VOLTAGE FAILURE
Voltage failure to class III bus condition is sensed by under voltage lockout relay BU
–P-27 –94 and initiates emergency transfer by energizing the relay 1P1 and 1P2.
The under voltage lockout relay BU-P-27 – 94 also trips all motor feeder breakers of
Bus ‘P’
The relay 1P1 enrgises the diesel start relay 5P, provided the diesel ready relay 8P
(indicating diesel generator ready for operation) is energized .The relays 3P1 & 3P2
trip the incoming supply breaker to bus P. The condition of DG running (viz engine
started, speed and voltage attained normal values) is indicated by relay 10 YP.
This will close the diesel generator breaker 5231-CB-7, through 11P relay
establishing power supply to class III bus provided the Bus P is healthy .The healthy
condition is supervised by the relay 15 P &15P1 which indicates all incoming and tie
breakers are in off condition and none of these breakers are tripped on fault
condition.
In case of 5231 DG–1 fail to connect on 5231 –BU-P, 5231– DG-3 will connect thro,
5231 –CB –70 and 5231–CB-5 after time delay. If DG-1 and DG-3 route fails then
closure the tiebreaker 5231 –CB-5 and CB-6 and establishing power supply to Bus P
will be initiated for the following conditions
a. Diesel Generator DG1 is not only ready – this is sensed by relay 8P.
b. Diesel generators fail to start- this sensed by relay 6P.
c. Diesel generator breaker 5231-CB-7/ 5231-CB-70 are not ready –this is
sensed by relay 9P.
d. Diesel generator breaker 5231 –CB-7/ 5231 –CB –70 fail to close. This is
sensed by relay 12P.
In the above conditions, the class III tie breakers 5231 –CB –5 and CB –6 will close,
provided that,
Rev. No. : 02, Oct. 2008

a) Permanent supply is available on Bus Q and

b) Bus P is healthy
The closing of CB-5 & CB-6 is initiated by relay ‘13P ‘.
When only one source of power is available for the entire class III system (either
through one of the auxiliary transformers from Class IV system or from one diesel
generator) the class III tie breakers (5231 –CB-5& CB-6) closing will be initiated by
EMTR, which inurn will initiate load shedding to become effective.
If supply restoration through class IV supply, EMTR scheme though initiates starting
of DG sets, will not be able to synochronise DG with available class IV supply (Since
automatic synchronising is not available during emergency transfer. Operator’s
intervention is required to synchronise DG with Bus-Q.
Incase CB –5 are not ready for close as indicated by relay 14 P and class III bus’s ‘
transfer is incomplete then lock out relay 2XP will energies.
4.2.2 CLASS II VOLTAGE FAILURE
The class II bus ‘S’ voltage failure is sensed by Bus ‘S’ under voltage relay BU –S-
27-94. This will initiate transfer scheme. The relay 1P1 & 1P2 will start diesel
generator No.1, 2 and 3 as mentioned above.
The class II and class III tie breaker 5231 –CB-19 will be closed by relay 32P
provided the following conditions are satisfied.
(a) Permanent supply to class III bus ‘P’ is available either from class IV or diesel
generator. This is sensed by relay BU –P –27 –X.
(b) Class II bus ‘S’ healthy –this condition indicates that the tie are off and MG set
No.1 breaker 5231-CB –34 is off and no fault on Bus ‘S’
In case class III to class II tiebreaker 5231 –CB-19 is not able to restore class II
supply (which is sensed by relay 33P) it will initiate emergency transfer incomplete
lockout relay 2XP.
4.2.2 POWER ACVR FAILURE
The power ACVR failure results in tripping of breaker 5231 –CB-9. This will energies
the relay 1P1. if the class II-III tie breaker 5231-CB-19 is also open, it will start the
diesel generator No. 1,2and 3. Since the class II is supplied from, motor generator
sets taking power from class I 250 V DC batteries for 30 minutes, the emergency
transfer will not take any automatic event other than starting the diesels. Only
emergency transfer incomplete and lockout feature appear after 4 minutes. The
operator action is requited to synchronies the diesel generator set to respective class
III bus and then synchronise motor generator set for the corresponding supply via
tiebreaker 5231 –CB-19 (CB-20). Once the class II bus is synchronised with DG set,
the motor generator sets can be taken out.
Rev. No. : 02, Oct. 2008

4.3 RESTORATION OF CLASS III AND II
When emergency transfer has been successfully completed, the system may be in
various states.
(a) Both diesel generators running and each class III bus fed from its own diesel
generator and class II bus normal and third diesel running and not connected.
(c) One class III bus fed from its own diesel generator and the other class bus
normal (class IV) supply with its diesel generator running not connected bus.
(d) Both class III busses fed from single diesel generator or class IV supply. In
this case, load shedding shall be operative.
(e) Class II buses fed from class III supply either class III to class II tie breaker
closed and motor generator sets out, or power out, or power ACVRS out.
(f) One class II bus fed from its own MG set and other bus from class III bus
thorough class II –class III tiebreaker.
When all normal supply routes are again available, the system requires operator
attention to reinstate all normal supplies. Special procedures should be used to
ensure a smooth uninterrupted transfer. For the above conditions, the procedures
are
(a) When class IV supply is available, the respective Diesel Generators shall be
synchronized with class. IV supplies by controling the diesel generator
parameters Via speed & voltage. After synchronizing, the diesel generators shall
be gradually unloaded and disconnected from class III supply.
(b) When one diesel generator is supplying both the class III buses, the diesel
generator may be synchronized first with class IV supply for the bus on which
Diesel generators not available. Then the class III tiebreaker 5321-CB-5 and CB-
6 may be tripped separating class II systems. Then the diesel generator may be
synochronised with the class IV supply of its own bus and then the diesel
generator may be taken out.
(c) Normal supply can be restored to class II after power ACVR available in case
power ACVR is out and with MG set available in case MG set is out.
4.3.1 CLASS III FEEDER RESTORATION
All motor feeder breakers are tripped and closing is blocked by bus under voltage
protection when bus is de-energized (in order to prevent picking up all loads
simultaneously when bus is re-energized). The closing of each feeder is blocked,
until the blocking feature is reset by the breaker hand switch (by moving it to ‘OFF ‘
position) or by the restoration sequence of EMTR scheme. This sequence is required
only after permanent supply is available to class III bus.
Rev. No. : 02, Oct. 2008

The sequence is initiated by the relay 16XP. This relay energises number of timers,
each of which is set at the time step of 4 seconds interval. The contact of each timer
will close the corresponding class III feeder breaker. The priority of this feeder
breaker is set based on the requirement of the auxiliaries. Once the last restoration
timer complete its timing sequence, it will reset the emergency transfer event .
During class III feeder restoration in case class –II supply lost, class II supply will be
restored immediately by closing the class III to class II tie breaker.
During sequential restoration of loads on bus ‘P’ if closing of tie breakers CB-5 & CB-
6 is called for, it will close only after sequential restoration of bus ‘P’ is completed.
Sequential restoration of Bus-Qwill start after closing of tie breaker CB-5 & CB-6.
4.4 CONTROLS AND INDICATION
Initiation of variation alarms and indications has been incorporated to enable the
operator the follow the progress of emergency transfer. The ON-OFF controls and
indications for this scheme are as follows. The scheme indicates for 415 Volt bus
P&S. The scheme for Bus Q&T is identical.
4.4.1 ON / OFF
On/off hand switches HS-7031 (HS –7024) and two pairs of indications lamPS LT
7030, 7029(7026,7025) are located in the control room panel PL –2 and together
with alarm points, provide supervision of emergency transfer equipment. The HS –
7031 and two lamPS LT7030, 7029 are for bus P&S system (HS-7024and two
lamPS LT –7026 and 7025 are for bus Q and T system). The HS –7031, 7024 shall
be ‘ON’ position for emergency transfer system to operate for both bus P& S.
4.4.2 READINESS
(g) Diesel generator E/G-1 ready to start condition is supervised by relay 8P is

energized if
(i) Local /remote selector switch HS –7214 in control room panel –1 is in remote
position.
(ii) Diesel Master set up relay 3.1 is energized.
(iii) Auto /Manual switch HS –7032in control room is in auto position.
(b) Diesel generator breaker CB –7 is supervised by rely 9P for ready to close provided
that
(i) Auto /manual switch HS7033 / HS-7254 of 5231 –CB –7/ 70 in the control room
is in auto position.
(ii) 5231 –CB –7 / 70 is in service position.
(iii) DG-1 or DG-3 ready.
Rev. No. : 02, Oct. 2008

c) Class III bus tiebreaker 5231 –CB –5 are supervised by relay 14P for ready to close
provided that –
(i) Auto /manual switch HS –7029of CB –5 in the control room is in auto position.
(ii) 5231 CB –5 are in service position.
d) Class III to class II tiebreakers 5231 –CB –19 is supervised by relay 32XP for ready
to close provided that
(i) Auto /manual switch HS –7028 of 5231 –CB –19 in the control room is in auto
position.
(ii) 5231-CB –19 is service position.
4.4.3 LAMP
The lamPS and alarm in control room normally functioned indicated condition as
follows
1. The amber lamp LT-7029 in control room / LT-7028 at EMTR panel

indicates that emergency transfer control switch HS –7031 is in the ‘OFF’
position.
2. While lamp 7030 in C/R and LT-7031 at EMTR panel indicates EMTR is in
service (HS-7031 in control room is ON and Normal / Test switch at EMTR
panel is in Normal position).
3. Both white and amber lamp OFF condition indicates the emergency
transfer equipment is in test position. This condition is annunciated in
control room. “as EMTR OFF/Test” (AN-317)
4.4.4 ALARMS
Annunciation associated with emergency transfer is as follows. The annunciation

description is given for 415 Volts buses P & S. Identical annunciation are there for
415V Bus-Q & T.
a. 5231-BU-P&S EEMERGENCY TRANSFER IN PROGRESS “Window No.AN-

315. This annunciation is initiated by relay (P). This indicates the emergency
transfer scheme is in progress.
b. 5231 –BU –P&S EMERGENYCY TRANSFER OFF/TEST”WINDOW No. AN-317.

This annunciation is initiated by HS –7031 & -HS 7030. This indicates either
emergency transfer scheme test switch is in test position or C/R HS is in off
position.
c. 5231-BU-P&S ENERGENCY TRANSFER INCOMPLETE “ WINDOW NO. AN-

316. This annunciation is initiated by relay 2XDand this indicates a failure EMTR
scheme and will require the operator to reset the lockout feature by turning the
emergency transfer control switch to off. The operator will then manually attempt
to restore whatever equipment is necessary to give a normal or emergency feed.
Rev. No. : 02, Oct. 2008
d. “5231-DG-1 OR CB-7 NOT AVILABLE” CRT ANN-2224. This annunciation is

initiated by either relays 8P or 9P and indicates that either diesel generator or CB
–7 is not ready for emergency transfer.
e. “5231-DG1 OR CB-7 FAIL” WINDOW NO. AN –307. This annunciation is initiated

by either relays 6P or 12P and indicates that either DG-1 or CB –7 fails to restore
class III bus supply.
f. “ 5231-DG-1 RUNNING & CB-7 OPEN”CRT ANN –2218. This is initiated by relay
10P and indicates that DG –1 is started; voltage and speed are building up and
ready to close CB –7.
g. “5231-CB -`19 NOT AVIALABLE” CRT ANN –2228. This is initiated by relay
32XP and indicates as that CB –19 are not ready for emergency transfer.
h. 5231- BU—P&S RESTORATION FAILS” WINDOW NO. 312. This is initiated by

relay 17 P and indicates that III feeder restoration is not complete due to failure of
restoration timers.
5.0 TEST FAXILITY :
The test equipments is provided to test the emergency transfer logic even during the
plants is in operation. The hand switch HS 7030, push buttons PB-7031 and PB –
7030 and indicating lamps LT –7028 LT 7031 are provided on emergency panel to
conduct-testing for bus ‘P’ and ‘S’.
5.1 TEST PROCEDURE
The control switch Hs –7031 in control room PL-2 is to be kept in ‘OFF’ Position and
HS –7030 in test panel in TEST Position Control switch HS-7030 in test position
isolates trip impulse going from emergency transfer equipment for breakers 5231-
CB-1, 3. 7, 19 & 5 of bus ‘P’. As an additional safety blocking switches BS –the
70227, 7029, 7030, 7031 shall be kept open to block the trip impulse going to above
breakers from emergency transfer equipment.
Additional blocking switches BS-7020, 7022, 7023 are provided on DG1 start 5231-
CB-7 close, CB-19 close, CB-5/6 close circuits. These blocking switches shall be
kept open if desired operation is not required during testing. BS-7018 shall be kept
open so as to prevent emergency transfer of bus ‘Q’ Amber lamp LT-7028 will
indicates control supply available and emergency transfer operation is blocked.
Now pressing the PB –7030, EMTR initiate relays 1P1 & 1P2 will energise and
initiates transfer events if DG1, CB –7, CB –19, CB –5 ready to start relays are
energized (i.e. 8P, 9P, 32XP, 14P, 5P to DG-1 and DG-3 and 5Q to DG-2 and DG-3
blanking switch is in service. 10P energise to indicate that DG-1 or DG-3 speed and
voltage bult-up to desired level). In such case DG1, DG-2, DG-3 start impulse is
given by relay.
Rev. No. : 02, Oct. 2008

Energisation of relay 10P will initiate restoration timers and operation of these timers
can be checked.
Other relay operation can be checked individually if required by shorting at

necessary terminals at out going impulse points. This will ensure all wiring with in the
panel is in the desired state.
A stop push button PB-7031 is provided to stop the test sequence in between if
required.
6.0 SYNCHRONISING Ref. NAPP-1/6230/60122/ED to 6016 ED)
Manual synchronizing facility is provided for various 220 KV, 6.6KV and 415V
breakers . Selection of the breakers for manual or semi automatic synchronizing is to
be done by operator by pressing key operatedpush button provided near breaker
control switches on the control panel. These breaker selection push buttons are key
operated type to ensure that one breaker is selected at a time. Further electrical
interlock is provided in the scheme to ensure that only one breaker selected at a time
for synchronizing.
6.1 MANUAL SYNCHRONISING
6.1.1 The following 220 KV circuit breakers are provided with manual synchronizing
facility.
513-CB-4 (Line –1Moradabad)
513-CB-6 (Line –2 Shimbholi)
513-CB-7 (Line –3 Khurja 1)
513-CB-8 (Line –4 Khurja2)
513-CB-11 (Line –5 Atrauli)
513-CB-1 (Bus coupler breaker between BU-B & BU –C)
513-CB-10 (Bus transfer breaker)
513-CB-2 Main Generator-1
513-CB-9 Main Generator-2
6.1.2 The following 220KVbreakers are not provided with synchronising facility
513-CB-3 (SUT-1)
513-CB-5 (SUT-2)
6.1.3 The following 6.6KV breakers are provided with manual synchronizing facility to be
used for transfer of 6.6KV auxiliaries from unit to start up transformer or vice versa
5241-CB-16 (incoming from unit Transformer)

5241-CB-17 (Bus section breaker)
5241-CB-34 (SUT breaker to Bu-G)
Synchronizing facility has been provided for these breakers only as extra safety
measures since the two supplies, which are to be paralleled, will always be
synchronism due to proper vector group selection of the transformers.
Rev. No. : 02, Oct. 2008

6.1.4 The following class II, class III, are provided with manual Synchronizing facility :-
5231-CB-1 (Incomer to BU-P from Transformer 5231-TR-1)

5231-CB-3 (incomer to BU-P from BU-J)
5231-CB-7 (DG-1Breaker to BU-P)
5231-CB-5/6 (tie breaker to BU –P&Q)
5231-CB-2 (incomer to BU-Q from transformer 5231–TR–2)
5231-CB-4 (Incomer to BU-Q from BU-J)
5231-CB-31 (DG-2Breaker to BU-Q)
5231-CB-19 (Class III to class II tie for BU-P to BU-S)
5231-CB-34 (MG-1 Breaker to BU-S)
5231-CB-32/33(tie Breaker between BU-S&BU-T)
5231-CB-20 (Class III to Class II tie between BU-Q and BU-T)
5231-CB-47 (MG-2 breaker to BU-T)
CL-IV, 415V supply breakers are not provided with synchronizing facility.
6.2 SYNCHRONISING EQUIPMENT
Manual synchronizing is carried out from control room. The 220 KV lines, bus
transfer and coupler are controlled from 6610 –PL-7 in the Control room. The main
generators, unit transformer, diesel generators and motor generators sets are
controlled and synchronized from panel 6610 –PL –2. Each of these panels are
provided with the following
(a) Two voltmeters one for incoming and one for

running.
VM-7&VM-8 for 6610-PL-7
VM-50& VM-51 for 6610-PL-2
(b) Two frequency meters one for incoming and one for running.
FM-7&FM-8 for 6610-PL-7
FM -11 &FM-12 for 6610-PL-2
(c) One Synchroscope
6500-SYNCHR-1for 6610-PL-7
6500-SYNCHR-2 for 6610-PL-2
(d) One selector switch for synchronizing mode selection (manual
semi auto)
HS-7015 for 6610-PL-7
Hs-7014 for 6610-PL-2
(e) One push button per breaker, which is lockable with a common
key for mechanical interlocking.
(f) One green LED per breaker which indicates breaker selected for
synchronized.
(g) One push button for bypassing contracts of synchronizing check
relay , if required .
(PB-7019 for6610-PL-7)
(PB-7018for 6610-PL-2)
Rev. No. : 02, Oct. 2008

(h) Two push buttons on 6610-PL-1 for by passing interlocks of machine

selector relays of DG1 and DG2 (PB-7033 and PB –7034)is provided in
6610 –PNL-2 to reset the bypass circuit and being back the interlocks
6.3 SYNCHRONISING SCHEMS
6.3.1 MANUAL SYNCHRONISING
Manual synchronising arrangement is explained by the following description of

synchronising procedure of 220 KV Line –1 (513-CB –4) as a typical example (Dwg.
No. 65230/6013 Sh 1&2 and 65230/6012).
1. Put selector switch HS –7015 9synchronisation mode selection switch) in

“Manual “ Position.
2. Selection CB-4 for synchronization through key operate push button PH B-

7021. Relays 6513-25, 25X&25Y of the breaker pick up and seal themselves.
NC contact of 25x relay provides for the electrical interlock by cutting DC
supply to 25 ‘25x &25Y relay of other breakers
3. a) Relay 6513-CB-4-25Y provided following function :-
i) Potential of 514-L-1 from 513-CVT-1 through auxiliary PT:-

6523-PT-1 to the “incoming “ bus of the synchronizing System.
ii) Potential of 513-BU-C(or BU-B) from 513-VT–1(or 513-VT-2)
through auxiliary PT-6523-PT-8 (6523-PT-7) through respective
main bus isolator auxiliary contact DS –15-33a (or DS-14-33a)
to be running bus of the synchronizing system.
iii) Permits 513- CB –4 closing through ‘3C’, if synchro-check relay
(6523-25-M5) permits.
b) Relay 6513-CB-4-25X provides following function: -
i) Relay 6523-25-3M –1 through contact of HS-7015.

ii) Resets the synchronising circuit through Relay 6523-25-R1 once
the breaker 513- CB- 4 Closes.
4. Relay 6523-25-3M-1 switches:

The voltmeter, frequency meters, synchroscope and synchronisng check relay
of panel 6610 –PL-7 to the running and incoming bus ((See Drg.65230/6012).
5. The necessary speed and voltage adjustments of the BU-C or BU-B can be
done by adjusting the speed and voltage of the connected generator.
Duplicate controls for adjusting speed and voltage of generators are provided
on 6610-PL-7 for purposes.
Rev. No. : 02, Oct. 2008

6. When systems are in synchronism as seen on the synchroscope the Control

switch of 513-CB-4 should be turned to close position to close the breaker.
7. Synchronizing check relay 6523-25-SYN-1 ensures that the phase angle
difference between the two system are not large this relay energies relay
6523 -25-M-5 &6 which permits closing of breaker.
1. Closing of the breaker 513-CB-4 would initiate reset relay 6523-25-R1 to pick
up through contacts of 6513-CB-4-25Xand 6513-CB-4-52ax contact. Relay
6523-25-R1 resets relay 6513-CB-4-25 25X, 25Y by the opening of ‘NC’
contact. These in turn remove the PT supplies to the incoming and running
bus bars. Resets relay 6523-25-3M-1 and cuts off supply to the indicating
lamp LT-7018.
2. Incase the synchronizing is to be stopped in between. Reset push button PB-
7027 on the panel should be pressed to operate reset relay 6523-25-R1
mentioned in (8)above.
6.3.2 DEAD LINE CHARGING
Since check synchronising relay interlock is provided in the closing circuits of all the
above-mentioned breakers, it will not be possible to close any of the breakers when
the bus or line associated with the breakers is not energized from any other source.
In this case, one of the PT supply to the synchronising scheme will be absent. For
such cases where dead line /bus charging is required, provision has been made for a
bypass switch to bypass synchronising check relay and close the breaker through
manual synchronising circuit. The operator should ensure dead line or bus condition
for such a bypass selection.
However, in the scheme there is a voltage check interlock to prevent bypass

operation If both running and incoming voltage are available when synchronizing is
selected. Push button PB-7019 is provided on panel on 6610-PL-7 for bypassing
check synchronising. This energizes 6523 –25-BY-1 which seals itself which seals
itself. A contact of 25BY-1 bypass contact of synchronising check relay in the circuit
of 6523 –25-M5 &M6 relays and permits closing of the breaker. Similarly PB-7018 is
used for panel 6610-PL-2.
6.4 ANNUNCIATTIONS (On Control Room 6610-PL-1 &7)
The following annunciations are provided
(1) Auto synchronizing failed (An-320 )

(2) Syncheck relay bypass (An –321 on PL-1)
(3) Syncheck relay bypass (An –322 on PL-7)
7.0 LOAD SHEDDING SCHEME
The purpose of the load shedding circuits is to detect an unusual condition which
may follow a partial or total loss of class –IV power failure where by total class –III
Rev. No. : 02, Oct. 2008
and class –II loads on each of Bus ‘BU-P and BU-Q exceed the capability of the total
power available from class –IV or diesel generator sets.
Once such a condition is detected, the load shedding circuits then operates to
reduce the class –III loads to a level, which is with in the capacity of power supply.
Only loads, which are non –essential to the safety of the plant, are allowed to drop.
Loads shedding once initiated remains in effect until reset by operation action when
two sources of supply are available. The power supply referred to include the normal
supply transformers to class –III from 6.6 KV class–IV, supply (5231-TR-1,2) CL-IV
transfer bus ( BU-J) supply (5242-TR-1) and emergency diesel generators (5231-
DG-1,2, & 3).
The automatic load shedding is initiated when number of power in feed to class –III
system is less than two (i.e. system will be initiated if there is only one transformer or
one diesel generator supplying the complete class –III and class –II system).
7.1 DESCRIPTION
7.1.1 GENERAL:-
Refer to Drg. NAPP1&2/65230/6010/ED for logic diagram for load shedding

scheme.
The initiating circuits for load shedding are duplicated (for example LS –3A1, LS-3A2
and LS-3B1 LS-3B2 etc.). For general, both the duplicate relays must actuate for
loads shedding to occur since a combination of the out puts of these two relays are
taken to various loads. For important auxiliaries trip signal consists of normally close
contacts of A and B relays mentioned above in series. This is done to achieve both
‘fail safe’ and process safe’ feature. However, for other less important auxiliaries,
only normally close connected of one relay is used in trip circuits.
The DG set has a two-hour capacity of 1750KW and the supply transformers have
2000 KVA rating.
Total –Maximum estimated operating load on the class III bus bars after load
shedding is effected is 1600KW (ECC COND). This does not include the loads due
to operation of various valves in class –III system as these loads will occur for short
time during closing or opening.
7.1.2 BRIEF DESCRIPTIONS OF SCHEME (Drg. NAPP 1,2 /65230/6011/ED)
Relay LS1-1 (LS-1-2) is intended for supervising the availability of class –III supply
through normal CL-IV route. It is energized as long as one of the following conditions
are met
This is monitored by closed position of the circuit breakers 5242-CB-1, 5231-CB-3or

5231-CB-4.
Rev. No. : 02, Oct. 2008

(i) Cl-III buses are charged through transfer bus (Bu-J) for is monitored by close
condition of 5242-CB-1, 5231-CB-3 or 5231-CB-4.
(ii) Class-III supply is though transformer 5231-TR-1 is available. This is monitored
by position of breaker 5231-CB-1.
(iii) Class-III supply through transformer 5231-TR-2 is available. This is monitored
by position of breaker 5231-CB-2.
Energization of LS –2-1(LS-2-2) will initiate annunciations “loads shed reset

permitted “ annunciation (AN –2230) in the control room. Operation of the reset PB-
7035 by operator would energies all the load shed relays LS-3A-1 (LS-3A-2) to LS-
14A-1 (LS14-A2) relay thus resetting load shedding. Any subsequent loss of one of
the sources of power supply will cause load shedding to take place through ‘NC’
contacts of the load shedding relays.
Load shedding relays LS- 5A, 5B, 6, 7A, 7B and 8 are intended for shedding FM
vault coolers and relays LS-9 and LS-10 are intended for shedding End shield
cooling pumps have additional interlocks in their circuits as shown in the drawing.
Incase the load on DG set exceeds its 2 hour rating for more than 2 hours, relay LS-
4 initiates an alarm (AN-301) through timer LS-4-1. At this juncture, the operator has
to manually shed loads further to reduce the load on the DG to its eight-hour
capacity.
7.1.3 LOADS SELECTED FOR SHEDDING
(1) 3211-PM-1, 3 and 5 (Moderator Circulating Pump)

One moderator pump shall always be available, 3212-PM-5 is never shed.
3211-PM-1 and 3211-PM-3 are tripped and inhibitated from starting by load
shedding relays. If 3211-PM-5 is not in service then 3211-PM-1 or 3 should be
available.
(2) 3341-PM-1 & PM-2 (PHT Stand By Cooling Pump)
One pump is required to run under HSD and CCD conditions. Contacts of LS-
3E1 and LS-3E2 are connected in series for tripping PM –1 those of LS-3D1
and LS-3D2 for PM 2. The 48 V scheme logic for pumps shall be such as to
have at least one pump running or to inhibit start of the second pump if one
was already running before load shedding.
(3) 3411-PM-1, 2,3 (End shield cooling Pumps)
One pump should always be running 3411-PM-3 is not Provided with load
shedding PM-1 is shed by LS-9 relay and PM-2 by LS10 relay.
(4) 7134 –PM-1, 2 (HPPW Pump non-active)
Only one pump is required to be run in under single DG conditions. Relay LS
11A, 11A-2 and LS 12A-1, 12A-2 to used load shed 7134-PM-1 and PM-2
respectively
Rev. No. : 02, Oct. 2008

(5) 7510 CPM2 & 3 (AIR COMPRESSORS)
ONE compressor is required to run HSD and ECC conditions. Relays 3C1 &
3C2 and 3Q1, 3D2 relay to 7510-CPM-3.
(6) 7120 F1 to F4 (IDCT fans)
All four fans can be shed under one DG conditions contact of relays 11B1,
11B2, 12B1, and 12B2 are used for fans 1 to 4 respectively. More over key
operated switches is provided in control room for each fan to run if required in
load shedding condition.
(7) 3251 PM 1& 2 (Moderator Leakage collection Pump)
Both Pumps can be shed under one DG conditions. Contacts of LS-11A1 &
11A2 relays are provided for PM-1 & PM 2 respectively.
(8) 3521 PM 7&8 (Oil Hydraulic Power F/M)
Only one Pump is required under ‘CCD’ condition. Contacts of LS –3B1, LS-
3B2. Relays are provided for PM-7 and PM-8 respectively.
(9) 3521-PM-3 (F/T Water Transport Pump)
This Pump can be shed under one DG condition. Contact of relay LS-14-A-1
is provided for this.
(10) 4321-PM-3 &17 (Aux Condensate Extraction Pump)
One pump is required under ’CCD ‘ conditions contacts of LS-11A-1 and 11A-
2 relays are used for PM-3 and PM-17 respectively.
(11 ) 5353-CP-1 (Heat traces for HSD tanks and Piping)
This Load can be shed under one DG conditions. Contacts of LS-13A-2 is

Provided for this.
(12) 3525-PM-11A&11B (F/M vault Doors Ross Oil Power Pack)
One Pump may be required to run (for a short time only )in CCD conditions .
Contacts of relayLS-14-B –1 and LS3G –2 are provided for PM –11A and PM-
11B respectively.
(13) 3525-PM-10A and 10 B (F/M services area oil power Pack)
One Pump may be required to run (for a short time only) In CCD
conditions Contacts of LS -14- B1 and LS –14B2 are provided for PM-10A
and 10 B respectively.
Rev. No. : 02, Oct. 2008
(14) 3522-PM-3A and 3 B (F/M Bridge Drive power Pack)
Both Pumps are not required under one DG conditions. Contacts of LS –3C –
1 and LS-3E2 are provided for PM-3A and 3B respectively.
(15) 7311 –FM-20, 21 and 23 (Pumps room cooling units)
One fan motor is required to be run under one DG conditions FM-23 is not
load shed contacts of LS 13A1 and 13 A2 relays are provided in series for
FM-20 and LS –13B1 & 13B2 relays are provided in series for FM-21.
(16) 7322-FM-72and 73 (Make up air fan for control room)
One fan is required to run under ‘ CCD’ Conditions Contacts of LS-11B1 and
11B2 relays are provided FM 72 and 73.
(17) 7322 FM 44 and 45 (Fan supplying air to Battery room & switch gear Panel
Rooms)
Both fans can be tripped under one ‘DG’ conditions. Contacts of LS –12B1
relays are provided for FM-44& FM 45 respectively.
(18) 7323 AHU 1,2,4, &5(AHU for Control room)
All AHU ‘s can be tripped under one DG conditions Contact ofLS-13B1, 13B2,
11B1 and 11 B2 are provided for AHU 1,2,4, and 5 respectively.
(19) 7322 AHU 8 & 16 (AHU for Control Maintenance shop)
One AHU is required under CCD condition contacts of relays T/B-1 and LS-
11B2 are provided for AHU-8 and AHU-16 respectively.
(20) 7510 FM 1 &2 (Air Dryer Blower)
Both blowers can be shed under ‘ one DG’ condition. Contacts of relays LS-
12A-1 and LS-12A are provided for FM 1 and FM –2 respectively
(21) 7510 HR 1 and HR2 (Ai r Drying Plant Heater)
Both heaters can be shed under one DG conditions. Contacts of relays LS –

12A–1 and LS 12A –2 are provided for Heater 1 and 2 respectively.
(22) 7312 FM 1, 2, 3, 4, 5 and 6 (FMV cooling Units –North)
7312 FM 11, 12, 13, 14, 15 and 16 (FMV Cooling Units –South)
Rev. No. : 02, Oct. 2008

Four fans should be running, two for north and two for south vault. FM-5 and
FM –6 of the north and FM 11 and FM 12 of the south are not load shed.
Allocation of L.S. relay contacts is as follows for the rest of the units
FAN MOTORS CONTACT

7312 FM 1 LS 5A
7312 FM 2 LS 5B
7312 FM 3 LS 6
7312 FM 4 LS 6
7312 FM13 LS 7A
7312 FM 14 LS 7B
7312 FM 15 LS 8
7312 FM 16 LS 8
7.1.4 BASIS FOR SELECTION OF LOADS FOR SHEDDING
The above mentioned load shedding arrangements are made based on the load
schedule for load shedding scheme, a copy of load shedding scheme is included in
the Annexure –2. Whenever main and stand by pumps are identified in this
scheduled, the 48 V DC schematics of respective auxiliaries should ensure that main
and stand by do not run simultaneously further the logic schemes should also ensure
that minimum requirements under ‘HSD’ ‘CCD’ and ‘ECC’ Conditions are met with
the drop from load shedding does not violate these requirements.
7.1.5 ANNUNCIATION
Following Annunciation are provided in the control room for load shedding scheme
1) AN-311-Load shed operating (Window ANN)

2) AN-2230-Load shed reset permitted (CRT ANN)
3) AN-310-Load shed trouble (Window ANN).
4) AN-301-Diesel generator-2 Hrs capacity exceeded (Window ANN).
Rev. No. : 02, Oct. 2008

ANNEXURE – 1
Legend of Relays used in EMTR Scheme
SL. Relay System Inscription

NO Description
6523- BU-P&S EMTR INITIATED
1P1,1P2,1P3
6523-1Q1, BU-Q&T EMTR INITIATED
1Q2,1Q3
6523-3P1 BU-P ISOLATION INITIATED
6523-3P2 BU-P ISOLATION INITIATED
6523-3Q1 BU-Q ISOLATION INITIATED
6523-3Q2 BU-Q ISOLATION INITIATED
6523-8P DG-1 READY SUPERVISION
6523-9P CB-7/CB-70 READY SUPERVISION
6523-10P DG-1 RUN OK INDICATION
6523-11XP CB-7/CB-70 CLOSE INDICATION
6523-11P CB-7 CLOSE INITIATION
6523-12- CB-7/CB-70 FAIL INDICATION
P,12XP
6523-13XP CB-5 CLOSE INDICATION
6523-14P CB-5 READY SUPERVISION
6523-5P DG-1/DG-3 START INITIATED
6523- BU-P FEEDER RECL START INITIATION
16XP,16P
6523-33P CB-19 CLOSED
6523-31P BU-P FEEDER RECL COMPLETE
INDICATION
6523-8Q DG-2 READY SUPERVISION
6523-9Q CB-31/CB-70 READY SUPERVISION
6523-10Q DG-2/DG-3 RUN OK INDICATION
6523-11XQ CB-31/CB-70 CLOSED
6523-11Q CB-31 CLOSE INITIATED
6523- CB-31/CB-70 FAIL INDICATION
12Q,12XQ
6523-13Q CB- 6 CLOSE INITIATION
6523-13XQ CB- 6 CLOSE INDICATION
6523-14Q CB- 6 READY SUPERVISION
6523- BU-Q FEEDER RECL START INITIATED
16XQ,16Q
6523-33Q CB-20 CLOSED INDICATION
Rev. No. : 02, Oct. 2008

6523-31Q BU-Q FEEDER RECL COMPLETE

INDICATION
6523-5Q DG-2 / DG-3 START INITIATED
6523-32XP CB-19 READY SUPERVISION
6523-32XQ CB-20 READY SUPERVISION
6523-2XP EMTR INCOMPLETE INDICATION
6523-6P DG-1/DG-3 FAIL INDICATION
6523-2XQ EMTR INCOMPLETE INDICATION
6523-6Q DG-2/DG-3 FAILED INDICATION
6523-2P EMTR INCOMPLETE TIMER
6523-2Q EMTR INCOMPLETE TIMER
15P, 15P1 BU-P ISOLATION SUPERVISION
15Q, 15Q1 BU-Q ISOLATION SUPERVISION
6523-17P BU-P FEEDER RECL INCOMPLETE
INDICATION
6523-17Q BU-Q FEEDER RECL INCOMPLETE
INDICATION
6523-32Q CB-20 CLOSE INITIATION
34P DG-1/CB-7 FAIL TIMER ( DG-3 / CB-70)
34Q DG-2/CB-31 FAIL TIMER( DG-3 / CB-70)
6523-4P BU-P SUPPLY & TIE CB'S TRIP IMPLUSE
LIMITATION
6523-4Q BU-Q SUPPLY & TIE CB'S TRIP IMPLUSE
LIMITATION
35P CB-31/CB-6 READY FOR AUTO SYN.
35Q CB-5/CB-7 READY FOR AUTO SYN.
36P SUPPLY ROM BU-Q CAN BE RE-
ESTABLISH
11P1 / 11PX CB-5/CB-70 CLOSE INITIATION
11Q1, 11QX CB-6/CB-70 CLOSE INITIATION
10YP DG-1 RUN OK INDICATION
10YQ DG-2 RUN OK INDICATION
10ZP DG-3 RUN OK INDICATION
10ZQ DG-3 RUN OK INDICATION
8PX, 8QX DG-3 READY SUPERVISION
6523-7P DG-1 / DG-3 / FAIL TIMER
CB-7 / CB-70
6523-7Q DG-2/DG-3 / FAIL TIMER
CB-31/CB-70
6XP DG-1/DG-3 FAIL TIMER
6XQ DG-2/DG-3 FAIL TIMER
18P to 29P FEEDER RESTORATION TIMER
18Q to 29Q FEEDER RESTORATION TIMER
Rev. No. : 02, Oct. 2008

ANNEXURE - 2
415V, AC CL-II/III LOAD SCHEDULE FOR LOAD SHEDDING SCHEME
SL EQUIPMEN USI TAG NO. SUPPL UNIT/ ONE DG LOAD SHEDDING

N T Y OP CONDITION KW SCHEME
O. DESCRIPTI LOA OPERATING
ON D LOAD WITH
(KW) EFFICIENCY
HSD CCD ECC
1. MODERAT 3211 PM-1 III 130 137 137 137 Load shedding (LS)
OR contact provided
CIRC 3211 PM-3 --- 63200/2003
PUMP
3211 PM-5 123 No LS contact
required.
2. HPPW 7133 PM-1 III 90 150 225 150 Instt. Logic ensures
PUMP 2 motors
ACTIVE 7133 PM-2 --- Running under
HSD/ ECC AND 3
7133 PM-3 70 motors under CCD
condition.
7133 PM-4 No LS contact
required.
7133 PM-5
3. AIR 7510 CPM-3 III 112.5 111 --- 111 LS contact provided
COMPRES for 1
SOR Motor logic shall
ensure tripping of
7510 CPM-2 100
compressor
under CCD
condition.
4. PHT 3341 PM-1 III 90 90 90 --- LS contact provided
STANDBY 3341 PM-2
COOLING
PUMP
5. AUXILIARY 4321 PM-18 III 90 85 85 85 1N+1S (SEE
BFP 4321 PM-8 77 NOTE-I)
(STANDBY)
Rev. No. : 02, Oct. 2008

6. F/M 3525 PM-1 II 85 147 147 --- 1N + 1S, Instt

SUPPLY group shall build
PUMP logic to trip under
MOTOR 3525 PM-1 ECC
condition (SEE
NOTE-I)
7. ECC 3335 PM-1 II 120 --- --- 265 2N+2S (SEE
PUMP NOTE-I)
MOTOR 3335 PM-2
3335 PM-3
3335 PM-4
8. HPPW 7134 PM-1 III 150 147 147 147 LS contact

PUMP provided
(NON 7134 PM-2 ---
ACTIVE)
85
9. EMERGE 7125 PM-3 III 120 121 121 121 1N + 1S (SEE
NCY PW NOTE-1)
COOLING 7125 PM-4 ---
PUMP
110
10. I.D. 7120 F-1 III 97 --- --- --- All load shed
COOLING since the temp
TOWER 7120 F-2 rises only to
FANS about 40 deg. C.
as per M/s
7120 F-3
DCPL. This is
agreed
7120 F-4 by ED ®
67120/2006.
11. F/T 3521 PM-1 II 37 58
HEAVY
WATER
CIRCULA 3521 PM-2
TION
PUMP
Rev. No. : 02, Oct. 2008

12. EMERGE 5310 ELC- II 55 78

NCY 143
LIGHTING 5351 ELC-
PANEL 144
13. DISEL 5351 PM-1 II 0.56 --- Trip when D6
PRE-TUBE start 65351/6001
OIL PM-2
PUMP
14. DIESEL 5353 PM- II 5.5 --- (SEE NOTE-2)
FUEL 2001
TRANSFE PM-
R 2002
PUMP PM-
2003
15. 48V D.C. 5232 SBC-I II 2.82 ---
STANDBY
BATTERY 5232
CHARGER
16. 412-61 4120 --- II 3.5 5.0
STATIC
EXCITATI
ON 4120
SYSTEM
AUX.
SUPPLY.
17. F/N HEAD 3522 PM-1A II 11.2 23. 2N+2S (SEE
DIL 5 NOTE-1)
HYDRAULI 3522 PM-2A ---
C POWER
PACK 3522 PM-1B 7.5
3522 PM-2B
18. FANS 7322 FM-16 II 2.2 14. ALL operating
EXHAUSTI 2
NG FM-17
AIR FROM
N.G. FM-18
SET
ROOM FM-19
Rev. No. : 02, Oct. 2008

19. FANS 7322 FM-10 II 0.18 0.5 ALL operating

EXHAUSTI 6
NG
AIR FROM
7322 FM-11
CONTROL
N. S.
ROOM
20. REGULATI 3131 PM- III 0.18 0.8 ALL operating
NG ROD
MECH.
LUBE
PUMPS
21. SHIN ROD 3133 PM- III 0.8
MECH.
LUBE
PUMP
22. MECH. 3135 GR-1 III 1.5
SHUT-
OFF ROD
SYSTEM
POWER 3135 GR-2
SUPPLY
GROUP 1
&2
23. HELIUM 3231 PM-1 III 3.0 3.4 1M+1S (SEE
CIRCULAT 3231 PM-2 NOTE-I)
ION
BLOWER
24. HEAVY 3251 PM-1 III 15.0 --- LS conatcts
WATER provided
LEAKAGE
COLLECTI 3251 PM-2
ON
PUMP
25. PHT 3371 PM-1 III 22.0 --- (SEE NOTE-2)
HEAVY
WATER 3371 PM-2 ---
LEAKAGE
COLLECTI
ON 18.5
PUMP
Rev. No. : 02, Oct. 2008

26. END 3411 PM-1 III 45.0 41. LS contacts

SHIELD 0 provided.
COOLING 3411 PM-2
PUMPS
3411 PM-3
27. ALPAS 3481 PM-1 III 0.75 0.8 1M + 1S (SEE

ADDITION 5 NOTE-1)
PUMP 3481 PM-2 III 0.75
28. F/T 3533 PM-5 III 1.5
ACTUATO
R FOR
FUEL
29. OIL 3521 PM-7 III 10.0 11. LS contact
HYDRAULI 0 provided
C
3521 PM-8
POWER
F/M
30. F/T 3521 PM-3 III 22.0 --- LS contact
WATER provided
TRANSPO
RT PUMP
31. BARRING 4114 XM-1 III 7.5 7.5
GEAR
DRIVE
32. A/C 4113 PM-2 III 30.0 33. DC seal oil pump
FLUSHING 5 is standby
OIL
PUMP
33. A/C SEAL 4134 PM-1 III 7.5 8.5 DC flushing oil
OIL PUMP pump is standby
34. JACKING 4135 PM-1 III 5.5 5.6
OIL PUMP
35. AUXILIAR 4321 PM-3 III 18.5 16. LS contact
Y 5 provided
CONDESN PM-17 ---- 64321/2007
ATE
EXTRACTI 15.0
ON PUMP
36. LUB OIL 4321 PM-15 III 0.75
PUMP
FOR
PM-16
AUX. BEP
4321-P18
Rev. No. : 02, Oct. 2008

37. LUB OIL 4321 PM-19 III 0.75

PUMP
FOR
4321 PM-20
AUX. BEP
4321-P18
38. MG SET 5231 M-1 III 0.37
PONY
MOTOR
M-2
39. FIELD 5232 FLD- III 15.0
PANEL
11.0
40. STANDBY 5232 RC-3 III 100.0 Standby to
BATTERY ACVR and
CHARGER annually
operated
41. 412 61 4120 III 10
FIELD
FLASHING
SUPPLY
42. DIESEL 5350 FM-1 III 0.56 0.6 FN1 & FN2 run
CRANK when DG1 &
CASE DG2 run
EXHAUST respectively
FAN
MOTOR
43. DIESEL 5350 HR-1 III 12.0 Trip when DG
LUB OIL starts considered
HEATER HR-2 Not to be
as DG loads
44. DIESEL 5350 HR-1 III 9.0 Trips when DG
JACKET starts
WATER Not to be
HEATER HR-2 consider as DG
Loads
45. DIESEL 5353 CPM-1 III 3.7 Trips when DG

STARTIN CPM-2 starts (Not to be
G AIR considered as
compresso DG loads)
r
Rev. No. : 02, Oct. 2008

46. HEAT 5353 CP-1 III 50.9 LS contact

TRACERS provided
FOR
HSD
(18.5)
TANKS
AND
PIPING
47. HEAT 5353 CP-2 III 15.31 5.0 CP3 to be
TRACERS shifted to unit-2
FOR CP-3 --- because it is
HSD meant for unit-2
TANKS 4.86 DG sets
AND
PIPING
48. FN VAULT 3525 PM- III 11.2 5.5 (SEE NOTE-2)
DOOR 11A
ROS PM- ----
DIL 11B
POWER
PACK
4.5
49. F/M 3525 PM- III 7.5 12.
SERVICE 10A 0
DRIVE PM- ---
POWER 10B
PACK
4.5
50. F/M 3522 PM-3A III 37.3 LS contacts
BRIDGE provided
DRIVE
PM-3B
POWER
PACK
51. PUMP 7311 PM-19 III 7.5 12.
ROOM 0
COOLING PM-22 ---
UNIT
5.6
52. PUMP 7311 FM-20 III 7.5 5.0
ROOM 7311 FM-21 ---
COOLING
UNIT 7311 FM-23 4.5
Rev. No. : 02, Oct. 2008

53. RB 7314 F-2000 III 37.0 26. 1M+1S (SEE

SECONDA 0 NOTE-1)
RY 7314 F-2001 ---
CONTAIN 19.5
MENT
ANNULAR
PURGE
FAN
54. RB 7316 FM-1 III 3.7 4.1 1M+1S (SEE
SECONDA NOTE-1)
RY
CONTAIN
7316 FM-2
MENT
ANNULAR
FAN
55. RB 7315 FM-1 III 3.7 8.0
PRIMARY
CONTAIN FM-2 3.7
MENT
FILTERATI
FM-3 3.7
ON AND
PUMP
BACK FM-4 3.7
FANS
56. RB 7316 F-2000 III 15.0 16. 1M+1S (SEE
SECONDA 5 NOTE-1)
RY F-2001 ---
CONTAIN
MENT
EXHAUST 11.0
FAN
57. MAKE UP 7322 FM-72 III 3.75 4.1 LS contacts
AIR FAN provided
FOR 7322 FM-73
CONTROL
ROOM
Rev. No. : 02, Oct. 2008

58. FANS 7322 FM-12 III 11.0 20. NO ls

EXHAUST 0 required as
ING 7322 FM-13 11.0 fans operate
AIR only when
FROM DG operates
DIESEL 7322 FM-14 11.0
GENERAT 7322 FM-15 11.0
OR ROOM
59. FANS 7322 FM-20 III 1.5 2.4
EXHAUST
ING 7322 FM-21
AIR FROM
7322 FM-22
RECTIFIE
R 7322 FM-23
ROOM
60. FANS 7322 FM-24 III 2.2 1.3
EXHAUST 5
ING
AIR FROM
COMPRE 7322 FM-25
SSED AIR
PLANT
AREA
61. FAN 7322 FM-30 III 0.37 0.5
EXHAUST
ING AIR 7322 FM-31
FROM
250V DC 7322 FM-32
CONTROL
BATTERY 7322 FM-33
ROOM
62. FAN 7322 FM-36 III 0.18 0.1
EXHAUST 2
ING AIR
FROM 7322 FM-37
48V
BATTERY
ROOM
Rev. No. : 02, Oct. 2008

63. FANS 7322 FM-38 III 0.75

EXHAUST
ING
AIR FROM
SWITCH
GEAR
(CL-II_
ROOM
64. FANS 7322 FM-39 III 0.55 0.4
EXHAUST 5
ING
AIR FROM
SWITCH
GEAR
(CL-II)
ROOM
65. FANS 7322 FM-40 III 0.55 0.9
EXHAUSTI 0
NG 7322 FM-41
AIR FROM
250V 7322 FM-42
POWER
BATTERY 7322 FM-43
ROOM
66. FAN 7322 FM-44 III 9.3 LS contacts
SUPPLYIN provided
G AIR
TO
BATTERY
ROOM 7322 FM-45
& SWITCH
GEAR
PANEL
ROOM
67. FAN 7322 FM-63 III 0.375 0.2
EXHAUSTI 5
NG AIR
FROM 48V 7322 FM-64
BATTERY
ROOM
68. AHU FOR 7322 AHU-1 III 1.0 1.0
DG
CONTROL
PANEL
ROOM
Rev. No. : 02, Oct. 2008

69. AHU FOR 7322 AHU-1 III 7.50 LS contact

CENTRAL provided
CONTROL 7322 AHU-2
ROOM AHU-3
AHU-4
70. AHU FOR 7322 AHU-3 III .75
COMMUNI AHU-4
CATION
EQPT
ROOM
71. AHU FOR 7322 AHU-6 III 3.75 NO LS As
CONTROL per NAB
MAINT. 7322 AHU-7
ROOM
72. AHU FOR 7322 AHU-8 III 7.5 8.3 LS contact
CONTROL provided
MAINT. 7322 AHU-16
ROOM
73. A/C -- -- III 25.0 20.
PLANT 0
FOR
COMPUTE
R ROOM
74. FANS F0R 7322 F-1 III 0.75 1.5
RECTIFIE 7322 F-2
R
ROOM
75. POWER 7322 --- III 15.0
SUPPLY
TO
EMERGE
NCY 5000
CONTROL
ROOM
76. EMERGE 5000 --- III 10.0
NCY
WALWAY
ELEVATO
R SUPPLY
77. AIR DYER 7510 FM-1 III 5.5
BLOWER 7510 FM-2
78. AIR 7510 HR-1 III 48.0 LS contacts
DRYING 7510 HR-2 provided
PLANT
HEATER
Rev. No. : 02, Oct. 2008

79. SHIPPING 7600 CR-1 III 82.0 Manually

FLASK operated
HANDLIN
G CRANE
(75 T)
POWER
SUPPLY
80. FMV 7312 FM-4 III 11.25 25. LS contacts
COOLING 0 provided
UNITS 7312 FM-5
7312 FM-6
7312 FM-14 LS contacts
7312 FM-15 provided
7312 FM-16
81. FMV 7312 FM-1 III 11.25 25. LS contacts
COOLING 0 provided
UNITS 7312 FM-2
7312 FM-3
7312 FM-11
7312 FM-12
7312 FM-13 LS contacts
provided
82. DC SEAL 4134 PM-2 11.0 Standby to
OIL PUMP AC seal oil
pump
83. DC 4133 PM-3 35.0 Standby to
FLUSHIN AC flushing
G OIL oil
pump
84. CONTROL 6523 MS-1 44.0 72
MG MS-2
MS-3
MS-4
Rev. No. : 02, Oct. 2008

85. FMV 7312 FM-7 III 3.75 17. 4M+4S (SEE

LINER 0 NOTE-1)
COOLING 7312 FM-8
FAN
7312 FM-9
7312 FM-10
7312 FM-17
7312 FM-18
7312 FM-19
7312 FM-20
TOTAL LOAD- 1572.18 (HSD) 1536.18 (CCD) 1600.18 (ECC)
NOTE-1
Instrumentation group shall ensure that main and standby motors do not run
simultaneously.
NOTE-2
These loads do not operate continuously. They are required very occasionally and
run for a very short duration. Therefore, these loads are not considered as DG loads.
Rev. No. : 02, Oct. 2008

CHAPTER - 21
POWER LINE CARRIER COMMUNICATION
(60222)
1.0 GENERAL
Communication between various generating and receiving stations is very essential

for coordinated operation of any power system. Apart from other modes of
communication like telephone system, wireless etc., communication can also be
established through the transmission line, which is known as Power Line Carrier
Communication (PLCC). PLCC has been found to be most economical and reliable
in a power network. For short distances, the ordinary telephone systems are found to
be more economical. This system provides direct & independent communication
between main plant and other substations and load dispatch center of UPSEB grid.
This will be exclusively used for communication in relation to Power Station Training
System Operations and Control. In addition to voice communication, the carrier
system is also used for tele protection and telemetry of the Power System. This
carrier system forms a part of the complete carrier communication system of U.P.
State Electricity Board (U.P.S.E.B.). Data transmission to NERB, Delhi is through
SCADA system which utilizing PLC network of Narora-Moradabad and Narora-
Khurja.
2.0 DESCRIPTION
The carrier communication system is coupled to the 220. KV power lines through
coupling capacitor voltage transformers (C.V.T' S.). Inter circuit coupling has been
adopted for the Narora-khurja double circuit line and inter phase coupling for NAPP-
Atrauli, NAPP-Moradabad and NAPP-Shimbholi single circuit lines. During initial
availing of commissioning power from Harduaganj (Which is now Atrauli line) and
Moradabad, phase to earth coupling is adopted on these single circuit lines as
UPSEB desire to maintain the direct express communication link between
Harduaganj and Lucknow via Moradabad. After installation of filter circuits at Narora
end, inter phase coupling provided on these lines .
The carrier frequency for various channels are given below :-
(i) Narora-Khurja
(ii) Narora-Simboli – 244KH2, 260KH2
(iii) Narora-Moradabad – 324KH2, 336KH2
(iv) Narora-Atrauli
The 48V DC battery and battery charger (2 sets) for the carrier communication are
located NAPS-1 48V DC control battery room ( near ATS-room) at Mezzanine floor.
Rev. No. : 02, Oct. 2008

The battery chargers are fed from receptacle distribution PR-6 located in TB-1
elevation 106m., which in turn is fed from main lighting panel (Class-IV supply.) The
carrier communication panels are located in control equipment room at E1-111 m. of
TB-1.
In PLCC voice, frequency is superimposed on radio frequency signals (know as

carriers) of frequencies between 30 KHz to 500 KHz and transmitted over the
transmission lines. Modern PLCC uses single side band, amplitude modulation
system. Frequency modulation is rarely used because of its considerable bandwidth
requirements.
PLCC components comprise of the following
i) Wave traps or line traps.

ii) Line coupling capacitors.
iii) Line impedance matching unit and protective equipment.
iv) Co-axial cable.
v) PLCC transmitter and receiver equipment.
2.1 WAVE TRAPS
These are high inductive chokes in series in the transmission line terminal at the
power station to block high frequency audio signals into the plant. The wave traps
offer negligible impedance to power frequency currents during normal operation as
well as during short circuit fault conditions but offer very high impedance to R.F.
carrier signals.
XL = ώL
2.2 LINE COUPLING CAPACITORS
These offer low reactance to high frequency given by expression
Xc = 1
ώC
R.F. carrier signal passes through the coupling capacitors to the transmitter/Receiver
set but offer high reactance to 50Hz power frequency signals. Also, since terminal
communication equipments work at low voltage they cannot be directly connected to
high voltage lines and hence suitable coupling devices have to be employed. Instead
of separate coupling capacitor, the CVT's (Capacitor voltage transformer) besides
using for measurement of line voltage and synchronising checks, it is used as
coupling capacitor for PLCC as well, thus reducing the capital cost. Thus, the
combination of wave trap and coupling capacitor effectively allows the power
frequency current to travel the power system network and diverting the radio
frequency waves only to live matching units for carrier communication.
Rev. No. : 02, Oct. 2008

3.3 LINE MATCHING UNIT AND PROTECTIVE EQUIPMENTS
(a) Protective Equipment
Drainage coil serves to ground the power frequency charging current of the capacitor
and allows the carrier frequency signal to appear in the unit. Thus, the person
handling the carrier phone does not get electric shock. Across the drainage coil, a
coarse voltage arrestor and a ground switch are provided. Coarse voltage arrestor
consists of an air gap, which sparks over at about 2.2 KV and protects the matching
unit against line surges, while grounding switch is kept open in normal operation. It is
closed if any work is to be done on communication equipment. This helps to provide
maintenance accessibility to PLCC equipment even at the time when line is charged.
(b) Line Matching Unit
Consists of a matching transformer which isolates the communication equipment

from the power line and it serves to match characteristic impedance of the power line
400-600 ohms to that of the co-axial cable to communication equipment. Matching
transformer is used so that maximum transfer of energy takes place between power
line and co-axial cable to the transmitter/receiver set.
The vacuum arrester, which sparks over at about 250 volts, is provided for giving
additional protection of communication equipment.
2.4 TRANSMITTERS AND RECEIVER
There are two types of carrier transmitter/Receiver equipment
(1) Simplex type

(2) Duplex type
In Simplex system, only one frequency is used for both transmission as well as
reception. Hence, when one station is transmitting, the other station is receiving and
vice-versa.
In Duplex type, two frequencies are used at each end, one for transmitting at a
station and the other for receiving.
2.5 CO-AXIAL CABLE
This consists of two concentric conductors i.e. having a common center, hence the
name. Co-axial cable is used to connect the matching unit with the PLCC equipment.
Since high frequency signals are handled, co-axial cable is used due to less
attenuation of signals. The inner conductor is used for carrying signal while the outer
conductor serves as the return lead, earth and/or shielding.
Rev. No. : 02, Oct. 2008

3.0 TYPE OF COUPLING
There are various ways of connecting the PLCC to the line. Some of which are given
below
(1) Phase to ground coupling.

(2) Two phase coupling.
(3) Phase to phase coupling.
(4) Inter-line or inter circuit coupling (used for double circuit).
Of the above, inter circuit coupling has been used for Khurja line and phase-to-phase
has been used for Harduaganj (Presently Atrauli), Shimbholi and Moradabad lines
Initially. At present phase to earth coupling has been used as UPSEB desires to link
Harduaganj (Presently Atrauli) with Luck now via Moradabad.
4.0 CARRIER PROTECTION
Carrier equipment is not only used for communication purpose, but also used for
protection of transmission lines. Some of the merits of carrier current protection are
given below
i) Fast, simultaneous tripping of breakers at both ends.

ii) Simultaneous auto re-closing of breakers.
Narora is using PLC for inter-tripping of lines on faulty only.
5.0 CARRIER TELEMETERING
Telemeter as the name implies, deals with the technique of transmission of

measurement data so that metered quantity is indicated at a location remote from
the point of measurement. Telemeter of information regarding active power, reactive
power etc. of each generating station, line etc. are very essential for the load
dispatch control. These quantities are transmitted to LDC,NREB by SCADA system
over Narora-Moradabad PLCC network. Following data’s is being transmitted from
NAPS :-
(i) Status of 220KV CB’s (11 Nos.)

(ii) Voltage & frequency at 220KV level.
(iii) Generating power (MW, MVAR) of both units.
Rev. No. : 02, Oct. 2008

Chapter 22
Billing and Metering System
(650000)
1.0 Metering
The metering system having metering for indication and control. Recording metering
and billing metering. Indication metering consists of indicating meters and provides
necessary information to the operator for control action.
Recording metering consists of recording meters. This provides continuous charts
recording of important electrical qualities for statistical purpose.
Billing metering consists of energy meters and printers.
2.0 Indicating Meters
The indicating meters are provided to give indication at any instant of the important
parameters such as amp. Volts, frequency. Vars to the operator in Control Room.
The indicating meters for amp, watts and VAR’s in the Control Room are DC
operated type with their basic movements in the range of 0-5 mA and are suitably
calibrated to read in the required ranges. These meters are fed from corresponding
amp, watt and VAR’s transducers which inturn are connected to the CT’s & PT’s to
measure the primary quantities. However, the voltmeters and frequency meter
directly operate on 110 volt AC.
Following indicating meters are provided in Control Room for 514, L1, L2, L3, L4, &
L5.
Quantity CT/PT Ratio Transducer Meter Calibration
output range
Power (MW) 800/1 1-5mA 100-0-300MW
220KV / 110V
3 3
Power(MVARR) 800/1 0-5 mA 100-0-300 MVAR
220KV / 110V
3 3
Current 800/1A 0-5mA 0-800A
3.0 For 220 kV bus bars
Quantity CT/PT Ratio Transducer Meter Calibration

output range
513-BV-B voltage 220kV / 110V 0-5 mA 0-300kV
3 3
513-BV-C voltage 220kV / 110V 0-5 mA 0-300kV
3 3
Rev. No. : 02, Oct. 2008

4.0 220 kV system synchronizing equipment
1. Bus Voltage Meter (Running)

2. Bus Voltage meter (Incoming)
3. Frequency Meter (Running)
4. Frequency Meter (Incoming)
5.0 Turbo Generator
1. Gen. Power Meter (MW)

2. Gen. Reactive Power Meter (MVAR)
3. Gen. Currant
4. Gen. Power factor
5. Gen. Volt Meter
6.0 Billing Metering
The total energy exported from the Narora Atomic power Station is measured by
summation meters. Two sets of metering by main and check (duplicate sets) are
provided to ensure that metering arrangement is reliable and available at all times
even in case of break down of elements in any one of the sets.
7.0 Export Metering
The currants from C.T. of the generators G1 and G2 are summated in a summation
C.T. which has two primary winding and a secondary winding for the summation.
The output of these summation C.T. secondary is fed to an energy meter ME-WHT-.
This energy meter measures the total MWH generated by generator&2 less the
energy consumed in the U.T. (As the generator C.T. ’s are located on 220 kV side).
The current from C.T. of SUT-1 & SUT-2 are summated in a summation CT and
secondary of Summation CT fed to an energy meter MI –WHT-8.
8.0 Check-I Metering
The check -I metering is identical to main metering.
9.0 Check –II metering
A third set of metering for export and import energy is provided based on entirely
different principle of measurement. The currents in all the five lines are summated in
a summation C.T. provided with five primary windings (one for each line) and a
secondary winding. This secondary winding are connected to two MWH meters (CE-
MWH-II and CI-MWH-12) CE-MWH-II which register active energy exported and CI-
MWH-12 register active energy imported. Similarly reactive energy meters are
connected to the same Summation CT and register export and import reactive
energies.
Rev. No. : 02, Oct. 2008

10.0 Other features
The metering scheme having automatic changeover facility for P.T. supply for 220
kV PTs to the billing meters separate recorders are provided in the billing metering
panel for recording the two 220 kV voltage and frequency.
11.0 Metering Panel
The summation CT’s, MWH & MVARH meters, summators and printers for the billing
metering scheme are located in a separate room in the 220kV Switchyard. Voltage
drops in the PT leads, which will affect the metering accuracy. There are three
separate panels, one for main meters, second for the check meters and third for
construction check metering. The Amp. Transducers, Walt and VAR transducers of
the five lines are also located in the panel for check-2 metering. The meters for the
station power metering are housed in a separate metering panel located in the
control equipment room.
12.0 Energy Meter Reading
Energy Generated = MWH 1 + MWH 2

Energy Consumed = UT 1 + UT 2
Export Energy = Energy Generated – Energy Consumed

Net Energy export to grid = Main export – Main Import
Energy import = SUT1 + SUT2
Capacity factor = Total energy generated

Generating capacity
13.0 Station Power metering
The power generating by two generators G1 & G2 is continuously recorded by the

MW and MVAR meters. These meters are located in a secondary instruments racks
panel.
The electrical energy generated by the two main generators and energy consumed
by the four plant auxiliary bus bars (6.6 kV) are measured by individual watt hour
meters.These watt hour meters are located at station metering panel in control
equipment room.
14.0 SEM ( Special Energy metering system)
L&T make energy meter are provided for GT-1,GT-2,SUT-1,SUT-2 & all 220KV feeders.
There are two energy meter for each. Energy are recorded for a block of 15 seconds.
Rev. No. : 02, Oct. 2008

CHAPTER-23
D2O UPGRADING ELECTRICAL SYSTEM
1.0 SCOPE
The chapter includes description of electrical system and equipment provided for
Heavy Water Upgrading Plant at Narora Atomic Power .
2.0 DESCRIPTION OF THE PLANT
NAPS-1&2 upgrading plant was initially planned for two distillation tower and
fourteen bank of electrolytic bank, however it had been decided to installed two
distillation tower & seven electrolytic bank .It was decided in 1999 to delete all
electrolytic bank, and etc associated storage section, purification section & cleanup
section installed third distillation tower to meet . It was also decided requirement of
up reactor grade D2O from down graded D2O.
3.0 ELECTRICAL DISTRIBUTION SYSTEM
One feeder each from main plant 6.6 KV switchgear of Unit I & II have been used to
feed the upgrading plant auxiliaries as shown in D2O upgrading plant single line
diagram No. NAPP-1/34930/2004/ED. The two sections of D2O upgrading plant 6.6
KV switchgear have to be operated in isolation mode keeping the bus section
breaker CB-3 open. Necessary interlocks have been provided such that only two
breakers out of three breakers (i.e. CB-1, CB-2, CB-3) can be closed at time. The 6.6
KV main feeder cables have been featured for operation to suit maximum current of
580 amps. If at any time load through any feeder increases beyond the above, the
loads have to be reduced manually. From 6.6 KV, switchgear transformer . These
transformer are located near road side at updrading plant building of two nos 2250
KVA, 6.6 KV/433V are fed to supply transformers located in the upgrading plant
building to feed all low voltage load including lighting. The 6.6 KV switchgear also
feeds one no. 1500 KVA, 6.6 KV/433V transformer and two no. 3MVA of 6.6 KV/12
KV transformer located out side upgrading plant building to feed raw water pump
house load and NAPS Town ship, CISF complex lighting load. 415V switchgear
receives power from low voltage side of 2250 KVA transformers three motor control
centers. Isolator (IS-1) is provided between two bus sections. Since individual 2250
KVA transformer is not featureed to meet entire plant load, when only one
transformer is available for service, part of the upgrading plant loads may have to be
shut down to reduce the load. In this event, common services load such as
ventilation fans, control power supply etc. fed from MCCs can be taken through
available bus and bus isolator (IS-1). In normal service, MCC-1 and MCC-2 are fed
by transformer 3493-TR-1 whereas in addition to MCC-3 fed by 3493-TR-2.
Distribution of power to all motor loads, lighting and receptacles, control power
supply etc. are derived from MCC-1,2&3. All electrical loads related to distillation
column no. 1 and other common services are fed from MCC-1 & 2 and distillation
column-2 are fed from MCC-3 . The entire exhaust fan DBs (DB-1 to DB-5) are fed
Rev. No. : 02, Oct. 2008
from MCC-2. Lighting and receptacle panels 3493-PL-7A & 9A are fed from MCC-1,
3493- PL-3, 4, 5, 6, 7B are fed from MCC-2 and 3493-PL-9B & 3493-PL-2 are fed
from MCC-3, toilet and change room, electrical. Similarly, exhaust fan DB-1, 2, 3, 4,
& 5 supply ,of feeder fabrication shop, non active laundry area, laboratory area
respectively. For instrumentation and control power supply 240V A.C., 1 phase 50
Hz. is used through C&I distribution boards. 48V D.C. ungrounded system is used for
breaker relay & trip controls and emergency lighting purposes.
4.0 GROUNDING SYSTEM
The grounding system for the entire D2O upgrading plant is featureed with 4/0 AWG
copper conductor having a cross sectional area of 107.2 sq.mm. It is interconnected
to the switchyard grounding grid and waste management facility grid at north and
west side respectively. In the vicinity of 6.6 KV, 415V switchgears and transformers,
the grounding grid is suitably reinforced and each of the two grounding leads
provided for each equipment is connected through 2 x 107.2 sq. mm conductors.
The following sizes of grounding leads are used for various equipment -
SN Description Conductor Size sq. mm

i) 6.6 KV and 415V switchgears & 2 x 4/0 AWG 214.4
transformers
ii) 415B MCCs distribution boards 4/0 AWG 107.2
lighting receptacle panels control
panels.
iii) Motors Size of Copper conductor
varying depending upon motor
rating.
Copper Rod electrodes are provided for grounding transformer neutrals, lightning
protection system and at several distributed locations to establish definite local
grounds.
Main grounding loop inside the building formed by 4/0 AWG size copper conductors
which is connected to outdoors grounding conductors at several places.
Horizontal runs of conductors on the floor is provided by placing the conductor

between layers of reinforcement steel with the provision of minimum 50mm cover. In
the run along the wall, column, ceiling etc. the conductors are cleated along the
surface at regular intervals. Grounding pads each connected to main grounding loop
by 4/0 AWG size conductor are provided on the floor, wall and ceiling of each area to
provided convenient points for equipment grounding. For grounding of equipments,
taps from main grounding and/or grounding pads provided near the equipment are
connected to the grounding terminals of the equipment.
Rev. No. : 02, Oct. 2008

5.0 ELECTRICAL EQUIPMENTS
Description of various electrical equipments provided in D2O upgrading plant is

given below-
6.0 11 KV EQUIPMENTS
Two Nos. 3000 KVA transformers are installed out side upgrading building for supply
electrical power to Raw water pump house and NAPS township as per the details
given below
KVA 3000 Type of cooling ONAN

Volts (HV) 12000 Vector Group YNd11
No load (LV) 6600 Max. temp. rise in 500C
Amps (HV) 144.34 Max. temp. rise above 550C
ambient
(LV) 262.43 Impulse voltage (HV) 75 KV peak
Phase 3 (LV) 60 KV peak
Frequency 50 Hz PF voltage (HV) 28 KV rms
% Impedance 6.07 (LV) 20 KV rms
Confirming to IS 2026 Appx. Weight core &
winding
Appx. Weight of oil 1650 Kg
Off circuit, tap changing switches provided with a range of +6.0% to –6.0 % in steps
of 2.0 %.
7.0 11 KV SWITCHGEAR
The 11 KV switchgear is of BHEL make and is of the metal clad draw out type suitable for
indoor installation. The circuit breakers and potential transformers are mounted on same
wheeled trucks, which can be drawn out for isolation. Siemens make VM-12AF type vacuum
circuit breakers are mounted in the draw out truck with front plate, which covers the cubicle
when breaker is in service position. The draw out truck has two positions for the circuit
breakers viz. isolated/test and service position. The metal enclosed panel is
compartmentalized with epoxy-reinforced fiberglass to give separate compartments for
a) Circuit breaker
b) Bus bar
c) CT and cable compartment
The switchgear confirms to IS- 3427and IEC 298 . Details of switchgear are as given
below
i) Number of panels 2
Incoming Two (3493CB-4 & CB-8)
Outgoing Two (3493CB-4A & CB-8A)
Bus PT Two
Rev. No. : 02, Oct. 2008

ii) Number of phases 3

iii) Rated voltage 12 KV
iv) Rated frequency 50 Hz
v) One minute P.F. withstand 35 KV
voltage
vi) Impulse withstand 75 KVP
(1.2/50 micro sec. full wave)
vii) Rated current 630 A
Bus bar current 800 A
viii) Rated short time current 40KA for 3 secs.

x) Dynamic short time current 100 KAP
x) Symmetrical breaking capacity 40 KA
xi) Equivalent MVA 500
xii) % DC component 53
xiii) Making capacity 100 KAP
xiv) TRV data
First pole to clear 1.5
factor
TRV peak 25 KV
Time to peak 62 sec.
Natural frequency 6900 Hz.
xv) Rated capacitive current 700A
xvi) Total break time 60 msec.
xvii) Make time 90 msec.
xviii) Spring charging time 15 sec.
xix) Auto re close duty 0-0.35-Co-31-Co.
xx) Operating duty 0-31-Co-31-Co.
xxi) Type of bus bar insulation Epoxy insulation
xxii) Temperature of bus bars over 1050C
the specified ambient
temperature (400C)
xxiii) Ground bus material Copper
8.0 6.6 KV EQUIPMENTS
8.1 Aux.Transformer
Two 2250 KVA transformers are installed as per the details given below at D2O
upgrading plant for feeding D2O upgrading auxilaries.

Volts 6600 (HV) Frequency 50 Hz
(No load) 433 (LV) Vector Group DY11
Amps 196.8 (HV) Max. temp. rise in 500C
3000.1 (LV)
Rev. No. : 02, Oct. 2008
Phase 3 (HV) Max. temp. rise in 550C

3 (IV) winding
% Impedance 6.25
Off circuit, tap changing switches provided with a range of +4.5% to -8% in steps of
1.5%. Estimated load on TR-1 & TR-2 are 1.9 KVA and 1.60 MVA respectively.
8.2 6.6 KV SWITCHGEAR
The 6.6 KV switchgear is of BHEL make and is of the metal clad draw out type
suitable for indoor installation. The circuit breakers and potential transformers are
mounted on wheeled trucks, which can be drawn out for isolation. Siemens make
VM-3AF type vacuum circuit breakers are mounted in the draw out truck with front
plate, which covers the cubicle when breaker is in service position. The draw out
truck has two positions for the circuit breakers viz. isolated/test and service position.
The metal enclosed panel is compartmentalized with epoxy-reinforced fiberglass to

give separate compartments for
a) Circuit breaker
b) Bus bar
The switchgear confirms to IS-2516 and 3427. Details of switchgear are as given
below
i) Number of panels 11
Incoming Two (CB-1 & CB-2)
Outgoing Five (CB-4, CB-5, CB-6,CB-7, CB-8)
Bus coupler One (CB-3)
Bus PT Two
Dummy One
ii) Number of phases 3

iii) Rated voltage 7.2 KV
v) One minute P.F. withstand 35 KV
voltage
vi) Impulse withstand 75 KVP
(1.2/50 micro sec. full
wave)
vii) Rated current 800 A
viii) Rated short time current 40KA for 3 secs.
ix) Dynamic short time current 100 KAP
x) Symmetrical breaking 40 KA
capacity
xi) Equivalent MVA 500
Rev. No. : 02, Oct. 2008
xii) % DC component 53
xiii) Making capacity 100 KAP
xiv) TRV data
First pole to clear 1.5
factor
TRV peak 25 KV
Time to peak 62 sec.
Natural frequency 6900 Hz.
xv) Rated capacitive current 700A
xvi) Total break time 60 msec.
xvii) Make time 90 msec.
xviii) Spring charging time 15 sec.
xix) Auto re close duty 0-0.35-Co-31-Co.
xx) Operating duty 0-31-Co-31-Co.
xxi) Material of bus bar & size Aluminum 2 x 12 x 75) mm
xxii) Type of bus bar insulation Epoxy insulation
xxiii) Temperature of bus bars 1050C
over the specified ambient
temperature (400C)
xxiv) Ground bus material Copper
8.3 Protections
The following protections are provided
(a) 3493 CB.1 & CB-2 ( Incomer)
i) 2 nos IDMT over current relays on R&B phase (51) with instantaneous
element (50A) for fast resetting (CDG-16, 1.3 sec) & CAG-19 (50 A) with VTT
timer relay for O/L alarm.
ii) 1 No. instantaneous earth fault relay (50 N) with VTT timer relay
(50NX)having time delay of 0.15 sec
(b) 3493 CB-4, CB-5, CB-6, CB-7 & CB-8 ( Feeder Breakers)
i) 2 nos IDMT over current relays for R&B phase (51) with instantaneous
element (50) for fast resetting (CDG-16, 3 sec. & CAG-13)
ii) 1 no. IDMT over current relays for earth fault (51N) (CAG-12).
(c) Following indicating meters are provided on the control panel.
i) Voltmeters for 3493 Bus A, 3493 Bus B (0-8 KV)

ii) Ammeters for two incomers from main plant 6.6 KV switchgear (0-700 A) for
each 6.6 KV/433V transformer (0-250A) and for 6.6 KV/12 KV transformer (0-
300A).
iii) KWH meters for incomers.
Rev. No. : 02, Oct. 2008

9.0 PROTECTION & MEASURING CT DETAILS
Feeder Protection CT details Measuring CT details

Type CT Out Clas Used Type CT Ratio Out Class Used for
Ratio put s for put
In-corner Protecti 750/ 7.5 5P20 51&50A Protecti 750/ 5A 20VA 1 0-700A
1&2 on 5A VA on
750/ 30 5P5 51N Ammeter
5A VA
3493-TR1 Protecti 400/ 7.5 5P20 50&51 (0-250) A

& TR2 on 5A VA
Core 100/ 10 5P10 50N Protecti 250/ 5A 10VA 1 Ammeter

on
balance 5A VA
CWMF Protecti 250/ 7.5 5P20 50&51 Protecti 150/ 5A 10VA 1 (0-150)A
on on
Trfe. 5A VA
Core 50/ 10 5P10 50N (Ammeter)
5A
balance VA
RWPH Protecti 100/ 7.5 5P20 51&50 Protecti 300/5A 10VA 1 (0-300)A
on on
Trfr. 5A VA (Ammeter)
Core 100/ 7.5 5P10 50N
balance VA
Spare Protecti 400/ 7.5 5P20 51&50

on
5A VA
Core 100/ 10 5P10 50N Protecti 250/5A 10VA 1 (0-250)A
on
balance 5A VA (Ammeter)
10.0 415V SWITCHGEAR
The 415V switchgear is of English Electric make having panels-with two air circuit
breaker in double tier formation with an additional 335mm wide panel to cater power
cable termination on ACB’s. In addition, this space is used for mounting
instruments/relays on front door. The circuit breaker has three distinct position i.e.
'service', 'test', & 'isolated' with position indicator. Automatic safety shutters are
provided to screen the live parts when the breaker is drawn out of the cubicle.
Rev. No. : 02, Oct. 2008

The switchgear conform to IS-8623, Details of this switchgear is given below
i) Number of panels Eight

Number of ACB’s Sixteen
Incoming Two (CB-,9& CB-,10)
Outgoing Nine spare( 13 ,15 ,16 ,18 ,19 ,20
,23,24 & 29 (CB-) MCCs (CB-
12,14,17,21& 22)
415V Bus isolator/ Coupler One (IS-11)
ii) Number of phases Three & neutral
iii) Rated voltage 415V
v) 1min. P. F. withstand voltage 2.5 KV
vi) Rated short time current 50 KA for 1 sec.
vii) Rated current Incomer-3750A/Outgoing-1300A
viii) Dynamic short time current 105 KA peak.
ix) Symmetrical breaking capacity. 50 KA (rms)
x) Equivalent MVA 35 KVA
xi) Making Capacity 105 KA
xii) Material capacity Aluminum
xiii) Type of bus bar insulation Air insulated FRP plates for bus bar
supports.
xiv) Temperature rise of bursars 87.50C (based on test report for NAPP
over the specified ambient temp. Main Plant switchgear)
xv) Ground bus material Copper
The following protection have been provided
CB-1 & CB-2
i) 1 no IDMT over current relay for earth fault (51N CDG 16) of incoming
transformers (setting of relay 20-80%).
ii) 3 nos. IDMT Over current relays (51)on each phase (CDG-31) (setting of
relay 50-200%).
Spare CB- 13,15,16,18,19,20 23,24 &29
i) IDMT o/c relays & earth fault relays (51, 50, 50N) (CDAG-54) provided for
each ACCR feeder.
. MCCs (CB-12,14,17,21& 22)
1. IDMT o/c relay (51N) provided for fault for MCC-1, 2 & 3 feeders (setting
20%).
Rev. No. : 02, Oct. 2008

11.0 415V MOTOR CONTROL CENTRES
MCC 5 have been manufactured and supplied by M/s.Siemens India for distillation
tower No. three. It cater load of column three. It have draw out type module with
single front construction. The 415V MCC-1, 2 ,3& 4 have been manufactured by M/s.
Control & Switchgear Company Pvt. Ltd., New Delhi as per IS-8623, MCC-1,2,3 & 4,
having semi-draw out cubicle modules with double front construction. The cubicle is
made up from cold rolled sheet steel of 2.0 mm thickness.
Details of MCCs are given below
11.1 GENERAL
i) MCC featureation & rated voltage MCC-1, MCC-2, MCC-3, 415V

ii) Bus bar continuous rating 530A, 1050A
iii) Size of vertical bus bar 2 (50 x 6) mm per phase
iv) Distance between bus bars 65mm to centers between phases
v) Degree of protection provided for IP-51 (as per IS-2147)
enclosure.
vi) Material of bus bars Aluminum
vii) Material of bus bar support DMC
viii) Temperature rise over the specified 350C
ambient when carrying rated current
ix) Short time rating 50 KA for 1 sec.
x) Momentary rating (peak) 105 KA
xi) Rated current of bus bar MCC-1 & MCC-3 - 530A MCC-2
bar 1050A, MCC-5-1050A
xii) Bus bar short time rating 35 VA, 50 KA for 1 sec.
xiii) Cable entry a) Power Top
b) Control Top
xiv) Max. Power frequency withstand
voltage (1 min.) for
a) Power circuit 2.5 KV
b) 110V control circuit 1.5 KV
xv) Locking arrangements Pad locking arrangement for all
feeder compartment with doors
having concealed hinges.
xvi) Voltmeter for bus voltage measure
Range 0-500V AC for MCC-1 & 3
Deflection 900
Case size 144 x 144 mm
xvii) Ammeter
Range 0-600A for MCC-1 & 3
0-1200A for MCC-2
Deflection 900
Rev. No. : 02, Oct. 2008
xviii) Current transformers

Rated voltage 415V
Operating voltage 415V + 10%
Frequency 50 Hz
Rated primary current i) 600A for MCC 1 & 3
ii) 1200A for MCC-2
Rated secondary current i) 5A
ii) 5A
Transformation ratio i) 600/5
ii) 1200/5
Instrument safety factor 5
Short time current rating 50 KA for 1 sec.
Rating 15 KA
Accuracy class Class-I
xix) Voltage Transformer for voltmeters
Rated voltage 415V, 3 phase, effectively earthed
Insulation level 3 KV
Frequency 50 Hz
Transformer ratio 415/110 V
12.0 POWER & CONTROL CABLE AND CABLE TRAYS
12.1 HV POWER CABLE
3 core, 300 sq. mm aluminum conductor, single wire armoured, XLPE insulated 6.6
KV unearthed grade PVC sheathed cable are used for feeding power to 6.6 KV
switchgear of upgrading plant from 6.6 KV main plant switchgear. In selecting the
size of cable, various de-rating factors as per manufacturer’s recommendation were
used. Since the total load of the two feeders is around 790 amp., two feeders each
having two runs of 3c x 300 sq. mm. cable used, and feature rating of each run (3c x
300 sq. mm) is taken as 290 amps.
3 core, 300 sq. mm aluminum conductor 6.6 KV PVC insulated & sheathed cable are
used to feed 2.25 MVA & 3 MVA transformers from 6.6 KV switchgear. Rated
current for each of upgrading plant transformer (2.25 MVA) is 196A & 3 MVA
transformers for RWPH & NAPS Township is 260 Amp . Considering all de-rating
factors, 3c x 300 sq. mm HR PVC cable has been used. Feature rating of each run
(3c x 300 sq. mm) is taken as 290 amps.
3 core, 185 sq. mm aluminum conductor 12.0 KV unearth grade MI cable are used
from 3 MVA transformers to 11.0 KV switchgear to feed Raw Water Pump House &
Township. Rated current for each 3 MVA transformer for RWPH & NAPS Township
is 144 Amp . Considering all de-rating factors, 3c x 185 sq. mm MI / XLPE cable has
been used from transformer to switchgear & from switchgear to RWPH/ NAPS
Township .
Rev. No. : 02, Oct. 2008

12.2 MV POWER CABLES
650/1100V grade aluminum conductor HRPVC insulated PVC sheathed armored /

unarmored cables are used for 415V system. Cables are adequately featured to
meet starting and running loads of various motors fed through motor control centers
1, 2,3 ,4 & 5.
12.3 CONTROL CABLES
2.5 sq. mm-copper conductors PVC insulated control cables of different core
numbers (2, 4, 10, & 24) have been used for control, indication and annunciation
purposes.
13.4 CABLE SUPPORT & LAYOUT
Cable are supported by cable trays supported from ceiling/wall/column through EPs.
Cables are routed suitably avoiding other services. Ladder type cable tray supports
are used for supporting power cable trays and perforated control cable trays. Layout
of cable trays is shown in drg. No. NAPP/34930/2014/ED. Cable tray support
structures are not analyzed for seismic accelerations. However, the feature generally
follows main plant cable support structures, which are featureed for seismic duty.
14.0 LIGHTING
Power supply to lighting and receptacles is provided through local wall mounted
distribution boards. Power supply to DBs is obtained from motor control centers. An
average illumination level of 200 Lux is provided for upgrading plant. In control, room
the illumination level is 450 lux. requirements. Different type of lighting fixtures used
in upgrading plant are given below.
i) 2 x 40 W fluorescent industrial fittings (240V AC)

ii) 2 x 40 W fluorescent recessed decorative fittings (240V AC)
iii) 2 x 40W weather proof fluorescent fittings (240V AC)
iv) 60W incandescent recessed fittings (48V DC)
v) 240V AC 60W bulkhead fittings
vi) 240A AC, 60W weather proof bulkhead fitting
vii) 240V AC 250W HPMV fixtures.
Emergency lighting is derived from 48V DC battery and battery charger located in
electrical equipment room. Power supply to emergency lighting is through 40V DC
distribution board through battery charger and battery can maintain it for one hour
(48V, 400AH) in the event of AC power failure.
15.0 MISCELLANEOUS EQUIPMENT
48V BATTERY & BATTERY CHARGER WITH DISTRIBUTION BOARD
Rev. No. : 02, Oct. 2008

48V, 400AH battery with battery charger and DC distribution board is located in the
electrical equipment room. This supply is used for breaker trip, control and
emergency lighting purposes. The capacity of the battery is such that it can supply
continuously for 1 hr. when the input to the battery charger is not available. Under
normal conditions, 48V battery charger maintains the 22 cell battery in float
condition. Battery charger can boost charge the battery when it is drained. 22 cells,
lead acid battery is supplied by M/s. Exide Batteries, 48V, 250 amps battery charger
cum rectifier is supplied by M/s. Keltron and 48 V DC, distribution board is supplied
by M/s. Susheel Engineering Co.
Details of battery charger are given below
Make Keltron Battery charger

Our ref: DPS/PPED/EEQ/438/MAPP/34930/PO/10540
Input 415VAC ±10%
Freq / Phase 50Hz / 3 Phase
Out put (V) 40-60 VDC
Current 250A
Type Full wave fully controlled SCR Bridge
Mfg. year 1988
Sr.No. 871111
Rev. No. : 02, Oct. 2008

CHAPTER 24
RAW WATER PUMP HOUSE

(52420)
1.0 SCOPE :
This chapter covers the description and salient features of Raw Water Pump House
electrical distribution.
2.0 BRIEF DESCRIPTION OF RWPH :

Raw Water Pump House Supply is tapped from 11 KV Underground cable /
overhead transmission lines which are emanating from D2O Upgrading plant (from
6.6 KV/11KV, 3MVA transformer) to RWPH through deen dayal upadhyay chowk as
under.
Sr.No. 11 KV Cable / O/H Line From To

1 11 KV Cable 3493 CB # 8 A 4 Pole structure
near 33 KV sub
station
2 11 KV overhead line 4 Pole structure Near Jairampur
near 33 KV sub drain
station
3 11 KV Cable Near Jairampur 6 Pole Structure at
drain Raw water pump
house
Where provision to draw or supply power from Township is provided as an

alternative. At R.W.P.H. 11 KV Cables are terminated on H type transmission pole
and is provided with a three-pole isolator and D.O. type fuses. 11 KV serves as
supply to two nos. 11 KV/433V, 1 MVA off load tap changer transformers, one
transformer of oil filled type and other is of cast resin dry type indoor transformer
through 11 KV vacuum circuit breakers with underground 3 core PILC / XLPE cable.
Output of oil filled transformer is fed to BU – AA and dry type transformer to BU – BB
through 415 V air circuit breakers featured as 5242 CB # 1 & 5242 CB # 7
respectively. If voltage on output side of transformer is to be charged at BU-'AA' and
BU ‘BB’ incomer to BU AA and BU BB & respective vacuum circuit breakers must be
energized. The Taps provided are at following voltages.
Tap position of oil filled transformer (off load tap changer)
SWITCH % TAPPING INPUT OUTPUT
POSITION VOLTAGE VOLTAGE
1 -6.0 10430 433
2 -4.5 10505 433
3 -3.0 10670 433
4 -1.5 10835 433
5 N 11000 433
6 +1.5 11165 433
7 +3.5 11330 433
8 +4.5 11495 433
Rev. No. : 02, Oct. 2008

Tap positions of Dry type transformer (off load tap changer)

Required voltage in LV side of transformer can be achieved by changing the link
position provided on HV side of winding in side transformer.
From BU 'AA' two Raw Water Pump motor feeders, one MCC feeder & one feeder
for tie to bus BB are used. One feeder is provided as spare.
Following are the feeder descriptions of BU ‘AA’
1 INCOMER BU 'AA' - 5242-CB-1
2 SPARE - 5242-CB-2
3 7112-PM-2 - 5242-CB-3
4 52422-MCC-S - 5242-CB-4
5 7112-PM-3 - 5242-CB-5
6 TIE BREAKER TO BU BB - 5242-CB-6
From BU 'BB’ one Raw Water Pump motor feeder and one MCC feeder are supplied.
One feeder is provided as spare.
Following are the feeder descriptions of BU ‘BB’
1 INCOMER BU 'BB' - 5242-CB-7

2 7112-PM-1 - 5242-CB-8
3 52422-MCC-R - 5242-CB-9
4 TIE BREAKER TO BU ‘AA’ - 5242-CB-10
5 SPARE - 5242-CB-11
For other auxiliary loads such as pumps, heaters, lighting etc. two MCC' s i.e. 5242-
MCC-S and 5242-MCC-R are provided. MCC-S as earlier explained is fed from BU-
'AA' and MCC- R is fed from BU ‘BB’.
3.0 11 KV SYSTEM
For NAPP Township, a facility is provided at Raw Water Pump House i.e. from 6-
pole structure 11 KV Bus bar a 11 KV underground cable is terminated to 6 pole
structure at TSL near sub station no. 5 to draw power as an alternative, which should
be kept isolated. In case of supply failure at RWPH or NAPS T/Ship, supply can be
extended from T/ship feeder to RWPH or vice- versa through this cable, which is
provided with AB switches at both ends.
4.0 415V SYSTEM
Refer D2O upgrading plant chapter for 415V ACBs and bus details. It receives supply
from 11KV/433V, 1MVA transformer. The systems consists of 415V switchgear,
MCCs, lighting panel, control and space heater panel for controlling loads.
Motor space Heater System
For Motor Space Heaters three phase supply with a neutral is coming to Motor
Space Heater Panel through 531-PLD-67 feed from MCC-S. From this panel 240 V
AC is supplied for Motor Space Heaters, spring charging motors of 415V switchgear
and raw water pumps control panel.
Rev. No. : 02, Oct. 2008
5.0 48 V DC SYSTEM
48 Volt DC control supply is supplied by a 48 V EXIDE make 200AH battery bank

and Advani Orlinkan make battery charger combination. The charger incoming
supply is from MCC-S. The above combination supplies to 11 KV breakers, 415V
switchgears and annunciation panel. Battery bank consists of 4 X 12 V Batteries
connected in series and has the capacity of 200AH.
5.1 BATTERY CHARGER
415V, 3 phase, 50Hz supply is given to main transformer through input ON/OFF
(SW1), contactor CONN1 & O/L relay. Secondary of the transformer is connected to
3 phase, full wave half controlled thyristor bridge. Output from the bridge is filtered by
means of L-C filter & taken out as D.C. output. When the system is in the Auto mode
& charger is in the 'float mode', battery bank floats across the output.
5.2 Distribution
48V, 200AH battery bank and battery charger supplies control supply to –
(i) 11 KV vacuum circuit breakers.

(ii) 415V SWGR Panels.
(iii) Annunciation Panels.
5.3 Battery Bank
Consists of 4 X 12 volts Batteries, which are connected in series. The bank has the
capacity of 200AH.
6.0 MCC SYSTEM;
Supply of MCC ‘S’ is through 5242-CB-4 of bus BU-'AA' and supply of MCC ‘R’ is
through 5242-CB-9 of bus BU-'BB'. Control supply in MCCs is 110V AC single
phase, 50Hz that is obtained from its own power circuit through control transformer.
7.0 LIGHTING SYSTEM
For lighting, 531-PLD-65 is provided which gets its supply from MCC-S. All lighting of
RWPH is fed from this panel. For chemical house lighting, a separate Lighting Panel
is provided which taps its power from MCC-R.
8.0 POWER SUPPLY TO AUXILARY RWPH:

Auxiliary RWPH supply is tapped from 11 KV underground cable/overhead
transmission line, which is emanating from 11 KV six pole structures at RWPH to sub
station at Narora barrage. 11 KV serves as supply to one no.11KV/433V, 400 KVA
distribution transformer through DO fuses and AB switch. 433 V AC supply from this
transformer is extended to LT distribution panel which in turn supplies 433 VAC
supply to various pumps and lighting load at Narora barrage.
Rev. No. : 02, Oct. 2008
9.0 PROTECTIONS
9.1 11 KV BREAKERS
Phase O/C Protection. 50-51-R

Phase O/C Protection. 50-51-B
Earth Fault Protection. 51 N
Buchholz Relay for Gas Protection. 63 BT
( Only for oil filled 1 MVA transformer)
Oil Temperature Trip 800C OTT
( Only for oil filled 1 MVA transformer)
Wdg. Temperature Trip. WTT
9.2 415V BU-'AA' & ‘BB’ 5242-CB-1&7
Instantaneous and Time CTZM

Delay O/C Trip.
Earth Fault Trip.
9.3 5242-CB-3, 5242-CB-5 & 5242-CB-8
Unbalance Protection. 46
Thermal O/L Protection 49
Instantaneous O/C Prot. 50
Definite O/C Earth Fault Protection. 50N
Locked Rotor Protection. 50 LR
Under Voltage Protection. 27-94
Instantaneous + Delayed O/C CTZM-71
Protection.
9.4 MCC-S & MCC-R FEEDER ( 5242 CB # 4&9 )
Instantaneous + Delayed O/C CTZM - 71

Protection.
Earth Fault Protection.
10.0 ANNUNCIATIONS
WINDOW ANNUNICATIONS
Win 1 11 KV BREAKER TRIP
Win 2 TRANSFORMER E/F TRIP
Win 3 INCOMER O/C TRIP
Win 4 BU-'AA' NO VOLT TRIP
Win 5 PT FUSE FAILURE
Win 6 INCOMER TRIP
Win 7 BUCHHOLZ TRIP
Rev. No. : 02, Oct. 2008
Win 8 WDG. TEMP. TRIP

Win 9 OIL TEMP. TRIP
Win 10 WDG. TEMP. ALARM
Win 11 BUCHHOLZ ALARM
Win 12 OIL TEMP. ALARM
Win 13 MCC O/C TRIP
Win 14 MCC E/F TRIP
Win 15 SPARE
Win 16 CB-4 TRIP CKT UNHEALTHY
Win 17 BATTERY CHARGER
TROUBLE
Win 18 SPARE
Win 19 PUMP-1 PROT. TRIP
Win 22 SPARE
Win 23 PUMP FEEDER TRIP CKT
UNHEALTHY
Win 24 SPARE
Rev. No. : 02, Oct. 2008

Chapter -25
STATION AUXILLARY TRANSFORMER
1.0 INTRODUCTION: -
This chapter covers the 6.6KV/415V auxiliary transformer system and associated
equipment. The system is shown in single line diagram of 50,000- FS-1. The
transformer used in this system is of HHE & EMCO make. There are 7 Nos. 2 MVA
auxiliary transformer are installed for NAPS #1 & NAPS #2 each. 415 V buses
(Class-IV & III) are fed from 6.6 KV class IV buses through, a 2MVA 6.6 KV / 433 V
auxiliary transformers. As per given detail
(i) 5242 TR #1 is for BU-K.

(ii) 5242 TR #2 is for BU-J.
(iii) 5242 TR #3 is for BU-L.
(iv) 5242 TR #4 is for BU-M.
(v) 5242 TR #5 is for BU-K1 (L1 for unit #2).
(vi) 5231 TR #1 is for BU-P.
(vii) 5231 TR #2 is for BU-Q.
There is also provision of stand by transformer 5242 TR #2 for BUS J. This

transformer can be connected to any of the class IV & Class III transformer in case
of non-availability of the associated transformer. This facility is not available for the
CW pump house transformer.
The neutral point of 2 MVA transformers is solidly earthed at the transformer end.
2.0 The sizing of auxiliary transformer: -
The sizing of auxiliary transformer were based on the following consideration
i- The load schedule of NAPP forecast on the basis of NAPP load schedule s.
ii- The maximum continuous rating of indigenously available 415-V circuit breaker
and switchgear. Rating of 3000A is reasonable practical limit for bus bars of the
indoor switchgear without forced ventilation. Also up to 3000A rating circuit
breakers are available. Higher rating requires parallel circuit breakers.
iii- Sizes and number of cables per phase required for the connection between
transformer secondary and the switchgear.( in case of class III switchgear)
iv- The short circuit levels obtainable at the 415V class IV and class lll, bus bars.
With the above considerations 2000KVA rating has been adopted for the five
class IV transformer and two class lll transformers.
3.0 Percent Impedance: -
The percent impedance of 7.5 percent has been specified for class-IV transformers
with this impedance the fault level at 415 Cl-IV bus-bars is about 9KA which is well
within the limits of the available switchgear rating of 50KA (35.5 MVA).
Rev. No. : 02, Oct. 2008

The percentage impedance of class-III transformer has been specified as 11% as

there is an additional fault current contribution from the emergency diesel generator,
which may work in parallel with this transformer.
4.0 Vector Group of 2 MVA Transformer: -
The same vector group of DY11 has been specified for all transformer to enable
paralleling with standby transformer of Bus-J.
5.0 Cooling Arrangement of Auxiliary Transformer:-
The transformers are specified with “ONAN” type of cooling as this is the normal type
applicable for this rating and no additional cooling equipment such as fans are
involved. M/s. Hack Bridge-Hewittic & Easun Ltd supplies all aux. Transformers
except for the pump house transformer. The pump house transformer supplied by
M/s. EMCO Electricals Ltd.
6.0 Maintenance outage of aux. Transformers: -
Whenever any one of the Cl-IV or Cl-III aux transformers have to be taken out for
maintenance, the transformer has to be first paralleled with the stand-by transformer
feeding Bus 5242-BU-J and after establishing this alternative source of supply to the
bus bars, the concerned transformer breaker can be tripped.
7.0 Installation :-
7.1 Class IV Aux. Transformers
The 415 V switchgear buses, K, J, L, &M are located in Turbines building (room T-
210) between grids 5-8 & E-F (19-22 & E-F for NAPP-2) on the Mezzanine floor i.e.
at EL 106.600 m. The 2 MVA Auxiliary Transformers supplying these buses are
located outside the Turbine Building on the west side (rooms T-106 to T-109)
between girds 5-8 & F-G (19-22 & F-G ) at EL 100 m the LV terminals of the
transformers are connecting to the switchgear by non segregated sheet steel
enclosed bus ducts.
The class IV CWPH switchgear is located in a separated switchgear

room/station North (South for N-2) of the CWPH. Grid location (site grid) are 34-
35/AL-A for NAPP-1 switchgear and 35-/F-G for NAPP-2 switchgear. The 2MVA
transformer is at EL 97 m and towards the Eastern end of the substation. Switchgear
for Bus K1 (L1) is at the same elevation and the connection between the LV
terminals and the Switchgear is by means of cables, which are 3 nos of 1 core 1000
sq.mm (A1) per phase.
7.2 Class III transformers: -
The 415V switchgear buses P&Q are located in the turbine building (rooms T-
216 and T-221 respectively) between grids 12-14. The transformers are located
outside of the switchgear panels. The transformers are located outside the turbine
Rev. No. : 02, Oct. 2008
building between grids 12-15 &west of G. (26-28 & west of G) at EL 100 m .The LV
terminals of the transformer are connected to the switchgear by cables (5 nos of core
1000 sq mm (A1) per phase.
8.0 In Built Protection of Aux. Transformers:-
There are following in built protection provided in aux. Transformer.
(i) Buchholz protection.
(ii) Over Temperature protection.
(iii) Explosion vent.
8.1 Gas operated Buchholz Relay: -
The relay serves as protection for any minor or major incipient faults. That may
develop inside transformer. Such faults always result in generation of gases, which
causes the operation of mercury switches giving signal for alarm & trip.
The buchholz relay is mounted in the pipe at an inclination of 3-7o .In healthy
condition of the transformer, the relay is full of oil and both the mercury switches are
open. In the event of minor fault like damage to core bolt insulation, local overheating
etc. The arcing causes slow generation of gas in the oil which passes up in the pipe
and gets trapped in the relay housing.
When a sufficient volume of gas is collected in the relay, the top bucket, because of
its extra weight due to oil contained tilts, overcoming the balance weight, which
closes the mercury switch and initiates an alarm in control room.
With major fault like short circuit between turns, coils or between phases: the
generation of gases is rapid and the gas and the displaced oil surges through the
relay and impinges on the baffle plates, causing the lower assembly to tilt and close
the mercury switch and provide signal for tripping the circuit breaker,
8.2 Over Temperature Protection: -
This protection is provided through temperature indicator. Normally two separate

instruments are used for indicating oil and winding temperatures .
(i) O.T.I (oil temperature indicator)

(ii) W.T.I (winding temperature indicator)
Temperature indicators are precision instruments, specially designed for

Protection of transformers and perform the following functions.
 Indicate temperature winding and oil.

 Operate an alarm or a trip circuit at a predetermined temperature.
Rev. No. : 02, Oct. 2008

Both are situated in marshalling panel of aux. transformer. These indicators normally
work on the principle of liquid expansion, the liquid being sealed in the bellow. The
indicator is provided with a sensing bulb placed in an oil filled pocket on the
transformer tank cover with change in the temperature the volume of the liquid in
sensing bulb expand or contract, transmitting the movement through a linkage
mechanism to the indicating pointer. Winding temperature indicator also work on the
same principle, except that winding temperature indicator is provided with an
additional heating element called WTI heater which is fed by a current transformer
with a current proportional to the load.
Explosion Vent :-
A major fault inside the transformer causes instantaneous vaporization of the oil
leading to extremely rapid build-up of gaseous pressure. If this pressure is not
relived within a few milliseconds, transformer tank can get ruptured.. The consequent
damage and fire hazard possibilities are obvious a pressure relief device provides
instantaneous relieving of dangerous pressure called explosion vent.
In the event of a serious fault, due to excessive pressure, the top diaphragm ruptures
, thus releasing the pressure.
9.0 Construction parts of 2 MVA Auxiliary Transformer: -
9.1 Off Circuit tap changer:-
The function of off circuit tap changer is to change the turn ratio of a transformer for
voltage regulation. As the name implies, it is essential to de-energize the transformer
before changing the tap. An off circuit tap changer, consists of principally the
following three parts.
(a) operating handle projected outside the transformer
(b) Fixed contact with connecting terminal.
(c) Insulating shaft with moving contact system.
To prevent unauthorized operation of an off-circuit tap changer, a mechanical lock is

provided.
9.2 Silica Gel Breather:-
A Silica gel breather is most commonly employed as a means of preventing moisture

ingress. It is connected to the conservator tank, which is flitted to transformer to
allow for changer in volume due to temperature variations. As the load reduces, air is
drawn into the conservator through a cartridge packed with silica gel which
effectively dries the air.
Normally Silica gel colour is blue and changes to pink when it adsorbs the moisture.
Before become pink it should be replaced from new regenerated silica gel. One kg
capacity silica gel breather is used for 2 MVA auxiliary transformers.
Rev. No. : 02, Oct. 2008

9.3 Oil level Indicator:-

Magnetic type oil level indicator is used for level measurement of 2 MVA auxiliary
transformer conservators, It is situated at conservator end side which is also
incorporates a mercury switch. This switch closes when there is low oil level in the
conservator. A float is used as a sensor, which moves with rise and fall of the oil
level. Its movement gets transmitted to the switch mechanism by means of magnetic
coupling, which ensures a complete seal between the conservator and switch
compartment. The pointer is also magnetically operated and picks up the correct oil
level.
10.0 Interlocks provision for 2 MVA aux. Transformer: -
(i) HV breaker close only when LV breaker in service position.

(ii) LV breaker can not close before HV breaker closing.
(iii) LV breaker trip whenever HV breaker trip.
11.0 Soak Pit: -
All auxiliary transformers soak pit except pump house transformer are inter
connected to GT soak pit.
12.0 Window & CRCS Annunciations of Auxiliary Transformer
Window Ann/CRCS Description of Annunciations

390/4390 6.6 KV/415 V transformer gas collection stage-1
388/4388 6.6 KV / 415 V transformer protection relay trip.
389/4389 6.6 KV /415 V Aux. Transformer trouble 5231 TR#1
2252 5231 TR-1 transformer gas collection
2239 5231 TR-1 transformer prot. Relay trip
2245 5231 TR-1 aux. Transformer trouble.
2246 5231 TR-2 aux. Transformer trouble
Rev. No. : 02, Oct. 2008
11.0 Technical data of Class IV auxiliary transformer

(5242-TRI to 5242-TR-5)
1 Manufacturer Hack bridge Hewittic / EMCO

Electrical
2 Standard IS 2026
3 Type of construction Outdoor, Core type
4 Rating 2000 KVA
5 No. of Phases and 3 Phase, 50 HZ
frequency
6 Transformation ratio 6600/433 V
7 Vector group Dy 11
8 Percentage impedance 7.5% 10%
9 Basic insulation level
Impulse (1.2/50us) for HV 60KV
Power frequency
HV 22KV
LV 2.5KV
10 Off circuit tapping + 4.5 to-6% on 6600V in 1.5% steps
Method of cooling ONAN
11 Temperature
Oil 40oC/45 oC
Winding (by resistance) 50oC/55 oC
12 Guaranteed losses
load losses at rated current 18.34 KW /22.0 KW
(at 75oC winding
temperature)
No load losses at rated
voltage and frequency 3.20 KW /2.6 KW
13 Amps.
HV 175
LV 2667
14 Volume of oil 1900 Liter
13.0 Class III transformers 5231- TRI &TR2: -
1 Manufacturer Hack bridge Hewittic and Easun Ltd

2 Standard IS 2026
3 Type of construction Outdoor –core type
4 Rating 2000 KVA
5 No. of phases &frequency 3 Phase, 50 Hz
6 Transformation ratio 6600/433V
7 Vector group Dy 11
8 Percentage impedance 11% + - 5%
Rev. No. : 02, Oct. 2008
9 Basic insulation hence

Impulse (1.2/50us) for HV 60KV
Power frequency test
Voltage for HV 22 KV
Power frequency
Test voltage for LV 2.5 KV
10 Off circuit tapping 4.5% to –6% in steps of 1.5%
11 Method of cooling ON AN
12 Temperature rises
Oil 40oC
Winding by resistance 50oC
13 Guaranteed losses
a) Load loss at 21.95 KW
rated current
(75ºc)
b) No load loss 2.54 KW
at
Rated voltage
14 Amps.
HV 175
LV 2667
15 Volume of oil 1900 Liter
Rev. No. : 02, Oct. 2008

Chapter-26
Waste Management Plant Electrical System
1.0 Scope: -
This chapter includes description of electrical system and equipment provided to

Waste Management Plant at Narora Atomic Power Station.
2.0 Description of the plant: -
Waste Management Plant provides facilities for storage/disposal of

solid/solidified radioactive wastes generated from reactor building during nuclear
reaction. Solid waste management system of waste Management Plant consists of a
process building called RSS building (Radiation Waste Solidification System) and
SWMF (Solid Waste Management facility) which are meant for storage/disposal of
solid/solidified radioactive wastes. RSS building is located next to Treatment and
Disposal System (TDS) building connected by a corridor. Main entrance for the
personnel to the TDS building is through administrative block which houses change
room, personnel monitoring and other health physics facility for WMP apart from the
office.
TDS, SWMF & RSS building receive all the solid waste generated at NAPS. The
solid waste after necessary processing is sent for storage/disposal to Solid Waste
Management Facility (SWMF). The SWMF comprises of an area admeasuring about
500m x 250m located adjacent to D2O upgrading plant. Low and medium level
wastes shall be permanently disposed in engineered containment above ground or
at shallow depth for the entire life of the station while for relatively higher active
solid/solidified radioactive waste, a retrievable storage system is planned at this site.
Such waste packages which are relatively small in quantity can be retrieved and
disposed at alternate site if conditions so demand. Liquid waste disposal Facility is
provided at LESS Area in service building.
Rev. No. : 02, Oct. 2008

3.0 ELECTRICAL DISTRIBUTION SYSTEM: -
One feeder from D2O upgrading plant (3493CB-7) have been used to feed the waste
management auxiliaries as shown in single line diagram. Two Nos. 6.6 KV VCB
have been used in series.3493CB-7 & 7922CB-9 to feed 1250 KVA Transformer 6.6
KV / 415 Volts, which is located in the waste management plant building to feed all
low voltage load including lighting. 7922 TR-1 feeds fours Nos. Motor control centers
viz 7922 MCC-1,2,3& MCC-4. 7922 TR-1 feeds to 7922 MCC-1 through 7922-CB-
1.This 7922 CB-1 is L & T make and houses in MCC-1 cubical. 7922 MCC 2 & 3 are
fed from MCC-1 and MCC-4 is fed from MCC-2 There is a provision to feed MCC-2,
3&4 from D2O upgrading plant directly via 3493. CB-14,MCC-1&2 are located in
WMP Electrical equipment room and MCC-3&4 are located in TDS Building & R SS.
Building respectively .
4.0 GROUNDING SYSTEM
The grounding system for the entire waste management plant is featureed
with 4/0 AWG copper conductor having a cross sectional area of 107.2 sq.mm. It is
interconnected to the switchyard grounding grid and D2O upgrading plant grid at
north and west side respectively. In the vicinity of 6.6 KV, 415V switchgears and
transformers, the grounding grid is suitably reinforced and each of the two grounding
leads provided for each equipment is connected through 2 x 107.2 sq. mm
conductors.
The following sizes of grounding leads are used for various equipment -
SN Description Conductor Size sq. mm

i) 6.6 KV VCB and & transformers 2 x 4/0 AWG 214.4
ii) 415B MCCs distribution boards 4/0 AWG 107.2
lighting receptacle panels control
panels.
iii) Motors (Copper) Size of Copper conductor
varying depending upon the
rating of motor.
Copper electrodes are provided for grounding transformer neutrals, lightning

protection system and at several distributed locations to establish definite local
grounds.
Rev. No. : 02, Oct. 2008

Main grounding loop inside the building formed by 4/0 AWG size copper conductors
is connected to outdoors grounding conductors at several places.
5.0 ELECTRICAL EQUIPMENTS
Description of various electrical equipments provided in waste management plant is

given below
5.1 6.6 KV SWITCHGEAR
One No 6.6 KV vacuum circuit breaker (7922-CB-9) of M/S BHEL make has been
provided for feeding WMP auxiliaries through 7922-TR-1. Vacuum circuit breaker is
of the metal clad draw out type suitable for indoor installation. The circuit breakers
and potential transformers is mounted on wheeled trucks, which can be drawn out
for isolation. Siemens make VM-3AF type vacuum circuit breakers is mounted on the
draw out truck with front plate, which covers the cubicle when breaker is in service
position. The draw out truck has two positions for the circuit breakers viz.
isolated/test and service position. The metal enclosed panel is compartmentalized
with epoxy-reinforced fiberglass to give separate compartments for
a) Circuit breaker
b) Bus bar
The switchgear confirms to IS-2516 and 3427
5.2 Aux.Transformer
One 1500 KVA transformer M/S Crompton Greaves Ltd. make is installed to feed
7922-TR-1 confirming to IS 2026-1977
Volt (HV) 6600 Frequency 50HZ
( LV) 437 Impedance 6.26%
Amp (HV) 131.2 Comn.Symbols Dyn11
(LV) 2000.0 Core and winding 2330 kg
Phase (HV) 3 Weight of oil 1138 kg
(HV) 3 Total weight 5000 kg
Diagram Drg no. T22BV4611D Oil letters 1300
Rev. No. : 02, Oct. 2008

Makers ser no 33306V Year 1983

0
Temp rise 50C oil Indian standard 2026-1977
Off circuit, tap changing switch provided with a range of +6.0% to –6.0 % in steps of
2.0 %. Estimated load on 7922TR-1 is 1.2 MVA.
5.3 415V MOTOR CONTROL CENTRES
The 415V MCC 1,2,3 &4 have been manufactured and supplied by
M/s.Andrew Yule for feeding load of Waste management auxiliaries . MCC-1
cater load of MCC 2,3&4 . MCC-1,3 & 4, having semi-draw out type having
cubicle modules with double front construction. MCC-2 have semi draw out
type the cubicle is made up from cold module with single front construction
rolled sheet steel of 2.0 mm thickness. MCC-1, 2, 3 & 4 have been
manufactured as per IS-8623,
Details of MCCs are given below
i) MCC identification MCC-1, MCC-2, MCC-3 &

MCC 4,
ii) Rated voltage 415V AC
iii) Bus bar continuous rating 530A, 1050A
iv) Size of vertical bus bar 2 (50 x 6) mm per phase
v) Distance between bus bars 65mm to centers between
phases
vI) Degree of protection provided for IP-51 (as per IS-2147)
enclosure.
vii) Material of bus bars Aluminum
viii) Material of bus bar support DMC
viii) Temperature rise over the 350C
specified ambient when carrying
rated current
ix) Short time rating 50 KA for 1 sec.

x) Momentary rating (peak) 105 KA
xi) Rated current of bus bar MCC-1 & MCC-2 –1050A MCC -3
bar & MCC-4-525A
xii) Bus bar short time rating 35 VA, 50 KA for 1 sec.
xiii) Cable entry a) Power Top
b) Control Top
xiv) Max. Power frequency withstand
voltage (1 min.) for
a) Power circuit 2.5 KV
b) 110V control circuit 1.5 KV
Rev. No. : 02, Oct. 2008
xv) Voltmeter
Range 0-500V AC for MCC-1, 2 ,3& 4
Deflection 900
xvi) Ammeter
Range 0-600A for MCC-1, 2 ,3& 4
Deflection 900
xvii Voltage Transformer for voltmeters
Rated voltage 415V, 3 phase, earthed
Insulation level 3 KV
Frequency 50 Hz
Transformer ratio 415/110 V
6.0 LIGHTING
Power supply to lighting and receptacles is provided through local wall mounted distribution
boards. Power supply to DBs is obtained from motor control centers. An average illumination
level of 200 Lux is provided for Waste management Plant. In control room the illumination
level is 450 lux. requirements. Different type of lighting fixtures used in Waste management
Plant is given below.
i) 2 x 40 W fluorescent industrial fittings (240V AC)
ii) 2 x 40 W fluorescent recessed decorative fittings (240V AC)
iii) 2 x 40W weather proof fluorescent fittings (240V AC)
iv) 60W incandescent recessed fittings (48V DC)
v) 240V AC 60W bulkhead fittings
vi) 240A AC, 60W weather proof bulkhead fitting
vii) 240V AC 250W HPMV fixtures.
Emergency lighting is derived from 48V DC battery and battery charger located in WMP
Control room.
Rev. No. : 02, Oct. 2008


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NAPS TRAINING MANUAL ON ELECTRICAL SYSTEMS NAPS/STC/TM/50000-05

1.3 CLASS -IV SUPPLY SYSTEM

1.4 CLASS III SUPPLY SYSTEM: -

1.5 CLASS II SUPPLY SYSTEM

1.7 CLASS II CONTROL SUPPLY SYSTEM

Rev. No. : 02, Oct. 2008

1.9 MOTOR CONTROL CENTERS SYSTEM

1.9.3 CLASS II SYSTEMS

1.12 PROTECTIVE RELAYING

Rev. No. : 02, Oct. 2008

GENERATOR AND STATIC EXCITATION SYSTEM

Rev. No. : 02, Oct. 2008

The output of an electric generator is a function of the volume of the machine,

Rev. No. : 02, Oct. 2008

3.1.3.4 DISTILLATE HEADER:

Rev. No. : 02, Oct. 2008

assembly is rigidly supported on an independent pedestal on the exciter side. There

Rev. No. : 02, Oct. 2008

3.1.4 GASES REQUIRED FOR FILLING GENERATOR:

Z = V1 = 112 ~ 10 CO2 cylinder

V1 = 2.5 x V = 2.5 x 56 = 140M 3.

Amount of H2 required filling the generator to operating pressure

V1 = pxv = 3.5 x 56 = 206 M3

Z= V1 = 206 = 42 cylinders of Hydrogen

Z = V1 = 112 ~ 10 CO2 cylinder

Amount of compressed air required for removing CO2 (3 generator volumes)

V1 = 3xV = 3 x 56 = 168 M 3 of air at NTP

Rev. No. : 02, Oct. 2008

i) Maximum continuous kVA rating. 264MVA

At Maximum capability & 0.9 p.f 98.6%

B) GENERATOR VOLUME AND FILLING QUANTITIES:

i) Total gas volume of the generator. 56 M3

C) HYDROGEN IN STATOR CASING:

i) Nominal pressure of hydrogen. 3.5 Kg/cm 2 (G)

D) DISTILLATE OR D.M. WATER TO STATOR WINDING:

3.1.5.3 HYDROGEN COOLER DATA:

Rev. No. : 02, Oct. 2008

3.1.5.4 SEAL OIL COOLER DATA:

Sl. No. Particulars Feature Units

i) Tubes Cupro Nickel

i) Feature pressure, waterside. 12 K/g/cm 2 (g)

3.1.5.5 STATION WATER COOLER DATA:

2. Heat Load 751 KW

i) Shell. Stainless steel

i) Feature pressure, (primary water) 8 Kg/cm 2

3.2.1 GENERAL DESCRIPTION

Besides these reliability measures taken in the converter section corresponding

Supplementary signal acting on the regulator is supplied from the stabilizer

3.2.2 AUTOMATIC CONTROL:

Rev. No. : 02, Oct. 2008

3.2.3 MANUAL CONTROL

Rev. No. : 02, Oct. 2008

3.2.4 AUTO/MANUAL CHANGEOVER

(i) AVR PT supply fail.

3.2.5 POWER SUPPLY UNITS:

Rev. No. : 02, Oct. 2008

3.2.6 SUPPLY A & M

The following protections are provided for the excitation system.

i) Transformer over current instantaneous & time delayed.

7.0 ALARM AND ANNUNCIATIONS

7.1 The following annunciations are provided in control room.

- General excitation control supply fails ANN 4335

- Supply for limiter circuit failed.

8.1 The following meters are provided on the excitation panel.