CHAPTER 1

BHARAT HEAVY ELECTRICALS LIMITED-THE COMPANY

 BHEL is one of the largest engineering and manufacturing enterprise in India in the energy-
related/infrastructure sector today. BHEL was established more than 50 years ago and has
been earning profits continuously since 1971-72 and achieved a milestone of being a 5.5
billion $ company. BHEL has been paying dividends over a quarter century.

 BHEL’S vision is to become a world-class engineering enterprise, committed to enhancing

stakeholder’s value. The company is striving to give shape to its aspirations and fulfill the
expectations of the country to become a global player.
 BHEL has :

 Installed equipment for over 90,000 MW of power generation for utilities,

captive and industrial users.

 Supplied over 2, 25,000 MVA transformer capacity and sustained equipment

operating in transmission & distribution network up to 400 kV AC & DC.

 Supplied over 25,000 motors with Drive Control System to Power project,
Petrochemicals, Refineries, Steel, Aluminium, Fertilizer, Cement plant etc.

 Supplied Traction electrics and AC/DC losses to power over 12,000 kms
railway network.

 Supplied over one million values to Power plants and other industries.

 BHEL’s operations are organized around three business sectors namely :

 Power
 Industry including Transmission, Transportation, Telecommunication
& Renewable Energy and
 Overseas Business
This enables BHEL to have a strong customer orientation, to be sensitive to his needs and respond
quickly to the changes in the market.

 The wide network of BHEL consists of :

 14 manufacturing divisions
 4 Power Sector Regional centers
 8 Service centers and
 18 Regional offices
 4 PS Region Centres namely :
- PS-NR Noida. ( J & K, Punjab, Haryana, Delhi,
UP, Uttaranchal, Rajasthan )

- PS-SR Chennai. ( Karnataka, Tamil Nadu, Kerala,

AP)

- PS-ER Kolkata. ( WB, Bihar, Orissa, Jharkhand,

North Eastern States )

- PS-WR Nagpur. ( Gujarat, MP, Chhattisgarh,

Maharashtra )

 The greatest strength of BHEL is its highly skilled and committed 42,600 employees. Every
employee is given an equal opportunity to develop himself and grow in his career.
Continuous training and retraining, career planning, a positive work culture and participative
style of management have engendered development of a committed and motivated
workforce setting new benchmarks in terms of productivity, quality and responsiveness.

UNITS AND PRODUCT PROFILE

UNIT PERIOD PRODUCTS

 Bhopal Established –1956 1. Thermal Sets (30/120/210 Mw)
2. Marine Turbines
(HEL) Production Started-
3. Nuclear Turbines (Upto 235 Mw)
1960
4. Hydro Sets (5 Mw To 200 Mw)
5. Power Transformer Upto0-400 Kv
6. Switchgear (Bulk Oil, Mocb, Sf6)
7. Heat Exchangers
8. Capacitors, Rectifiers And Thyristor Convertors
9. Traction Systems
10. Avr & Static Excitation

Haridwar Established-1963 1. Thermal Sets (210/250/500 Mw)

2. Gas Turbine Sets
(HEEP) Production Started-
3. Nuclear Sets (235/500 Mw)
1967
4. Hydro Sets
5. Ac/Dc Motors

Hydrabad Established-1963 1. Thermal Sets (60/110 Mw)

2. Bowl Mills
(HPEP) Production Started-
3. Synchronous Condensers
1965
4. Industrial Turbo Sets
5. Pumps
6. Oil Rigs
7. Heat Exchangers
8. Gas Turbines

Tiruchy Established-1963 1. Boilers

2. Boilers Auxiliaries
(HPBP) Production
3. Industrial Boilers
Started-1965 4. Valves
 Haridwar Established-1974 1. Ci Castings 12000 Mt
2. Nf Castings 250mt
(CFFP) Production Strarted-
3. Steel Castings 6000mt
1976
4. Forgings 3250 Mt
5. Billets & Blooms 4000mt
6. Ingots 10000 Mt
7. Hot Die Steel

Jhansi Production Started- 1. Dry And Special Transformers (Upto 220 Kv)
1976 2. Freight And Locomotives
(TP)

Tiruchi Established-1976 1. Seamless Steel Tubes

(SSTP) Production Started-

1979

Bangalore Established-1976 1. Energy Meters,

2. Plant Electronics(Digital Switching Systems,
(EDN) Remco (Merged With
Simulators, Rural Automatic Exchange(Rax))
Bhel) -1980
3. Power Devices

4. Thyristor Convertors

Bangalore (EPD) Set Up-1932 1. Disc Insulators

2. Line Hardware
Remco (Merged With
3. Bushings
Bhel) -1980
4. Solid Core Insulators

Bangalore (ISG) Established-1977 To Provide Integrated Services In Project Engg.,

Marketing, Erection & Commissioning Of Industrial drive
 Control Systems Related To Industries

Ranipet Established-1976 1. Fans

2. Electrostatic Precipitators
(BAP) Remco (Merged With
3. Air Preheaters
Bhel) -1980
4. Bag Filters
5. Wind Mill Generators

Goindwal Established-1983 1. Gate Valves

(IVP) Production Started-

1984

Jagdishpur Production Started- 1. High Tension Ceramic Insulators

1984 2. Repair Shop (Can Be Engaged For Production Of
(IP)
Critical Spares)
Varansi

(HERP)

Rudrapur Production Started- 1. Solar Water Heating Systems

1984 2. Solar Lantern
3. Busducts

Gurgaon 1. Solar Photovoltaic Cells

(ASSCP)

 Project Engineering Management Division (PEM) is a division within the power

group to provide total Systems Engineering for BHEL equipment, as well as for procurement,
erection & commissioning of non-BHEL systems & equipment for thermal power stations.
 BHEL business is in the field of power generation equipment, which is handled by the Power
Group and covers all the services related to power projects from concept to commissioning
in keeping with the corporate aim of developing BHEL into a world-class engineering
organization.

Customer
Consultant National Bodies

Project Engineering
Contracting Project/site Management
Agencies Management

BHEL
Mfg. Units Quality/Inspection Agencies

Balance of Plant Vendors

Fig: PEM & its Co-ordination

 In 1974, BHEL set up its engineering consultancy wing

under the name Consultancy Services Division (CSD) to address the market demand for
turnkey services in power and related areas. In 1977,CSD was re-christened as Projects
Engineering Division (PED). Since 1984, it has been known as Project Engineering
Management (PEM).

 In a span of around 28 years PEM has engineered Thermal Power Stations with a total
capacity of around 23,000MW. In view of the high degree of technical excellence
achieved, there is an ever-increasing participation in National & International Power
Projects.

BHEL PERFORMANCE HIGHLIGHTS (2009-10)

- BHEL notched up its highest-ever turnover of Rs. 34050 Crore, registering a growth of 21
% over the previous year. Profit Before Tax (PBT) surged 31 % at Rs. 6353 Crore, Net
Profit (PAT) is Rs. 4287 Crore, as against Rs. 3138 crore of last year - a growth of 37%. The
company is on track to becoming a $10-11 billion turnover company by 2011-12 in line with
its strategic plan.

- BHEL secured orders worth Rs.59,031 Crore while operating in competitive domestic
and overseas markets. At the end of the year, total orders in hand for execution in
2010-11 and beyond, stand at about Rs. 143800 Crore - the highest-ever.

- First supercritical order from the private sector for 3x660 MW Bara, Prayagraj Power
Generation Company Ltd. of the Jaypee Group

- BHEL and Toshiba Corporation, Japan have signed a MoU to explore the possibility
of establishing a Joint Venture Company to address Transmission and Distribution
(T&D) business in India and other mutually agreed countries. The JV company will
undertake marketing, designing, engineering, supply, erection, testing and
commissioning of equipment and projects in Extra High Voltage Alternating Current
(EHVAC) and Ultra High Voltage Alternating Current (UHVAC) range including
765kV transformers and reactors and Gas Insulated Switchgear (GIS), in addition to
other products and systems.

- MoUs have been signed with Alstom for participating in the tender for setting up a
factory for Electric Loco components at Dankuni, West Bengal and with GE for
participating in the tender for setting up a Diesel Loco factory at Marhowra, Bihar.

- BHEL synchronized/commissioned 6,583 MW of power plant equipment during the

year which includes 5,220 MW for Utility, 634 MW for Captive/Industrial sets and
729 MW in overseas markets. In addition, BHEL was ready for commissioning of 412
MW of hydro power projects and is awaiting critical inputs viz. water / power
evacuation system
- The installed capacity of BHEL supplied Utility sets went up to 91,481 MW and
BHEL maintained its two-third share in the country's total installed capacity.
- Capability to deliver 15,000 MW of power equipment per annum established and
further augmentation to 20,000 MW per annum by March 2012

- During the year, BHEL-built power generating sets generated an all-time high 490
Billion Units of electricity which was 74% of the total power generation in the
country.

- BHEL’s products and systems are technology intensive and R&D/technology

development is of strategic importance to the company. During the year, BHEL
invested Rs.788 Crore on R&D efforts : 14 % higher than the previous year. This
corresponds to 2.3% turnover of the company.

- BHEL also filed 263 patents and copyrights, enhancing the company’s intellectual
capital to 1100 patents and copyrights filed, which are in productive use in the
company’s business. The year witnessed a massive growth in grant of patents and
copyrights. A total of 145 patents and copyrights were granted which is 60% higher
than last year.

- Continuing its winning streak in the CII Exim Award Scheme for business excellence
as per the globally recognised model of European Foundation for Quality
Management, BHEL has become the first Public Sector Company in the country,
whose six units participated in the CII-EXIM Business Excellence award scheme and
all got recognition certificates from CII. While its Bhopal, Trichy and Power Sector
Eastern Region have won the ‘Commendation for Significant Achievements in TQM’,
its Ranipet unit, Electronics Division and Power Sector Southern Region have
received the ‘Commendation for Strong Commitment to TQM’

- In conformity with its concern for the environment, BHEL has been contributing to
the national effort for developing and promoting renewable energy based products on
a sustained basis. During the year, as its contribution to the Jawaharlal Nehru National
Solar Mission, BHEL is in the process of setting up two eco-friendly Grid-Interactive
Solar Photovoltaic (SPV) Power Plants of 2 MW & 1 MW, on turnkey basis, for
 KPCL in Karnataka. This is the first order won by BHEL for megawatt size grid
connected SPV power plants.

- In recognition of BHEL’s contribution to the greening of the Lakashadweep Islands,

BHEL was awarded the ‘India Power – Jury award 2009’. BHEL has commissioned
1065 kw of solar photo-voltaic grid interactive as well as stand-alone plants at 12
locations contributing to the preservation of the natural habitat of these pristine
islands

- Business Standard newspaper recognised BHEL as the Star Public Sector Company of
the year 2009. Significantly, BHEL was earlier awarded the same recognition in 2006,
making it the only PSU to have won it twice.

- For the fourth consecutive year, BHEL’s performance was recognised by the
prestigious publication ‘Forbes Asia’, which featured BHEL in its fifth annual
‘Fabulous 50’ list of the best of Asia-Pacific's publicly-traded companies with
revenues or market capitalisation of at least US$ 5 billion, having highest long-term
profitability and sales & earnings growth. Notably, BHEL is the only Indian PSU to
figure on the elite list.

Power plant Electrical Distribution system

Modern power plants have an extensive electrical distribution system to provide reliable
power to all of the support equipments in the power plant. The utility operating the power
plant is to generate electricity 24 hours a day and 7 days a week.
Large electrical generation power plants utilize fossil fuels such as coal , oil and natural gas
to fire boilers that produce massive amounts of heat to spin large turbines connected to
electrical generators. Regardless of the type of plant ,the station auxiliary components require
substantial electrical distribution system to produce to produce reliable power.Tn thermal
plant , auxialiries include water pumps that provide cooling water to the turbine condenser,
large fans that move the combustion air through the boiler. The also have large battery banks
that provide backup DC power to the power controls. These batteries are charged by large
battery banks.
The one line diagram shows the simplified arrangement of the primary electrical
components.The output of the generator is connected to isolated phase busducts (shown as
green line)It connects to two other components station auxialiary transformer and step up
transformer.
The step up transformer steps up the generator voltage to 22KV to 500KV (in this e.g.).
The unit auxiliary transformer is the power transformer that provides power to the station
auxiliaries during normal operation. This transformer is connected directly to main genartor
to produce the cheapest power since any power from the transmission lines has losses
associated line losses and transformer losses. The UAT is a three winding transformer having
one primary winding rated 22KV and two secondary winding rated 6.9KV and 4.2KV.
The UAT’s secondary windings are connected to the Non segregated phase bus duct.This bus
work conveys the power to different medium voltage switchgears located in the plant. Tn this
plant, there two sets of switchgear buses rated at 6.9KV and 4160V. Each 6.9KV and 4160V
bus can be energized from UAT.
The start up transformer is energized from an incoming transmission line rates at 230KV.This
transformer is also a three winding and can feed all four of the switchgears lineups.It is used
to power the plant equipment while starting the unit up from the cold conditions.
Generator
The generator produces electrical power whose utility is in business to produce and sell.
The three main primary components are : stator, rotor ,exciter
Rotor: The rotor on the main generator is composed of a steel shaft to which a field winding
has been added. This shaft connects to the main turbine shaft and rotates at the same
rotational speed as the turbine. The field winding is located in the slots in the rotor. When DC
current is passed to the field windings, the rotor forms an electromagnet with North and
South
Isolated phase bus ducts
It is used to connect the high voltage and high current output of the genrators to transformers
that either transform the voltage higher for the transmission of the power over the utilty
transmission grid or steps the voltage down for use in the station.In this fig,it is connecting to
an auxiliary transformer. The isolated phase bus duct is comprised of Al tubes approx. 18
inches in diameter.The tubes form a protective enclosure to hosue the actual energized bus
bar which is mounted on insulators. Each phase of the three phase system is isolated from
other two phases.The isolation minimizes the possibility of a short circuit involving al three
phases .
Step up transformer
The step up transformer transforms the voltage from the generator to a higher votage
necessary for the transmission of the generator’s power over the utility’s electric
grid(transmission network).These large power transformers come in two basic
configurations:single three phase transformer or three single individual transformers.
Station startup transformer
The station startup transformer is a power transformer used to connect the power station to
the transmission system so that power is available for the plant equipment when the plant is
being started. Power plants are routinely brought down for servicing of major equipments or
when the demand for power is low such as in the spring or fall.This transformer provides the
so called “Startup power”. The Start up transformer is also used when the plant is being
shutdown to power the station equipment that operates regardless of whether the plant is
producing power.Finally, the Startup transformer is used when ever the station auxiliary
transformer is unavailable such as planned maintainence or repair .
Power plants usually have a transmission substation close to the plant. Here several
transmission lines, sometimes at different voltages, come together and a line will be brought
to the plant startup power.
Unit Auxiliary Transformer
The SAT is connected to the generator output by a tap off of the isolated phase bus duct.The
high voltage winding of the transformer is designed to match the generator output voltage
which is 22000or 22KV.It has a primary winding and two separate secondary windings at
different voltages.This allows the station to have two different voltage level at one 6.9KV
windings allows the use of similar higher voltage motors for large pumps or fans.The higher
voltage motors offer several advantage over 4.16KV motors such as higher starting torques
and lower full load currents.
This transformer and the station start up transformer have to be specified and connected in a
configuration so that output voltages will be in phase. The bus voltages need to be in phase so
that live bus transfers can be facilitated. This is accomplished by the internal connections of
the transformer phases, as specified, as either delta or wye connected. This will assure that
the incoming voltage from the transmission line is in phase with the voltage from the
generated(after being transformed by the auxiliary transformer).
The UAT is the normal power source for the station equipment when the plant is operating.
Once the generator is brought on line and is connected to the transmission grid, station loads
can be transferred from the start up transformer. This would normally be done by closing the
feed breakers from auxiliary transformer (1A-1 and 1B-1 transformer breakers on the
A6.9KV bus) while the feed breakers from the startup transformer (brkr 1A-2 and 1B-2) are
still closed.The two transformers are now operating in parallel.As soon as the Auxiliary fees
breakers are closed the plant operators open the feed breakers from the Start up transformer
as parallel operation of the transformers is not desired operating mode.this is because having
two transformers connected to the switchgear provides two sources of fault current should a
short circuit occur in the switchgear or downstream of the switchgear.The resulting total fault
current may exceed the switchgear’s short circuit rating and a catastrophic failure of the
switchgear could occur.
Non segregated phase bus duct
Non segregated phase bus duct is typically used to connect the station auxiliary transformer
low voltage winding to the station switchgear. Some stations use run of cable or more
isolated phase bus duct in lieu of non segregated bus.
Non seg bus duct is comprised of Cu bars which are insulated and held in place with a
support system made of fibreglass or some other non conducting material.All three bus bars
are surrounded by a grounded metal enclosure.
Medium voltage switchgear
The 6.9KV and 4.16 KV buses in the one line diagram represent the plant medium voltage
switchgear.Switchgear refers to a line up of equipment to house circuit breakers,protective
relays and control wiring.The switchgear is completely enclosed in a metal structure that
prevents individuals from coming in contact with the lethal voltages within this equipment.
Switchgear is made up of a series of cubicles which are bolted together in a row.
Secondary unit substations(SUSs)
SUSs are essentially a repest of the configuration of the station auxiliary and medium voltage
switchgear but at lower voltage. Breakers from one part of the plant switchgear will feed a
transformer that will reduce the voltage to 480 V.This transformer is an integral part of a line
up of 480Vswitchgear.Sometimes the unit substation are designed with a transformer at each
end of the switchgear.These are referred to as “double ended “secondary unit substation.The
one line diag is single ended substations witht tie breakers which provides essentially the
same reliability as a double ended substation.
SUSs are used to feed the large majority of components ina power plant by further
distributing power to load centers, motor control centers and battery chargers.
Chapter
Switchgears
Switchgear is a set of electrical panels through which switching, metering, controlling and
protection of electrical equipment is performed.

The National Electrical Code® (NEC®) defines a Switchboard as a large single panel, frame, or
assembly of panels on which are mounted, on the face or back, or both, switches, over current and
other protective devices, buses, and usually instruments.

Switchboards are generally accessible from the rear as well as from the front and are not intended
to be installed in cabinets.

The term Switchgear used in association with the electric power system, or grid, refers to the
combination of electrical disconnects, fuses and/or circuit breakers used to isolate electrical
equipment. Switchgear is used both to de-energize equipment to allow work to be done and to
clear faults downstream.

Switchgears are located where isolation and protection may be required. These locations
include generators, motors, transformers and substations.

Switchgear forms an important part of electrical plant or equipment. The trouble-free functioning of
a power station depends to a great extent to its properties, just as do the continuous supply of
power to an industrial factory or the reliable operation of a drive.

Increasing demands on the electrical and mechanical properties of the devices and on their
adaptability and economy have all accelerated the process of their development and considerable
impetus was given by advances in rationalization and automation.

TYPES OF SWITCHGEAR
A piece of switchgear may be a simple open air isolator switch or it may be insulated by
some other substance. An effective although more costly form of switchgear is "gas insulated
switchgear" (GIS), where the conductors and contacts are insulated by pressurized sulphur
hexafluoride gas. Other common types are oil or vacuum insulated switchgear.

Circuit breaker is a special type of switchgear that is able to interrupt fault currents. Its
construction allows them to interrupt fault currents of many hundreds or thousands of amps.
The quenching of the arc when the contacts open requires careful design, and falls into four
types:

 Oil circuit breakers rely upon vaporization of some of the oil to blast a jet of oil through the
arc.
 Gas (SF6) circuit breakers sometimes stretch the arc using a magnetic field, and then rely
upon the dielectric strength of the SF6 to quench the stretched arc.
 Vacuum circuit breakers have minimal arcing (as there is nothing to ionize other than the
contact material), so the arc quenches when it is stretched a very small amount (<2-3 mm).
Vacuum circuit breakers are frequently used in modern medium-voltage switchgear to
35,000 volts.

Air circuit breakers may use compressed air to blow out the arc, or alternatively, the
contacts are rapidly swung into a small sealed chamber, the escaping of the displaced air thus
blowing out the arc.

 By voltage class:
 Low voltage (less than 1000 volts AC)
 Medium voltage (1000-35,000 volts AC)
 High voltage (more than 35,000 volts AC)

FUNCTIONS

 One of the basic functions of switchgear is protection, which is interruption of short-

circuit and overload fault currents while maintaining service to unaffected circuits.

 Switchgear also provides isolation of circuits from power supplies.

  Switchgear also is used to enhance system availability by allowing more than one
source to feed a load.

Low voltage switchgear

415V power is derived from LV service transformers connected to the various sections of the 6.6kV
switchboard as shown in the 'Electrical Single Line Diagram for Auxiliary Power Distribution’. Dry type LV
service transformers are generally envisaged for Unit PCC (Power Control Center) and Station PCC, ESP &
other auxiliary plants for indoor installation (in line with the customer spec). The service transformers
are rated as per the power requirement of the associated loads. Power Control Centers (PCCs), Motor
Control Centers (MCCs) and Power-cum-Motor Control Centers (PMCCs) are provided as shown in the
drawing to feed auxiliary loads and services. Incoming supplies to PCCs & PMCCs are duplicated with
auto changeover facility to ensure reliability of distribution supplies.

Motors rated 160 kW and below are connected to 415V system.

Low voltage switchgear is not manufactured by BHEL.

USE OF LOW VOLTAGE SYSTEM

 Used to feed auxiliaries such as pumps, fans, actuators.
 Power supply to various distribution boards, control panels, lighting boards, battery
chargers.
 All other miscellaneous loads requiring 415V or 240V.
SINGLE LINE DIAGRAM SHOWING PART OF THE LOW VOLTAGE (415V)
SWITCHGEAR OF A TYPICAL COMBINED CYCLE POWER PLANT

POWER CONTROL CENTER (PCC)

The switchboards are single front draw out type and compartmentalized to accommodate circuit
breakers in single tier or double tier. The switchboard has a short circuit rating of 50kA rms for 1 sec.
All switchboards up to 1600A rating conform to DOP IP: 52, while the switchboards rated above
1600A are provided with louvers and conform to DOP IP: 42. The outgoing feeders rated 630A and
above are provided with ACBs. Switch fuse units are provided for rating up to 400A. Each ACB feeder
is compartmentalized and has a hinged door for independent access during maintenance. The
compartment height is adjustable for maximum utilization of panel space. The circuit breakers are
triple pole, air break, horizontally draw out type having 'test/service/isolated' positions. The circuit
breakers are electrically operated having motor wound, spring charged stored energy mechanism.
The control voltage of circuit breakers is 220V DC.

Metering, protection and control equipment like ammeter, voltmeter, relays, control and selector
switch etc. are housed in the switchboard. Interlocks, auto changeover between incomers and bus
coupler breaker are provided as per requirement. Feeder protections comprising over current and
earth fault relays are provided. Alternatively, circuit breakers may have built–in releases for the
same purpose. Breaker controlled starters for motors are generally connected directly to PCC and
provided with short circuit, overload and earth-fault protection. Interposing relays for interface with
C&I systems are provided, wherever required. Cable glanding and termination arrangement is
envisaged at the rear side of the ACB panels.

Busbar System:
The busbar system can be either TPN-E or TP-E. Each vertical section is provided with its
own set of vertical droppers and vertical earthbar. Horizontal busbars run throughout the
length of the switchboard. Auxiliary busbars have a separate chamber.

Interleaved Busbar System:

In the conventional busbar system, conductors of each phase are grouped together. At higher
current ratings in each phase, more than one flat of busbars are used. Theses flats are placed
quite close to each other. As a compounded result of ‘skin effect’ and ‘proximity effect’,
current distribution in each flat of the same phase is uneven. It also results in unequal
temperature rise in different phases. At very high currents, say above 2500A, any
enlargement of the cross section of conductors does not result in a proportionate increase in
the current carrying capacity of busbars.

The interleaved Busbar System therefore offers a cost effective solution, specially at high
currents. In this busbar system, conductors of each
phase are placed as R-Y-B-R-Y-B instead of RR-YY-
BB. Such an arrangement offers much lower impedance. Also, impedance of each phase is
fairly even. This results in uniform temperature rise in all three phases. It also reduces
dynamic forces caused by short circuits, enabling the system to withstand much higher fault
levels.

CONVENTIONAL SYSTEM INTERLEAVED SYSTEM

The interleaved busbar system, thus enhances the busbar current carrying capacity, and
therefore enables optimum utilization of busbar conductors. Reduced power loss leads to
energy savings. The reduction in temperature rise, especially important in high ambient,
increase the reliability and life of equipment, and also reduces ventilation and cooling
requirements.

Moulded Support System:

Busbar supports are made of fiber glass reinforced thermosetting plastic. Individual supports
for each phase eliminate risk of tracking between phases.

Cabling:
The cabling chamber of each panel is at the rear and is separated from the busbar zone and
ACB compartment. The cabling space can be extended to accommodate extra cables by an
add-on chamber. To enhance safety, the control terminals can be mounted in a separate
compartment below the ACB chamber, away from power cables.

Safety Interlock:
Door interlock ensures safety of operating personnel.
 The door cannot be opened unless the breaker is in ‘Isolated Position’, i.e. prevents
the door from opening when the breaker is in the ‘Connected and Test Positions’.
 The breaker cannot be racked in or out of the ‘Service Position’ unless the door is closed.
 Defeat facility is provided to facilitate testing/inspection.
 Maintenance:
Precautions before starting maintenance:

 Switch off incoming power supply before removing top plates and side cover. Look out incoming
power supply.
 Measure voltage on busbars to ensure that busbars are de energized.
 Switch off control supply.
 Isolate remote control voltage sources.
 Short all CT secondaries.
 For safety of personal, while working on busbars, provide temporary earthing using a metallic
chain / strip near the work place. Remove this earthing only after the job is completed.

MOTOR CONTROL CENTER (MCC)

Many motors are used in industrial applications. It is often desired to control some or all of the
motors from a central location. Motor control centers are designed for this purpose. They group
combination motor starters in a single enclosure. A combination motor starter contains the starter
and circuit protection in one unit.

Required numbers of motor control centers are provided for the power plant and these are located near
the respective loads/plants.

 Motor control centers are fixed/drawout type, double front/single front with degree of
protection IP: 52.
 Each vertical panel is divided into distinct zones for busbars, feeders, power cabling and auxiliary
busbars.
 The compartment house modules for individual feeders comprising equipment such as fuse
switches, contactors, relays, timer and associated auxiliary equipment.
 For optimum utilization of panel space, compartments have variable heights- from 100mm up to
1300mm in steps of 100mm thus allowing up to 20 feeders in a panel.

MCCs rated above 400A have air-circuit breakers as incomers. For ratings up to 400A, load switches are
provided. Outgoing supply feeders of rating 400A and below are equipped with switch fuse units. MCCs
fed by circuit breakers have a short circuit rating of 50kA rms for 1 sec. whereas MCCs fed by switch fuse
units have a short circuit rating of 50kA for 0.2 secs.

Motors rated up to 160 kW are provided with bi-metallic relays for thermal overload protection and HRC
fuses for short circuit protection. Motors rated above 160 kW are provided with locked rotor protection
in addition to above. Motor starters are direct-on-line type.

Motor starter schemes have provision for 240V supply for space heating for motors rated above 30kW.

Two common control transformers of ratio 415/110V and adequate rating (one on each section of MCC)
are provided in each motor control centre for the purpose of control supply to all starters in that MCC.
Each section of MCC is provided with bus voltage module comprising of fuse and voltmeter with selector
switch. An ammeter is provided for motors rated above 30 kW. For drives requiring ammeter on remote
control equipment, transducer is provided in the MCC.

Fig. Showing Motor Control Centre (MCC)

POWER CUM MOTOR CONTROL CENTRES (PMCC)

In many cases, it is required to control the supply side as well as control and protect the load. In such
cases a combination of MCC and PCC is used which is known as Power and Motor Control Center
(PMCC). In this type of control centers, the PCC and MCC are combined together to form a single
panel. The incomer feeders receive the supply voltage and transfer it to the busbars. The busbars
run throughout the length of the panel. The equipment in the MCC taps the voltage from these
busbars.

For load centers where the associated loads/plant are located in the vicinity of the auxiliary transformer,
power control centers and motor control centers are made common to form a PMCC having features
described above for PCC and MCC and are in double front execution.

The switchboards are factory assembled indoor, metal enclosed, floor-mounted, double front
drawout type and compartmentalized to accommodate circuit breakers in single tier. However
double tier arrangement may be provided for motor feeders (No two similar application motor
feeders will be kept one above the other in this case) The main bus-bars are of aluminum. The
switchboard shall be designed to withstand a short circuit rating of 50kA rms for 1 sec. All
switchboards conform to DOP IP: 52, however incomer & bus coupler breakers of switchboards
having rating of 1600A & above shall conform to IP-42. The switchboards shall be provided with
ACBs as required. The circuit breakers are triple pole, air break, and horizontally draw-out type
having ‘test/service/isolated’ positions. The circuit breakers are electrically operated having motor
wound, spring charged stored energy mechanism. The control voltage of circuit breakers is 220V DC.

Metering, protection and control equipment like ammeter, voltmeter, relays, control and selector
switch etc. are housed in the switchboard. Interlocks, auto changeover between incomers and bus
coupler breaker are provided as per requirement. Feeder protections relays as per specifications are
provided.

AC Distribution Boards (ACDBs)

AC distribution boards are provided for three phase and single phase power distribution. The DBs
are fixed type and floor mounted. Switch fuse outlets are provided, as required.
CHAPTER
DC Control Power System

The DC system is the ultimate power source for the control of power station under normal
and abnormal working conditions. It also provided power for the safe shut down of the sets
under emergency conditions. The most critical component of a protection, control and
monitoring (PCM) system is the auxiliary dc control power system. Failure of the dc control
power can render fault detection devices unable to detect faults, breakers unable to trip for
faults, local and remote indication to become inoperable etc.
The auxiliary dc control power system consists of the
battery, battery charger, distribution system, switching and protective devices, and any
monitoring equipment. Proper design, sizing, and maintenance of the components that make
up the dc control power system are required.

Main Components of a DC system

 Battery
 Battery Charger

Battery Systems
Under normal operation, the battery charger supplies dc power to recover the battery voltage
after a discharge and to maintain the float voltage while supporting any self-discharge
losses in the battery system. The charger also supplies the continuous loads on the auxiliary
dc system, while the battery supports intermittent medium-rate and momentary high-rate
loads, such as trip coils and dc motors. Upon failure of the battery charger or loss of its ac
supply, the battery has to support the continuous loads along with the intermittent and
momentary loads that may occur before the battery charger is repaired or the ac supply is
restored. Battery sizing calculations are based upon assumptions of a worst-case scenario
load profile of continuous, intermittent, and momentary loads during outage of the battery
charger and/or loss of ac supply.

The total battery charger outage duration is a critical factor that must be based upon realistic
operational criteria. For example, upon failure of a battery charger, if the design criteria
for sizing the battery uses an eight-hour load profile, then available spare equipment,
operating, monitoring, and inspection practices must ensure that maintenance personnel can
respond to and resolve the problem in less than eight hours. When evaluating a battery’s
ability to meet the design criteria, the minimum and maximum acceptable operating voltage
of critical equipment determines the “voltage window” for battery sizing and the end of the
discharge cycle.

If corrective action cannot be guaranteed within the design criteria time frame, the protection
and control system must be designed such that there is some means of protection for
complete loss of auxiliary dc control power. In many cases, remote backup cannot provide
detection of all faults covered by the local PCM system (transformer low-side faults in a
radial distribution substation for example). Unmanned facilities without
remote monitoring capability such as SCADA are especially problematic in this regard.

The various battery types have different discharge performance characteristics that often
result in different capacity (ampere-hour) ratings to meet the same load profile. Some
batteries may require larger ratings than others in order to meet the momentary high-rate
tripping duty portion of the load profile. Another factor that can affect battery sizing is the
design margin required to compensate for capacity and performance degradation caused by
aging and the prescribed capacity testing intervals. The expected low ambient temperature
at which the battery will have to perform requires a capacity derating factor for lead acid
designs in sizing calculations.

There have been several developments in substation equipment technology that can have an
impact on battery size requirements. These changes will result in different battery sizes being
required than may have been used in the past. This must be considered when building a new
substation or when upgrading the PCM systems in existing substations.

One factor that tends to increase the continuous load portion of the load profile for a given
size of substation is the use of microprocessor-based protective relays. Electromechanical
relays derived their operating power from the power system quantities that they were
measuring. The relays themselves typically did not have any continuous load draw, nor did
they store any data to assist in troubleshooting faults. Microprocessor relays, on the other
hand, have power supplies that continuously draw power. In addition to the relays, there are
often additional devices such as communications processors, HMI computers, etc., that
replace physical switches, lights, annunciators, and SCADA RTUs. These typically represent
a net increase in continuous loads on the battery system.

The intermittent and momentary loads may be reduced or increased with modern circuit
breakers. For example, lighter mechanisms may use smaller trip coils to operate. On the
other hand, independent pole operators have become prevalent, which means three times as
many trip coils as there were with ganged operators.

The stored energy operating mechanisms of modern circuit breakers have also changed. In
the past, the stored energy mechanism typically used pneumatic or hydraulic pressure to
store enough energy for multiple operations. These mechanisms were charged from the ac
station service supply. Springon-spring breaker mechanisms have become increasingly
common. These mechanisms have a large closing spring that closes the breaker and charges
the tripping spring. Thus they can only store enough energy for a single trip-close-trip
sequence.
If the motor that charges the closing spring is supplied from the dc system, this can add a
significant high-performance load to the worst-case load profile used in the design criteria.
One way to mitigate the impact of this type of mechanism on battery sizing is to
automatically disable automatic reclosing during a battery charger outage. This logic is
easy to implement in an integrated PCM system.

There are three major configuration for connecting the specified connected load
 One battery + one set of chargers(fig3)
 One battery + one set of chargers(one standby float charger)(fig4)
In this scheme, one charger supplies the DC load and other charger is in the standby
mode .In case one charger goes out of service the other charger supplies the DC load .
 Two batteries +two chargers(fig5)
Under normal conditions both chargers will be ON, each catering to 50% of the loads.
In case ,one charger goes out of service , its associated battery shall meet the load
requirements till the bus coupler of the DCDB is switched ON.The other healthy
charger will then cater to 100%of the loads along with float charging both the
batteries.The incomer circuit in the charger circuit is manually switched OFF.
 In case of station AC supply failure,bot chargers are out of service and the batteries
will supply the loads each catering to 50% of the loads .On restoration of AC supply ,
the chargers take over the load requirements.
One battery bank is provided with one number Float-Cum-Boost Charger (FCB).
Each battery charger will be able to supply the unit load current while float charging
two battery sets, one highest rated DC motor for initial (trial) run and station
continuous load current. Typical details of batteries and chargers for each unit are
shown below :

Battery
Batteries are designed to cater the required load with a design margin of 20%.Duty cycle on
the battery shall include the following loads
 Continuous loads
 Momentary loads
 Intermittent loads
Maximum design ambient temperature is 50 deg. Celcius and minimum is 8.9
.
There are two common types of batteries that are used in substations. This may change with
time because there is continual development of new battery technologies. Selection of
which type to use should be based upon both reliability and economic criteria.
The two common designs presently used are:
 Ni –Cd pocket plate batteries
 Lead Acid Batteries

Properties Ni-Cd pocket plate batteries Lead acid batteries

Nominal voltage 1.2V/cell 2.0 V
End voltage 1.14 V 1.8 V
Float voltage 1.4-1.42 V/cell 2.15 -2.25 V
Boost voltage 1.7 V/cell 2.75 V/cell
Discharge rate 5 hrs 10 hrs

Containers are made up of glass fibre reinforced plastics or propylene .Vent

plugs

Battery Chargers
The function of 220 V DC battery chargers is to provide 220 V DC power to the 220 V DC
loads while simultaneously maintaining providing variable power to charge or maintain a full
charge on the battery. The battery chargers are 200 % slid state float cum boost chargers with
a design margin of 20 %.The battery chargers are interchangeable and typical within each
system. recharging of the battery occurs whenever 415 V power becomes available.

Float cum boost chargers

During float charging, each charger shall feed DC distribution board and as well as float
charge both batteries and shall maintain a DC voltage that will pass the minimum current
through cells to keep them charged without overcharging. In order to change the current
output , the chargers shall sense a DC voltage drop or rise at their output.
During boost charging, the battery charger operates on constant current mode(when
automatic voltage regulator is in service).It is possible to continuously adjust the boost
charging current over a range of 50 to 100 % of the rated output current for boost charging
mode. The charger output voltage automatically goes on rising, when it is operating in the
boost mode , as the battery charges up. For limiting output voltage of the charger a
potentiometer is present. All battery chargers are provided with automatic and manual
voltage regulators. A selector switch is provided to choose the float or boost mode.

Input to the charger is 415V ,3 phase 50 HZ power supply. The charger output voltage
remains within +/- 1% of the set value for AC input voltage of +/-10% frequency variation of
+/-5% .
The chargers are self regulating, natural air coiled ,static type provided with suitable double
wound transformer, full wave thyristor type rectifiers ,filter circuits. Solid state electronic
circuits have DC and AC transient voltage.
Nature of the DC loads

 System design with respect to

 Voltages
 Sizing of batteries
 Sizing of chargers
 Earthing
 Protection
 Emergency lighting
 System configuration
 Type of batteries
 Layout aspects
 Influence of emergency diesel generators in the power station
 Motor Starters

Choice of DC voltages
It is important to choose proper voltage levels for a dc system , depending upon the loads to
be fed and their permissible voltage tolerances. Loads connected to the dc system in India
have generally the following operating voltages :

Equipments Voltage levels

Switchgear protection 220 V (+10 % to-15%)
Motor driven valves 220 V (+/-10 %)
Emergency motor drives 220 V (+/-10%)
 Emergency lighting 220 V (+10% to-15%)
Field flashing 220 V (+10% to-15%)
Annunciation systems 24/48/220 V(+/-10%)
Fire fighting 12/24 V (+10% to -15%)
Communication 50 V (+/-10%)
Governing systems +/-24 V(20 V to 30 V)
Automatic TRS +/-24 V(20 V to 30 V)
Exitation systems +/-24 V(20 V to 30 V)
Static protection relays +/-24 V(20 V to 30 V)

It can be observed from the above that besides equipments suitable for 220 V dc , most of the
modern electronic equipments need lower dc voltages. Where only one voltage level is used,
then dc to dc convertors are to be used in respective equipment panels.
Trickle charging
Trickle charging, or float charging, means charging a battery at a similar rate as to its self-
discharging, thus maintaining a full capacity battery. Most rechargeable batteries, particularly
nickel-cadmium batteries or nickel metal hydride batteries, have a moderate rate of self-
discharge, meaning they gradually lose their charge even if they are not used in a device.
Care must be taken, however, that if a battery regulator is not employed, the charge rate is not
greater than the level of self-discharge, or overcharging and possible damage or leakage may
occur.

Float charger
The difference between a float charger and a trickle charger is that the float has circuitry to
prevent overcharging. It senses when the battery voltage is at the maximum level and
temporarily shuts off the charge (floats voltage at zero or a very minimal charge until it
senses that the battery output voltage has fallen, then resumes charging ). It may be kept
connected indefinitely.
Trickle charger
A trickle charger, on the other hand, will charge no matter whether the battery is fully
charged or not, so it needs to be connected and disconnected periodically. If left in place too
long, it will eventually boil the electrolyte out of the cells or damage the plates. Trickle
chargers will work to keep the battery charged, if used once a month or so for a day or two,
but the float chargers can be left connected indefinitely without potential harm to the battery.
Example
For example, a 24 volt battery pack, comprising twelve 2-volt flooded lead-acid cells, which
has been deeply discharged, would normally be restored by a boost charge of approximately
2.4 volts per cell for a short time (perhaps around 72 hours). Once the collective cell voltage
reaches a surface charge of 28.8 volts (2.4 volts x 12 cells), the charge rate would be switched
to the sustained lower float-charging rate of typically 2.23 volts.
Eventually, with the Boost charge removed, the surface charge will diminish slightly and the
battery-bank voltage will stabilise at a preset float voltage, in the case of the example above
to approximately 27 volts (2.23 volts x 12).
Charging rate
Charging rates for a trickle charge are very low. For example, if the normal capacity of a
battery is C (ampere-hours), the battery may be designed to be discharged at a rate of C/8 or
an 8-hour rate. The recharge rate may be at the C/8 rate or as fast as C/2 for some types of
battery. A float or trickle charge might be as low as C/300 ( a 300-hour discharge rate) to
overcome the self-discharge. Allowable trickle charging rates must conform to the battery
manufacturer's recommendations.

Economy
In low duty-cycle applications, where a relatively high current or power is required
infrequently, charger costs can be minimized by applying trickle-charging principles. This
can be an economy measure in cases where the charging method could be quite expensive if
the full charging rate were employed, such as solar-cell installations. Full battery capacity can
be achieved at a low charging current over a long period of time to provide a high-power load
for a short period.

Sizing of Battery
Following factors govern the battery size:
 Duty cycle
 No of cells
 Maximum and minimum system voltages permissible at the loads
 Battery life and ambient temperature
Duty Cycle
Duty cycle is a diagram which shows the load in amperes and lengths of time in minutes for
which they must be supplied by the battery under worst emergency conditions. Total time
span (duration of an emergency) of a duty cycle is determined by the requirements of
installation and need not exceed the time required to reduce the battery load to zero.
 Restoration of a.c. power
 Restoration of battery charger output
 Termination of battery loads
One of the major loads on the battery is the emergency oil pump. It is to be run till the turbine
comes to stand still. This generally takes 25 to 35 minutes. Considering this aspect and
allowing some margin the duration of emergency is generally taken as one hour in thermal
power stations.
With uniform provisions of 100 %main and standby emergency diesel generators in thermal
power stations, as also extensive interconnection in the grid, a.c. power can be restored faster.
In particular, properly maintained diesel generators can restore power to the a.c. emergency
board within a few minutes, thus adding considerably to the reliability of the DC system.
The a.c. loads supplied by battery during the duty cycle are classified as momentary loads
and continuous loads.
Load duty cycle for 220 V DC system
CURRENT
781
(AMP)

A1
68
3 A3 A4 A5
47 A2
0
A7
54 A6
51

1 15 16 60 120 599 600

TIME IN MINUTES
  Number of cells
The maximum allowable system voltage primarily determines number of cells

No. of cells = Maximum allowable battery voltage

Cell voltage required for float charging
However no of cells should also be checked for following considerations and rounded for
nearest number.
Minimum system voltage

Number of cells = Minimum allowable battery voltage

End of discharge cell voltage

The use of the largest possible number of cells allows the lowest end of discharge cell voltage
and hence the smallest size cell for the duty cycle.

 Temperature correction factor

Capacity requirement is to be corrected by temperature correction factor, Tcf.

R
Tcf =
[ 1+
100
(27−t ) ]
Tcf = Temperature Correction factor

t = Ambient temp of 15o C

R = Variation factor as per table 2 of IS: 1652 (=0.9)

 Tcf = 1.108

 Float Voltage
It is desirable to establish a float voltage at the high end of the manufacturer’s recommended
range to eliminate the need for frequent equalising charges to the battery. This higher float
frequent equalising charges to the battery .This higher float voltage reduces the number of
cells and increases the cell size.

 Charging rate
The time required the battery can affect number of cells and its size. The time required for a
recharge decreases as the charging voltage increases.

 Ambient Temperature
The standard temperature for stating battery capacity is 27 0C.The available capacity of a
cells affected by its operating temperature. Low ambient temperatures result in reduced
battery capacity. Higher ambient temperatures result in increased battery capacity but reduced
battery life. So as to have optimum use of battery capacity , it is necessary that the battery
room shall be well ventilated and proper temperature maintained. During low ambient
temperature conditions, local rooms heating may be provided.

Sizing of chargers
The float charger is sized for
 Feeding continuous dc loads
 Float charging the battery
The continuous dc loads des not normally include the emergency motor loads since whe ac
power is available the emergency d.c. motor loads are to be fed and when ac power is
available care must be taken to isolate the float charger. Additionally float charger should be
fitted with a dependable current limiting feature.
The boost charger is required to restore charge to a partially or fully discharged battery. The
voltage and current requirements of the boost charger, apart from being dependant on the cell
characteristics, are also decided on the time allowed to restore charge to a fully discharged
battery. Since the voltage requirements for boosting and considerably higher than required for
float charging proper integration of the boost and float chargers in the dc system
configuration is required to ensure that no part of the system are subjected to voltage in
excess of their limit.

DC system Earthing

The following method of DC system earthing are used

 Negative pole earthed

 Mid point earthed
 Isolated system
 Negative biasing

As d.c. system is the ultimate standby power source, and the wiring and cabling associated
with dc system extends to practically all parts of the power station it is necessary that a
single earth fault in any part of the DC system, should not cause loss of supply but should
give an alarm and allow the system to continue in operation. In view of this first two systems
are not in use .

 Isolated systems

DC system is completely isolated and is extensively used in India. A supervisory relay to

monitor the insulation resistance of the system is used which causes an alarm when the IR
value goes below a set limit. Difficulties are experienced in applying this relay so that it will
operate for all earth fault, have a setting compatible with the insulation resistance of the
extensive DC wiring and cabling in the power system while at the same time not cause
picking of the sensitive DC relays.

 Negative biasing

To obtain a more distinctive detections of earth faults as also to reduce commission of

equipment directly connected to the positive pole , a method used in UK which operates off
station ac power supply and biases the positive pole of the dc system at negative voltage of
about 30-60V with respect to earth.

System configuration
System configuration is intended to denote a combination of batteries, float and boost
chargers, and the distribution board, to form the dc system in which the number of batteries,
chargers and their ratings are so chosen and interconnected that under various normal and
abnormal conditions, the dc system is able to meet its load with or without a pre-designed
reduced capacity.

Figures and Tables show the usual configuration and their relative merits; the following
points may be noted.

(a) The float charge voltage is of the order 2.35 volts per cell whereas the boost charge
voltage is of the order of 2.7 volts per cell. If the system boosts charge, it is still to be
connected to the loads; a tapping has to be taken from the battery to match the normal
dc system voltage. This is shown in the figure
(b) In any power station, whether to have one dc system for the power station as a whole
or for each half of the power station or for each unit in the power station or for each
unit in the power station is influenced by the largest sizes of the cells available, the
cabling distances etc. Frequently the unit concept is extended to include the dc system
also.

c) As already mentioned during normal working, when the ac supply is available, the dc
system is operated at its maximum allowable voltage. Typically for a 220 Volts system, the
float charger will be operating at say 242 Volts. This means for the bulk of the time all the
equipment connected to the dc system will be impressed with this system higher voltage. All
equipment should therefore be selected on this basis rather than on the system nominal
voltage of 220 Volts. Due to this reason, in a number of power stations, there have been
frequent fusing of indicating lamps, burning of coils etc.

When a configuration consists of 2 batteries and 2 sets of chargers, two alternative

approaches can be adopted for sizing the batteries .

(a) Each battery can meet the duty cycle loads for the entire durations of emergency of 1
hour.

(b) The batteries in parallel can meet the duty cycle loads for the entire duration of
emergency of 1 hour, but one battery by itself can meet the duty cycle requirements for the
first five minutes of the duration of emergency. This can result in battery sizes of order of
70% of (a) above. This method of sizing can safely be adopted in stations where diesel
generator sets are provided for emergency power supply.

DC Motor Starters

DC motors driving emergency lubricating oil and seal oil pumps come into operation when
the normal pumps (direct driven or ac motor driven) have failed for whatever reason.
Considering that the DC motor driven pumps may remain idle for long periods, it is
extremely important that the starting scheme used for these motors be simple and reliable,
and that the components of the scheme, such as dc contactors, timers, resistances and
auxiliary relays etc are also chosen on the same basis.

It is also common practice to consider these DC motors as sacrificial, in that, it is more

important to keep the motor and pump running than to protect and trip the motor and prevent
it from being damaged. The over-load relays used in these starters schemes are therefore used
to sound an alarm only and are not connected to trip the motor.

The scheme in use is: In which the starting resistance are in one or more steps.

This is briefly described below:

In the starting resistance scheme, (shown in figure) the starting resistance have one or more
steps. Timers and dc contactors are used to cut out the resistances one by one during the
starting sequences. While relatively fast starting and low starting currents are achieved, this
scheme has the disadvantage of using a large number of components.

Description of Equipments

The figure 5 gives the DC system used in the power plant

Rectifier Assembly

Rectifier assembly shall be full wave bridge type and designed to meet duty as required by
the respective charger. The rectifier cells shall be provided with their owm heat dissipaton
arrangement with natural air colling. The rectifier cells is provided with their wn heat
dissipation arrangement with air cooling.The rectifier uilises diode/thyristors and heat sinks
to carry 200% of the load current continuously and the temperature of the heat sink doesnot
exceed 850Cabsolute.Necessary surge protection devices and rectifier type fast acting HRC
fuses are provided in each arm of the rectifier connections.

Rectifier Transformer and chokes

The rectifier trasformer and chokes are dry and air cooled type .

Blocking diode

Blocking diode is provided in the output circuit of each charger to prevent current flow from
the DC battery into the charger.

Voltage Regulators

The float charger have both auto and manual voltage regulation arrangements.The voltage
regulator have bothauto/manual option of static type.A selector switch for the selection of the
mode is provided.

The boost charger also have auto/manual voltage regulation arrangement.

Printed Circuit Boards

PCB is made up of epoxy of 1.6 mm thick , fire resistant, bonded with 99.8% pure copper
foil,free of wrinkles, blisters, scratches and pinholes. The contact surface of the edge
connectors of PCB are plated with hard gold to a minimum thickness of 5 microns. The
component identification shall be printed on PCB by Silk Screen method.

Control and Selector Switches

The control and selector switches are of rotary type escutcheon plates showing functions and
positions.The contact rationgs shall be atleast the following :

 Make and carry current continuously :10A

 Breaking Current at 220V DC :0.5A
 Breaking Current at 240 V AC 5A at 0.3 p.f.

Indicating lamps

To indicate AC supply availability , thre indcating lamps are provided

Relays and Transducers

The relays are enclosed in flush or semi flush dust tight cases. Transducers shall be panel
mounting type and suitable for operating temperature from 0o to 550.Transducer output is
used for remote display at DDCMIS.Transducers are provided at charger panels for DC
battery voltage.

Contactors

All battery chargers have AC contactor at the input side.It shall be air break typesuitable for
continuous duty and operating coil shall be rated at 415V.

Thermal Overload Relay

A thermal overload relay is provided with single phasing protection is provided for the AC
input which will trip the co ntractor. The DC contactors shall be single/double pole air break
type and suitable for continuous duty.

Air Break Switches

All chargers have AC input and Dc output switches of air break type single throwload break
and fault make type.The contacts of the switches shall open and close with a snap action and
the switches are rated for 120% of maximum continuous load.

Fuses and variable metallic resistors

Fuses are HRC cartridge fuse type.They are mounted on fuse carriers which are mounted on
fuse base. One set of variable metallic resistors and shunt suitable for carrying out discharge
tests( 5 hour discharge rate for Ni-Cd battery and 10 hour discharge rate for lead acid
battery).

Metering on charger panels

(a) Each float charger panel shall be provided with the following meters:
(i) One (1) D.C. ammeter (for charger output).
(ii) One (1) no. D. C. voltmeter with selector switch (for charger output/ battery
voltage)
(iii) Necessary shunts for local and remote metering shall be provided.
 (iv) Measurement for AC input voltage and current (through Voltmeter/Ammeter
selector switch)

(b) Each float-cum-boost charger panel shall be provided with the following meters:
(i) One (1) D.C. ammeter (for charger output).
(ii) One (1) no. D. C. voltmeter with selector switch (for charger output/ battery
voltage)
(iii) One (1) D.C. ammeter for monitoring trickle charging current.
(iv) Necessary shunts for local and remote metering shall be provided.
(v) Measurement for AC input voltage and current (through Voltmeter/Ammeter
selector switch)

(c) Each central panel shall be provided with the following meters:
(i) One (1) D.C. ammeter (for load circuit).
(ii) One (1) no. A. C. voltmeter with selector switch (for main A.C. supply)
(iii) One moving coil center zero ammeter, with shunt to read discharge/charge
current of the battery, with suitable range.
(iv) Battery trickle charging current(through amplifier)
(v) DC bus voltage (through selector switches) to measure between positive to
earth, negative to earth and positive to negative.

Indicating Lamps shall be LED type. LED lamp shall be made in accordance with InP
Technology (Aluminium Indium Gallium Phosphide Technology).

3.1 The indications to be provided on each float charger and float-cum boost charger panel
shall include but shall not be limited to:
a) Charger power supply ON
b) Charger D.C. output healthy
c) Control supply ON
3.2 The indications to be provided on the central panel of each charger set shall include but
shall not be limited to:
a) Annunciation D.C. healthy
b) Float-cum-boost charger in equalising mode.
c) Float-cum-boost charger in boost mode
d) Float-cum-boost charger in float mode.
e) Float charger selected
f) Float charger tripped on fault \

3.3 Solid-state, audio-visual annunciation system shall be provided for battery chargers.
Annunciation system shall operate on 220 V DC. Suitable annunciation in DDCMIS
shall be provided like charger trouble, battery on boost mode etc. Further 4-20mA
signals to DDCMIS shall be provided for important parameters like chamanshurger O/P
voltage, current and battery voltage. Charger panels shall also be provided with charger
I/P & O/P Voltmeter & Ammeter, battery Voltmeter & Ammeter.

3.4 Following visual annunciation shall be provided by means of one (1) minimum ten
point facia windows on each float charger & float cum charger panel:
- A. C. supply failure
- D. C. voltage low
- D. C. voltage high
- D. C. system ground
- Charger overload
- SCR fuse blown
- Filter fuse blown
- D. C. output fuse blown
- Float bus over/under voltage
- Boost bus over voltage
- Boost over current for each charger
- Failure of thyristor/diodes for each charger
- Failure of blocking diodes
- Output MCCB open for each charger
 - Battery MCCB open

3.5 The central panel shall be provided with one (1) minimum eight point annunciation
facia. Alarm points shall include:
- Battery on boost charge
- Float charge fail
- Float cum boost charger in float mode.
- Battery earth fault
- Main A. C. Fail

In addition to above requirement, each section of battery charger shall have at

least two (2) nos. spare annunciation channels and window facia.

3.6 The charger panels will have an enclosure DOP IP-42. The charger panels shall be
painted with light grey shade (shade 631 of IS-5) with two coats of synthetic enamel
paint from outside and shade 632 of IS-5 from inside.

3.7 All the terminals & inter-cell connectors will be fully insulated or shrouded.
6.0 TESTS ON BATTERY AND CHARGER

6.2 Following type tests on two cells of the Battery are conducted:

a) Capacity test i.e. test for voltage on battery during discharge will be carried
out at site on completion of E&C and immediately prior to putting battery in
service.
b) Ampere hour & watt hour efficiency test
c) Endurance test.
d) Discharge performance at low temperature
e) Retention of charge test
f) Life cycle test
 6.3 Following routine tests are conducted on charger:

 Visual checks for dimensions and general arrangement

 Wiring checks
 Functional checks
 Voltage regulation for rated input supply for loads from 0-100%
 Load test to show the charger can deliver the rated duty without the current
limiter device operating
 Ripple measurement by oscilloscope at different loads
 Demonstration of guaranteed efficiency and power factor
 Insulation test with 500V megger (Dielectric test )
 High voltage test, excluding electronic controller, at 2kV AC for one minute

6.4 Heat run test, as a type test is conducted on charger.

Chapter 6
Comparison of DC systems of various project
Battery chargers

S. No. Pragati Power plant Bhilai Power plant

1. In Pragati, 2 charger and 2 batteries In Bhilai power plant , 2 chargers are
are present .Each of the charger caters required to maintain a full battery
to 50% of the loads. In case one charger and also supply DC power to
charger goes out of service its DC loads and other battery charger is in
associated battery shall meet the load the standby mode.
requirement still bus coupler of DCDB
is switched ON. The healthy charger
will cater to 100 % of the load along
with float charging both batteries.
2. 2 FCBC and 2 batteries FCBC for unit-1,unit-2 and station
battery
3. Ambient temperature is 400C Ambient temperature is 50oC
4. Rectifier transformer and chokes have Class F insulation with temperature rise
class B insulation with temperature limited to class B insulation
rise limited to class A epoxy resin
impegraneted with adequate number
of taps