A REPORT ON INPLANT TRAINING

AT

NEYVELI LIGNITE CORPORATION LIMITED NEYVELI

Submitted by Shri. A.GHOPI SYLESH B.Tech EEE (IIIrd year Completed) NIT- PUDUCHERRY

Under the guidance of Mr.E.SANKARAN Deputy Chief Engineer, Electrical Base Mine-II.

DECLARATION
This is to declare that the In-plant training report, submitted in partial fulfillment of the requirement is an original work carried out under the guidance of Mr. E. Sankaran, Deputy Chief Engineer, Electrical Base Mine-II.

Place: NEYVELI Date: 26-06-2013

A.GHOPI SYLESH B.Tech EEE (IIIrd year Completed) NIT- PUDUCHERRY

NEYVELI LIGNITE CORPORATION LIMITED (Biggest Open-Cast Mechanised Lignite Mines in India)

NEYVELI LIGNITE CORPORATION LIMTED

The main core activity of NLC is Lignite Excavation and power generation using lignite excavated. NLC is having lignite mining units named as Mine I, Mine II, Mine IA and Barsingsar Mine. Also Raw Lignite is being sold to small scale industries to use it as fuel in their production activities.

MINES MINE I MINE I A MINE II BARSINGSAR MINE

CAPACITY 10.5 MT / A 3 MT / A 15.0 MT / A 2.1 MT / A

NLC is generating power in its Thermal Power Station I, Thermal Power Station -II and in Thermal Power Station I Expansion. All the southern states are beneficiaries of this power generation project. NLC is started generating power in Barsingsar Power Station in Rajasthan also.

THERMAL UNITS TPS I (3x100 + 6x50) TPS II (3x210 + 4x210) TPS - I EXPANSION (2x210) BARSINGSAR TPS (2x125)

CAPACITY 600 MW 1470 MW 420 MW 250 MW

MINE II

History:
In February, 1978 Government of India sanctioned the Second Lignite Mine of capacity 4.7 MT of lignite per annum and in February `83, Government of India sanctioned the expansion of Second Mine capacity from 4.7 Million Tonnes to 10.5 Million Tonnes. Unlike Mine-I, Mine-II had to face problems in the excavation of sticky clayey soil during initial stage. The method of mining and equipment used are similar to that of Mine-I. The seam is the same as of Mine-I and is contiguous to it. The lignite seam in Mine-II was first exposed in September 1984 and the excavation of lignite commenced in March, 1985. GOI sanctioned the expansion of Mine-II from 10.5 MTPA to 15.0 MTPA of lignite in October 2004 with a cost of Rs. 2295.93 crore. Mine-II Expansion project was completed on 12th March 2010. The lignite excavated from Mine-II meets the fuel requirements of Thermal Power Station-II and Thermal Power StationII Expansion under implementation.

Present:
Mine-II has a lignite capacity of 15 Million Tones per Annum. The earth above the lignite named as overburden is removed in different phases of excavation viz 1. New Surface bench, 2. Surface bench, 3. Top bench, 4. Middle bench and 5. Bottom bench. The excavation of lignite is carried out in the Lignite bench. GROUND WATER CONTROL

The water encountered due to deep excavation is pumped out. A department called GROUND WATER CONTROL carries out this work. The Earth and Lignite excavated are transported to surface using Conveyors. Specialised Mining Equipments (SME) 1400 L Bucket Wheel Excavator (conventional Type) 1400 L Bucket Wheel Excavator (Bridge Type) 700 L Bucket Wheel Excavator (conventional Type) 20000T/hr Spreader with Tripper 11000T/hr Spreader with Tripper 6000T/hr Stacker 2800T/hr Reclamier Conveyors 2400mm width, 1250KW Motor with 6.6 K.V 2000mm width, 630KW Motor with 3.3K.V Description Bucket Wheel Excavator : 4 nos : 3 nos : 6 nos : 3nos : 2nos : 1nos : 2nos

Bucket-wheel excavators (BWEs) are heavy equipment used for continuous overburden removal in surface mining applications. They use their cutting wheels to strip away a section of earth (the

working block) dictated by the size of the excavator. The primary function of BWEs is to act as a continuous digging machine in large-scale open pit mining operations. What sets BWEs apart from other large-scale mining equipment, such as bucket chain excavators, is their use of a large wheel consisting of a continuous pattern of buckets used to scoop material as the wheel turns. 750KW with 3.3KV Bucket wheel Motors are used here.

Conveyor Belts A Conveyor belt (or belt conveyor) consists of two or more pulleys, with a continuous loop of material - the conveyor belt - that rotates about them. One or both of the pulleys are powered, moving the belt and the material on the belt forward. The powered pulley is called the drive pulley while the unpowered pulley is called the idler. There are two main industrial classes of belt conveyors; Those in general material handling such as those moving boxes along inside a factory and bulk material handling such as those used to transport industrial and agricultural materials, such as grain, coal, ores, etc. generally in outdoor locations.

Spreader

Spreaders in mining are heavy equipment used in surface mining and mechanical engineering/civil engineering. The primary function of a spreader is to act as a continuous spreading machine in large-scale open pit mining operations. The purpose of the spreader is to receive overburden from the haulage conveyor from the sorting area and dump it in an orderly and efficient manner.

Types of Cables Landline Cables (Black) Trailing Cables (Pink) Cross-sectional Area: 185 , 95 sq.mm Cross-sectional Area: 185 , 95 , 50 , 35 sq.mm

MINE-II SUB STATION

POWER SUPPLY. For electrical power supply requirement of all the equipment for the above said activities is fed from a 335 MVA, 230/11 KV sub station located at the pivotal point that is centre of mines.

SOURCE OF SUPPLY The above sub station is fed from the Thermal Power station-II, through 230KV, 250MVA tower line feeders called MF3 & MF4 CRITICAL ROLE OF 335MVA, 230/11 KV SUB STATION This sub station caters to the entire needs of the Mine-II project. The 230 KV received is converted into 11 KV supply using 12 power transformers. The 11 KV switch yard has been provided with 120 numbers outlets for connecting the mines loads. There is a control room manned round the clock with engineers and technicians to monitor the Sub Station.

Substation Equipments. Transformers 30 MVA -------------7Nos (3 Main + 4 Expansion) 25 MVA -------------5Nos (Main)

25 MVA TRANSFORMER KVA 20000 / 25000 HV LV Ampere HV LV Phases Frequency Type of cooling 30 MVA TRANSFORMER KVA Volts at no load 24000 / 30000 HV LV Ampere 230000 11550 230000 11550 50.3 / 62.76 1000 / 1250

Volts at no load

HV/LV 3/3 HZ 50

ONAN / ONAF

HV 60.25 / 75.3 LV 1200 / 1500

Phase Frequency Type of cooling

HV/LV 3/3 HZ 50 ONAN / ONAF

Circuit breakers. A device capable of making and breaking an electric circuit under normal and abnormal conditions such as short circuits. It can operate automatically and clear fault current safely and quickly.

Isolator (Disconnecting Switch): A switching device, which can be opened or closed only under no current condition. It provides Isolation of a circuit for the purpose of maintenance. Earthing Switch: It is a switch that connects a conductor to the earth so as to discharge the charges on the conductor to the earth. Earthing switches are generally installed on the frames of the isolators.

Relay: It is an automatic device that closes its contacts when the actuating quantity/quantities reach a certain predetermined magnitude/phase. Current Transformer (CT). The current ratio of current transformer is generally high (e.g. 500 A/5A and volt-ampere capacity is relatively low (e.g. 50 VA) as compared with that of the power transformers. Voltage Transformer (VT) The volt-ampere capacity of a potential transformer is low (e.g.) 100 VA) and the voltage ratio is relatively high (e.g. 230 KV. / 110V). The protective relays are connected in the secondary circuits of CTs and VTs. Lightning Arrester (Surge Arrester) The equipment connected between the conductor and ground, to discharge the excessive voltages to earth. Distribution of 11 KV Supply From Substation to Machines & Conveyors, The 11 KV supply comes through Landline Cables terminating with Pillor Boxes, Couplers and Distribution Kiosk. All the Excavators and Spreaders get supply through Trailing cables which are flexible in nature. Classification of Systems in Machines 11 KV, H.T. System 6.6 / 3.3 KV H.T. System 415V L.T. System 230V Lighting System 110V Control System 24 V Hand Lamps

11 KV System in Machines Trailing cable Cable drum slip ring Bottom Isolator 11 KV OCB / VCB at U/C 11 KV OCB / VCB at S/S 11 KV Isolators 11 KV/ 110V, P.T and C.T 6.6 / 3.3 KV System OCB / VCB Isolators Electrical Protective Devices for Drives Fuse cum Isolator Fuse Monitor Relays Bimetal Relays Thermistor Relays Single Phase Preventer Earth Fault Relays

Electrical Protective Devices for Machines L.T. Emergency Switches H.T. Emergency Switches Rope Emergency Switches Control Limit Switches Safety Limit Switches Belt Slip Monitor

Electricity is a good Servant, but a bad Master