Operating Manual Consolidated - 02.01.2017

OPERATING MANUAL
FOR
ELECTRICAL EQUIPMENTS
Page | 1
Table of Contents
Section – 1
1.0 Introduction.................................................................................... 6
1.1 Overview of Paradip BOOT Terminal............................................ 6
1.2 Purpose .............................................................................................. 6
1.3 Scope and Applicability............................................................... 10
2.0 Design Basis ................................................................................ 14
2.1 Design Basis for Electrical equipment’s...................................... 12
3.0 Electrical Facilities ...................................................................... 17
3.1 Crude Location .............................................................................. 31
3.2 Finished Products Location .......................................................... 32
4.0 Roles & Responsibilities ................................................................. 46
Page | 2
Table of Contents
Section – 2 (Standard Operating Procedures)
5.0 Transformers ..................................................................................... 19
6.0 Diesel Generator ............................................................................. 26
7.0 HT Switchgear .................................................................................. 39
8.0 Air Circuit Breaker........................................................................... 45
9.0 Motor ................................................................................................. 49
10.0 UPS .................................................................................................... 67
11.0 Battery Charger and DCDB ......................................................... 89
12.0 High Mast ..................................................................................... 100
13.0 Self Regulating Heat Tracing..................................................... 104
14.0 Skin Effect Heat Tracing ............................................................. 108
15.0 HVAC System .............................................................................. 112
16.0 Pressurization .............................................................................. 118
17.0 Cathodic Protection System .................................................... 121
Page | 3
Table of Contents
Section – 3 (Appendix)
1 Log sheet ..............................................................................................
2 Abbreviation ...................................................................................... 125
Page | 4
Section: 01
Page | 5
CHAPTER 1– INTRODUCTION
IOT Utkal Energy Services Limited is a consortium of IOT, OT and IVRCL. IOT is a 50:50
jointventure company of Indian Oil Corporation Limited (IOC) and Oiltanking Gmbh
(based in Hamburg, Germany).
The contract for Installation, Operation and Maintenance of crude and finished product
tankage facility at Paradip Refinery Project, Paradip is awarded to IOT Utkal Energy
Services Limited IOTUESL) on Build-Own- Operate-Transfer (BOOT) Basis for 15 years from
the date of commissioning.
IOT, one of the parent companies of IOTUESL is handling Petroleum storage and
distribution, related Operations and Engineering activities for Oil Industries in India and
Abroad.
PURPOSE
The purpose of this manual is to ensure that operation of all Electrical equipments is
carried out as per standard operating procedure.
 Zero breakdown for all Electrical equipments.

 Minimum breakdown time for Electrical equipment’s.
 To ensure that routine operations are not hampered in any way.
 To be used as a guidelines for safe and best operating practices as per OEM and
standards.
 Highest level of safety and security in operations as per HSSE guidelines.
 Best possible working conditions and achieving preset operational goal
successfully.
 To achieve greater satisfaction for IOCL Paradip Refinery by ensuring that facilities
are handled as per the best operating practices.
SCOPE AND APPLICABILITY

This Standard Operating Manual is applicable to IOT Utkal’s Paradip BOOT 3 Electrical
facility, to be operated by IOT for all associated facilities and shall apply to all its
employees, contractors, visitors and other agencies operating within this facility
premises.
Page | 6
CHAPTER 2- FACILTY DETAILS
This chapter describes the electrical facility at Crude and Product side. The facilities
include.
 Transformer
 Diesel Generator
 Switch gears (HT & LT)
 Motor
 UPS
 Battery Charger
 Cathodic protection System
 Heat Tracing System
 Lighting
 HVAC
 Pressurisation System
 EOT Crane
CRUDE LOCATION
Sl.No. Equipment / System Tag No. Rating / Type Qty
1 Distribution Transformers 335AS-201-TR-401/402 2.5MVA ;6.6kV/415Volts 2
2 Bus Duct 335AS-201-BD-401/402 4000A 2
3 Diesel Generator 335AS-201-DG-501 125kVA 1
4 AMF Panel 335AS-201-PA-501 415 Volts; 400Amps 1
5 HT Switchgear 335AS-201-SG-301 6.6kV 1
6 LT Switchgear (PMCC) 335AS-201-SG-401 415Volts 1
--------
77 7 Vacuum Circuit Breaker 6.6kV,2000 3
Page | 7
--------
77 7_1 Vacuum Circuit Breaker 6.6kV,1250 11
7 --------
5000A 3
Air Circuit Breaker
8 800A 5
--------
335AS-201 - MCC
9 Motor Control Centre 415Volts 2
401/402
10 806-201-UPS-601(R/N) 110 Volts / 40KVA 1

Uninterrupted Power
Supply system
11 806-201-UPS-501(R/N) 220Volts / 20KVA 1
12 335AS-201-BCH-701(R/N) 110V,133AH 1
Battery Charger System
13 335AS-201-BCH-702(R/N) 220V,57AH 1
1300 kW
14 Crude Charge Pump 201-PM- 001A/B/C/D/E
5
15 Inter-Tank Transfer Pump 201-PM-002 A/B 285 kW 2
16
Oily Water Transfer Pump 203-PM-024 A/B 18.50 kW 2
17 2
Water Transfer Pump 203-PM-25 A/B 30.00 kW
Skimmed Oil Transfer
18 2
Pump 203-PM-26 A/B 11.00 kW
Steam Condensate
19 2
Transfer Pump 201-PM-102 A/B 30.00 kW
Melting Pit Pump
20 2
201-PM-110 A/B 37.00 kW
21 High Mast ----- 30M / 6.4 kW/ Each 21
22.3
22 Heat Tracing System ----- Self-Regulating tracers
kms
Electrical Heat Tracing 335AS-201-DB-404/405
A 415 Volts 02
Panel
Electrical Heat Tracing
B 415 Volts 13
Distribution boards 201-HT-401 to 413
Page | 8
23 ------ ICCP for storage tanks 11
Cathodic Protection
System SACP for Storage Tanks and
24 ------ 1
UG pipelines
Cathodic Protection
A 11
Transformer Rectifier 201-CPTR-401 to 411 50V/75A
B Panel
Anode(CPTR)
Junction Box 201-AJB-701 to 711 ----- 11
C Cathode Junction Box 201-CJB-701 to 711 ----- 11
25 HVAC system For SRR 806 ----- 01
Power Panel for HVAC 806-201-PP-401 / 402

A 415 Volts 01
system
B AC Scroll Chilling Unit SRR 806 56TR 2
C Air handling unit SRR 806 200000 CFM Double skinned 2
26 Pressurisation System SS 335AS ------- 1
A Pressurisation Panel 335AS-205-PV-401 415 Volts 1
Substation Automation
27 SS 335AS ------- 1
System
Field MOV Distribution
28 415 Volts 7
Boards -------
Indoor Distribution
29 SS 335AS 415 Volts 8
boards
Field Lighting Distribution
30 415 Volts 3
boards -------
31 Earth pit ------- 103

-------
32 Welding Socket 201-WS-401 to 413 415 Volts / 63 Amps 13
PRODUCTS LOCATION
Sl.
Equipment / System Tag No. Rating Qty
No.
Page | 9
1 Power Transformers 312N-205-TR-301/302 20MVA; 66KV/6.9kV 2
312N-205-TR-
2 Distribution Transformers 2.5MVA; 6.6kV/415Volts 4
401/402/403/404
3 Heat Tracing Transformer 312N-205-HTTR-401 250KVA 1
4 Booster Transformer 366N-205-TR-401/402 400KVA 2
Neutral Grounding
5 312N-205-RR-301 10 ohms;400A 2
Resistor
312N-205-BD-
6 Bus Duct 4000A 4
401/402/403/404
7 Diesel Generator 312N-205-DG-501 415 Volts; 380 kVA 1
8 AMF Panel 312N-205-PA-501-P1 415 Volts; 400 Amps 1
9 HT Switchgear 312N-205-SG-301 6.6kV 1
10 LT Switchgear (PMCC) 312N - 205 -SG 401/402 415Volts 2
2000A 3
11 Vacuum Circuit Breaker
1250A 39
------- 800 Amps 44

12
Air Circuit Breaker
11
------- 5000Amps 6
13 Motor Control Centre 312N - 205 - MCC 401/402 415Volts 2
110 Volts / 40KVA

14 819-205-UPS-601(R/N) 1
Uninterrupted Power
15 801-205-UPS-601(R/N) 110 Volts / 130KVA 1
Supply system
819-205-UPS-501(R/N)
16 220 Volts / 20KVA 2
801-205-UPS-501(R/N)
16 312N-205-BCH-701 110V,133AH 1
Battery Charger System
17 312N -205-BCH-702 220V,57AH 1
Page | 10
Diesel(Domestic) Supply
26 205-PM-008 A/B/C 1120.00 kW 3
MOTOR (Jetty)
Diesel (Export) Supply
28 205-PM-010 A/B/C 1120.00 kW 3
MOTOR
25 Naphtha Export MOTORs 205-PM-002 A/B/C/D 1100.00 kW 4
MS Regular Supply
18 205-PM-003 A/B/C 180.00 kW 3
(Marketing) MOTORs
MS Regular Supply
19 205-PM-004 A/B 280.00 kW 2
(Pipeline) MOTORs
MS Premium Supply
20 205-PM-005 A/B/C 1060.00 kW 3
MOTOR (Jetty)
MS Recirculation MOTOR
33 205-PM-025 A/B 135.00 kW 2
(MFA Dye dosing)
DPK Supply MOTORs
21 205-PM-006 A/B/C 1120.00 kW 3
(Jetty)
DPK Supply MOTORs
22 205-PM-007 A/B 300.00 kW 2
(Pipeline)
SKO Supply MOTOR to
29 205-PM-017 A/B 125.00 kW 2
Marketing Terminal
DPK Supply MOTORs
24 205-PM-030 A/B 330.00 kW 2
(Marketing)
LPG Transfer MOTORs –
31 205-PM-001 A/B/C/D/E/F 132.00 kW 6
Marketing
34 Off spec LPG 205-PM-027 A/B/C 7.50 kW 3
Sulphur Truck Loading

32 205-PM-016 A/B/C 30.00 kW 3
MOTOR
75.00 kW
35 HDT HSD Supply MOTOR 203-PM-006 A/B 2
3
30 Propylene Export MOTOR 205-PM-028 A/B/C 150.00 kW
36 Propylene Supply MOTOR 205-PM-029 A/B/C 45.00 kW 3
27 205-PM-009 A/B 250.00 kW 2
MOTOR (Pipeline)
23 205-PM-018 A/B/C 820.00 kW 3
MOTOR (Marketing)
Diesel circulating Pump
50 205-PM-026A/B 110.00 kW 2
(Lubricity/ Centane/ Imp.
Dosing)
Page | 11
Steam Cond. Transfer
37 205-PM-101 A/B 18.50 kW 2
MOTORs
38 241-PM-100 A/B 18.50 kW 2

COC Pit MOTOR
39 241-PM-101 A/B 18.50 kW 2
40 205-PM-109 A/B 2
Sanitary water MOTOR 3.70 kW
41 205-PM-110 A/B 2
3.70 kW
Ethyl Mercaptan Dosing
42 2
MOTOR 205-PM-043 A/B 0.37 kW
43 MS Dosing MOTOR 205-PM-041 A/B 3.70 kW 2
44 Diesel Dosing MOTOR 205-PM-042 A/B 11.00 kW 2
Propylene Vapour
49 Compression Motor 205-A-006-KM-01 90.00 kW 1
Package
Cooling Water
46 MOTOR(Propylene Vapour 205-A-006-PM-01A/B 3.70 kW 2
Compression Package)
Auxiliary Lube Oil MOTOR

47 (Propylene vapour 205-A-006-PM-02 1.10 kW 1
Compression Package)
48 Agitator Motor 205-AGM-001 1.10 kW 1
Water Heater (Propylene

51 205-A-06-H01 3.00 kW 1
Vapour Compression
Oil
MotorHeater
Package)(Propylene 205-A-06-H02 0.50 kW 1
52 Vapour Compression
53 Motor Package)
High Mast 205-LTM-401 to 428 30M / 4.8 kW 28
Skin Effect Heat Tracing

55 Heat Tracing System For Sulphur line 1
system
56 Cathodic Protection System 1
Page | 12
I ICCP for storage tanks 1
Cathodic Protection 205-CPTR-404 to 407

Transformer Rectifier 205-CPTR-411 to 419
A 50V/50A 20
Panel (CPTR) 205-CPTR-422 to 427
205-CPTR-438
Cathodic Protection 205-CPTR-408
B Transformer Rectifier 205-CPTR-451 50V/25A 3

Panel (CPTR) 203-CPTR-417
205-AJB-404 to 408
205-AJB-411 to 419
205-AJB-422 to 427
C Anode Junction Box ----- 23
205-AJB-438
205-AJB-451
203-AJB-417
205-CJB-404 to 408
205-CJB-411 to 419
D Cathode Junction Box 205-CJB-422 to 427 ----- 23
205-CJB-438
205-CJB-451
203-CJB-417
II ICCP for mounded bullets
205-CPTR-V-403
A Cathodic Protection 205-CPTR-V-412 50V/75A 3
Transformer Rectifier 205-CPTR-V-406
Panel (CPTR) 205-AJB-V-403/404
B Anode Junction Box 205-AJB-V-412/413 ----- 6
205-AJB-V-406/410
205-CJB-V-403
C Cathode Junction Box 205-CJB-V-412 ----- 3
205-CJB-V-406
Page | 13
205-TSJ-V-403/404/405/
407/408/409
Test Station Explosion
D 205-TSJ-V-412/413/414 ----- 15
proof
205-TSJ-V-406/410/411/
415/416/417
205-EJB-V-403/404/405/
407/408/409
E Earth Junction Box 205-EJB-V-412/413/414 ----- 15
205-EJB-V-406/410/411/
415/416/417
205-MJB-V-403
Measurement Junction
F 205-MJB-V-412 ----- 3
box
205-MJB-V-406
SRR – 801 ----- 1

HVAC system for Control
57
room buildings
SRR – 819 ----- 1
A 415 Volts 1
Power Panel for HVAC 801-205-PP-401
B system 415 Volts 1

819-205-PP-401
C SRR 801 74.1 TR 2

AC Scroll Chilling Unit
D SRR 819 74.1 TR 2
E SRR 801 28000 CFM Double skinned 2

Air handling unit
F SRR 819 24000 CFM Double skinned 2
58 Pressurisation System SS 312N ----- 1
312N-205-PV-401
A Pressurisation Panel 415 Volts 1
Substation Automation
59 SS 312N ----- 1
System
Field MOV Distribution 16
60 415 Volts
Boards -------
Page | 14
CP DISTRIBUTION BOARD 205-DB-428 1
Indoor Distribution boards

61 SS 312N 415 Volts 8
(MLDB/PDB/ESB)
Field Lighting Distribution
62 205-MLDB-425/426/427 415 Volts 3
boards
63 Earth Pit ------- 179

-------
2 312N- 205-WS-401 41 415 Volts / 63 Amps 01
205-WS-402 to 417 16
64 64 Welding Socket 415 Volts / 63 Amps
PH1-205-WS-401 to PH1-
415 Volts / 63 Amps 10
205-WS-401
205-WS-401 41 415 Volts / 125Amps 11 1
Page | 15
CHAPTER 3 – DESIGN BASIS FOR FACILITY
3.1) TRANSFORMERS - The normal burden on each Transformer is maximum 50% of its full
rated capacity. Under normal conditions, Bus Coupler is in OFF condition and the two
transformers share the entire load equally. In case of failure of supply or breakdown of
one transformer, the Bus coupler goes to ON and the other transformer takes the entire
load via bus Bus coupler connected using with an automatic transfer scheme.
In crude location there are two numbers of 6.6 kV / 0.415 kV Distribution Transformers of
2.5 MVA rating each. In finished products location, there are two 66 KV / 6.9 kV Power
Transformers of 20MVA rating each, four numbers of 6.6 KV / 0.415 kV Distribution
Transformers of 2.5 MVA rating each, one no of heat tracing transformer and also two
numbers of booster transformer. Refer Chapter No 5 for Standard Operating procedure.
3.2) NEUTRAL GROUNDING RESISTORS - The Neutral Grounding Resistor is for connecting
between the neutral or star point of the Power Transformers and earth. One Neutral
Grounding Resistor is given for each Power Transformer. 2 No’s of NGR provided for
product site power transformers. Refer Chapter No 5 for Standard Operating procedure.
3.3) BUS DUCT - Bus Duct is provided to carry the high current from Distribution
Transformer secondary to the PMCC. Since the current in the secondary side of the
Distribution Transformers is very high, Bus Duct of high current carrying capacity (4000A) is
used to feed power to PMCC from the secondary of Distribution Transformers. Each
Distribution Transformer has a Bus Duct connected to its secondary side. Crude location
two bus ducts and product location four bus ducts are connected. Refer Chapter No 5
for Standard Operating procedure.
3.4) HT SWITCHGEAR 6.6 kV- The switchboard has two Incomers and a bus coupler with
an automatic transfer scheme to transfer load to the alternative feeder if a failure occurs
in one of the incoming supply feeders. HT switchgear has Vacuum Circuit Breaker (VCB)
that shall be used for Transformer feeders and HT Motor Feeder Units (above 160kW). All
the Protection and metering instruments for the Motors and Transformers is incorporated
in the HT Switchgear. In crude location 16 HT panels and product site 44 HT panels. Refer
Chapter No 6 for Standard Operating procedure.
3.5) LT SWITCHGEAR 440V - The switchboard has two Incomers and a bus coupler with an
automatic transfer scheme to transfer load to the alternative feeder if a failure occurs in
Page | 16
one of the incoming supply feeders. LT switchgear has Air Circuit Breaker (ACB) that shall
be used for Transformer feeders and LT Motor Feeder Units (below 160KW and above 55
KW). All the Protection and metering instruments for the Motors and Transformers is
incorporated in the LT Switchgear. Refer Chapter No 7 for Standard Operating
procedure.
3.6) HT Motors- HT motors are operated using supply voltage of 6.6 kV. Vacuum Circuit
Breaker (VCB) is provided for HT Motor Feeder Units (above 160kW). For all HT Motors,
Numerical Relays are incorporated in the respective feeder to monitor the critical
parameters and for protection purposes. In crude location 7 no’s HT motor and product
30 no’s HT motor. Refer Chapter No 8 for Standard Operating procedure.
3.7) LT Motors- LT motors are operated on supply voltage of 415 Volts. Air Circuit Breaker
(ACB) is provided for LT Motor Feeder Units (Below 160kW and above 55 KW). MCCB is
provided for LT motors below 55KW. For all LT Motors, Numerical Relays or LTMR Relays
are incorporated in the respective feeder to monitor the critical parameters and for
protection purposes. In crude location 10 no’s LT motor and product 49 no’s LT motor.
Refer Chapter No 8 for Standard Operating procedure.
3.8) DIESEL GENERATOR - This is an independent back-up source of electric energy upon
failure or outage of normal source. It automatically provides reliable electric power for
emergency lighting purposes, Battery charger and UPS system. Under normal
circumstances the machine will be at rest on stand-by duty. One AMF Panel is located in
the Substation which gives signal to the DG about failure of Mains power and resumption
of Mains power. Upon loss of normal power to the Essential services switchboard, the unit
will automatically start and sequentially assume load. Upon restoration of the normal
mains, the load is automatically transferred to the Mains power and the generator will
be shut down after running idle for a period of 30 seconds. Crude location has one 125
KVA DG set and protect location has one 380kVA DG set one numbers each. Refer
3.9) UNINTERRUPTED AC POWER SUPPLY- Uninterrupted AC Power Supply is provided to
feed critical process loads and essential services. It supplies 230V AC to Communication
systems, PA/paging system, Rim seal fire protection system, PMSetc. and 110V AC to
Distributed Control system, Tank Gauging system, Emergency Shutdown, Gas Detection
system, Analyser Units, Blending skids etc. Uninterrupted power supply system has power
source from Mains power as well as from DG set, so that in case the Mains power fails the
UPS can be fed power from the DG set. Also, it has a battery bank for uninterrupted
back-up in case of any power failure. In crude site there are two number’s UPS 20 KVA
Page | 17
and 40 KVA each. And product site 20 KVA(2nos) and 40 KVA and 125 KVA each. Refer
3.10) BATTERY CHARGER UNIT- The main function of the Battery Charger unit is to supply
110V DC to all the Numerical Relays and Control Circuits in Switchgear units and 220V
DC supply Critical lighting. The battery charger unit has power source from Mains power
as well as from DG set, so that in case the Mains power fails it can be fed power from the
DG set. Also, it has a battery bank for uninterrupted back-up in case of any power
failure. Crude location and protect location has one 110V and one 220V Battery charger
set each. Refer Chapter No 11 for Standard Operating procedure.
3.11) HIGH MAST - High masts are installed for the illumination purposes in Tank Farm and
adjacent areas. The high Mast is 30m high and has 12 light fittings in each Mast. Each
high mast has 60 m dia. coverage area. The High Mast also has aviation obstruction
lights for safety of the tall structure. In Product location 28 no’s of High Masts are there
and in Crude location 20 no’s are there. Refer Chapter No 12 for Standard Operating
procedure.
3.12) ELECTRICAL HEAT TRACING- Electrical heat Tracing is a principle provided for
maintaining temperature in a pipeline used to transfer petroleum product and Crude
Oil. The principle use for Crude is “Self Regulating heat Tracing” and the principle used
for Sulphur is “Skin Effect heat tracing”. Refer Chapter No 13&14 for Standard Operating
procedure.
3.13) HVAC SYSTEM - The HVAC system is provided in SRR-806/819 and OMS -801 building
to control the temperature using Air Handling Units in conjunction with Air Cooled Chillers
Unit. The inside of building will be positive pressurised relative to the outside of the
building. Auto dampers are fixed on the buildings to release excessive pressure build up
inside. Refer Chapter No 15 for Standard Operating procedure.
3.14) PRESSURISATION SYSTEM - The Pressurisation system is used to maintain a dust free
environment inside the Substation building. The inside of building will be positive
pressurised relative to the outside of the building. Auto dampers are fixed on the
buildings to release excessive pressure build up inside. Refer Chapter No 16 for Standard
Operating procedure.
3.15) CATHODIC PROTECTION SYSTEM - Cathodic protection (CP) is a technique provided
to control the corrosion of a metal surface by making it the cathode of an
electrochemical cell. For storage tanks, the technique used in Impressed Current
Cathodic Protection where a Transformer Rectifier unit feeds the system, as and when
Page | 18
required, to compensate for corrosion. We can monitor and regulate the system as per
the corrosion status.
Another technique, installed as an additional measure, for protection of storage tank
bottom plate is Sacrificial Anode Cathodic protection system. The method used for
corrosion control in underground pipelines is also Sacrificial Anode Cathodic Protection.
There is no provision for monitoring or regulating the system in case of Sacrificial Anode
Cathodic Protection. It is also self-losing in nature. In crude location 11 no’s Cathodic
protection and product location 26 no’s Cathodic protection system. Refer Chapter No
17 for Standard Operating procedure.
3.16) SUBSTATION AUTOMATION SYSTEM- Substation Automation system is provided to
monitor the critical parameters and status with respect to the Electrical system. The
parameters of transformer and motors are continuously monitored and the status is
linked to the DCS at Control Room.
3.17) EARTHING - The plant earthing system has an earthing network with required
number of earth electrodes connected to it. The following are earthed:
 Neutral system
 The Neutral of Current and potential transformer secondary.
 Metallic non-current carrying parts of all electrical apparatus such as transformers,
Switchgears, motors, lighting/power panels, terminal boxes, control stations, lighting
fixtures, receptacles etc.
 Steel structures, loading platform etc.
 Cable trays and racks, lighting mast and poles.
 Storage tanks, spheres, vessels, columns and all other process equipment.
 Electrical equipment fencing (e.g. transformer yard etc.)
 Cable shields and armour shield wire.
 Flexible earth provision for truck loading.
 The Pumps handling Hydrocarbon where Pump’s base plate is separate from motor’s
base plate.
 Crude location 113 no’s earth pits and protect location 147 no’s earth pits.
Page | 19
CHAPTER 4 – ROLES AND RESPONSIBILITIES
The roles and responsibilities of IOT are as under:-
 To operate and maintain all the Electrical facilities as per the Standard Operating
and Maintenance procedures.
 To update and maintain all the records relevant to the O&M of the electrical
facilities as per the schedule.
 To meet all the statutory requirements for the Electrical system as per the
regulatory bodies.
Page | 20
Section: 02
STANDARD OPERATING
PROCEDURES
Page | 21
CHAPTER 5 –TRANSFORMER
This chapter describes the Standard Operating Procedure for Transformers.
1.0) INTRODUCTION
There are two different locations for Crude and finished products storage facility at
Paradip.
In crude location there are two numbers of 6.6 KV / 0.415 KV Distribution Transformers of
2.5 MVA rating each, feeding power to 415 Volts PMCC panel.
In finished products location, there are two 66 KV / 6.9 KV Power Transformers of 20MVA
rating each for the incoming power source which is coming from GIS-303. The secondary
of the Power transformer is fed to 6.6 KV HT Panel 312N -205-SG-301. In addition to that,
there are four numbers of 6.6 KV / 0.415 KV Distribution Transformers of 2.5MVA rating
each. The incomers of the Distribution Transformers are from the 6.6. KV HT Panel and the
outgoings are fed to the 415V PMCC Panels.
2.0) DATA SHEET
POWER TRANSFORMER
1 Vendor’s name Voltamp Transformers Limited, Vadodara
2 Equipment reference number 312N-205-TR-301/302
3 Rated power 15/20 MVA
4 Rated voltage: primary 66 KV
5 Rated voltage: secondary 6.9 KV
6 Rated frequency 50 HZ ± 3 %
7 175 A @ 20 MVA base

Rated primary current
131.2 A @ 15 MVA base
8 1673.47 A @ 20 MVA base
Rated secondary current
1255.11 A @ 15 MVA base
9 Enclosure degree of protection IP : 55
10 Type of cooling ONAF
Page | 22
11 Number & rating of cooling fan 6 (Working) + 2 (Standby) :
motors Each 0.24 KW
DISTRIBUTION TRANSFORMERS
1 Vendor’s name Voltamp Transformers Limited, Vadodara
312N-205-TR-401/402/403/404
2 Equipment reference number
335AS-201-TR-401/402
3 Rated power 2.5 MVA
4 Rated voltage: primary 6.6 KV
5 Rated voltage: secondary 0.440 KV
7 Rated primary current 218.69 A
8 Rated secondary current 3280.39 A
9 Enclosure degree of protection IP : 55
10 Type of cooling ONAN
3.0) OPERATING CONDITIONS:

 Ambient temperature does not exceed 40°C; or average more than 30°C over any
24-hour period.
 Keep on the transformer energized even at low voltage so that the oil temperature
is about 10 to 15 degree C higher than the surrounding ambient temperature.
 The temperature rise in the transformer oil and transformer winding should not be
above the reasonable limits.
 Use forced Air Circulation in case of Power Transformers.
 The transformer yard shall have a fence with lockable provision.
 Sufficient illumination should be available in the transformer yard. Minimum required
illumination is 100 lux.
4.0) PRE-STARTUP ACTIVITIES:
Page | 23
 Check proper connection of incoming and outgoing cable with single line
diagrams.
 Check for proper wiring and termination for all control and protection circuits.
 Check whether all oil valves are in correct position, closed or open as required.
Radiator Valves – Open.
Buchcholz Relay Valves – Open.
Drain Valves / Sampling valves – Close.
 Check that no air pockets are left in the tank / radiator / conservator.
 Check that all thermometers pockets are filled with oil.
 Check whether oil is at the correct level in the main tank and conservator tank
(3/4th of the full capacity).
 Check if all Bushings /tanks/conservator surfaces are clean.
 Check whether earthing connections for tanks, neutral earthing, marshalling box
earthing etc. have been properly done. Check for loose earthing connection.
 Arrow heads of Buchholz Relay is pointing towards conservator tank.
 Diaphragm at the top end of Explosion vent is intact.
 Check condition of Oil soak pit and drainage arrangement.
 Ensure the availability and readiness of Fire Fighting System and Equipments like
Deluge Valve system, Sand buckets and Fire extinguishers etc.
 Colour of silica Gel in main breather is blue / blockages in the breather pipe.
 Check the position of the tap changer. For distribution transformers Tap changer
position is “3” and for Power Transformers the Tap changer position is “3”.
In case the transformer is being energized some major maintenance works following
additional checks are to be ensured:-
 Manual and remote operation of primary and secondary breaker.
 Functional checks for cooling fans and space heaters.
 Check if the cable trench is filled with sand or covered.
 Testing of transformer oil has been carried out.
 Basic test for transformer like ratio test, Tan delta tests have been carried out.
 Testing of all protection instruments and circuits has been done.
 Alarm & Trip contact settings of O.T.I /W.T.I. and Buchcholz relay are done and
tested.
 Ensure that all the earth pits are tested.
Bus- Ducts
 Sealing of bus-duct entries through walls (for vapour, dust, water tightness).
 Vermin & dust proofness and earth connections of bus ducts and bus Ducts
Page | 24
supports.
 Check for proper earthing.
 Colour of silica Gel in main breather is blue / blockages in the breather pipe.
Neutral Grounding Resistor
 Visual inspection for any damage / cracks.
5.0) STARTUP PROCEDURES:
 After all the pre-start up checks are completed, the transformer can be energized
at no load by operating the breaker connected to the transformer primary, with the
tap changer at normal position.
 Check if there is any undue noise or vibration during operation.
 Gradually increase the load on the transformer.
 Check whether the voltage,current and frequency are as per name plate details.
If the transformer is being energized after a major overhauling job following
additional measures to be taken:-
 The transformer should be switched off after about three hours of energizing at no
load.
 Sometimes trapped air is released and gets accumulated in the Buchcholz Relay.
 The Buchholz relay should be checked for collection of air/gas.
 Air should also be released from Bushings, Bushings Pockets, Main Tank covers,
Radiators etc.
 The transformer can now be energized and loaded gradually to full load in about
three hours time.
 During the gradual increase in the load, check whether the voltages, currents and
frequency are balanced.
 During the period and for further three hours, transformer should be under
observation.
 Check whether the voltage, currents and frequency on the HV & LV sides are
balanced, increase the load to the rated value and check that the noise is not
appreciable. A good transformer operates with a healthy hum.
 Check that all instruments, OTI, WTI, MOG are reading properly and all the radiators
are uniformly hot.
 Check that there is no gas accumulation in Buchcholz Relay.
 Observe the operation for a period of 24 hours. If the operation is satisfactory, the
transformer is kept on load and readings of voltage, current and frequency on all
the phases of both HV & LV sides are checked.
6.0) OPERATIONAL MONITORING:
Page | 25
 Monitor and record the readings of Winding Temperature Indicator and Oil
Temperature Indicator. Check that observed temperatures are not high for the
prevailing load and ambient temperature.
 Continuous over loading of the transformer beyond rated capacity should be
avoided. If the connected load is more than the rated load capacity, reduce non
–priority load.
 Always Check for Improper tap position as it can cause excessive core loss and
consequently excessive heating.
 Check whether the voltage, currents and frequency on the HV & LV sides are
balanced.
 Check the oil level in conservator/transformer and top it up whenever required to
preset levels.
 Check the condition of silica gel. Reactivate the silica gel if silica gel has turned pink
in colour.
 Check if there is any undue noise/humming or vibration during operation.
7.0) STOPPING ACTIVITY / SHUTDOWN:
 Inform all the concerned officers about the shutdown.
 Work permit to be prepared and circulated among the concerned officers.
 Ensure that the connected load is entirely transferred to the other Transformer via
ATS facility provided in the HT Panel / PMCC Panel.
 Run the transformer on no load for a few minutes.
 Incoming electric power and auxiliary supplies are to de-energised and positively
isolated (from all possible sources) locked out (through a permit system) throughout
the duration of overhauling work and a caution board indicating the nature of work
should be displayed near the isolating point.
8.0) AUTOMATION/INTERLOCKING:
Protection of transformers is taken care of by Numerical Relay REF615. The relay has
the following trip circuits
 Instantaneous over-current 50 – This relay is operated in case of over-burden on
transformer and without any time delay.
 IDMT over-current 51 – IDMT Over current relays are inverse definite minimum time
relay which operate in case of over-burden on transformer and with a set time
delay.
 Instantaneous Earth Fault 50N - The high set element is meant for instantaneous
operation at high values of fault current to limit the stress on the transformer and
may have an operating time of about 20 milli-seconds.
Page | 26
 IDMT Earth Fault 51N - IDMT Earth Fault relays are inverse definite minimum time relay
which operate with a time delay at high values of fault current to limit the stress on
the transformer.
 Buchcholz Relay Alarm and Trip 63TX – An incipient fault within the transformer
generates small bubbles of gas which in passing upwards towards the conservator,
get trapped in the Buchcholz relay thereby causing the oil level to fall as a result of
which the upper element rotates and when sufficient oil has been displaced the
mercury switch contacts close thus completing the external circuit which is
connected to audible alarm. In the event of a serious fault within the transformer,
the gas generation is more violent and the oil displaced by the gas bubbles flows
through the connecting pipe to the conservator. This abnormal flow of oil causes
the lower element to be rotated thus actuating the contacts of the second
(bottom) mercury switch thereby completing the external circuit which is
connected to trip the circuit breaker/breakers to isolate the transformer.
 Winding Temperature High Alarm and Trip – Winding temperature of the transformer
windings is to monitored using the Winding temperature indicator. The indicator
gives the continuous reading of the temperature of the windings. The system has
alarm and trip facilities. The ambient temperature is considered as 42 deg C. The set
temperature for Alarm and trip are as under:
Alarm – 87 deg C. Trip – 97 deg C
 Oil Temperature High Alarm and Trip – Oil temperature of the transformer windings is
to monitored using the Winding temperature indicator. The indicator gives the
continuous reading of the temperature of the windings. The system has alarm and
trip facilities. The ambient temperature is considered as 42 deg C. The set
temperature for Alarm and trip are as under:
Alarm – 82 deg C. Trip – 92 deg C
 MOG Alarm – Magnetic Oil level gauge is provided to indicate the oil level in the
Conservator Tank. Fall in the oil level in the conservator tank below the set level
results in an alarm.
 PRV Trip – A pressure relief valve is placed on the transformer tank. Any abnormal
rise in the pressure inside the tank due to an incipient fault will result in activating the
PRV and the transformer will be tripped.
 Fire fighting interlocks with FACP panel for the transformer yard.
AUTOMATION
The following critical parameters of the transformer are interfaced with Substation
Automation system
Page | 27
 Voltage
 Current
 Frequency
 Power – kWh and kVAR
 Power factor
 Circuit Breaker ON/OFF position.
 Circuit Breaker Service status.
 Trip / faults status in Numerical Relay
 Temperature – Oil and winding.
 Oil Temperature Alarm and Trip.
 Winding Temperature Alarm and Trip.
 PRV Trip
 Buchcholz Alarm and Trip.
 Local / Remote switch position
ON/OFF operation of Transformer via Vacuum Air Circuit breaker can be done from
Control using SAS.
9.0) HANDING OVER TO MAINTENANCE
 Report the problem to maintenance department.
 Electrical permit to be issued.
 Everything mentioned in the electrical permit should be ensured.
 Isolate the transformer from electrical supply.
 For the transformer being handed over to maintenance, ensure that the connected
load is entirely transferred to the other Transformer via ATS facility provided in the HT
Panel / PMCC Panel.
 Disconnect the transformer from all external circuits and all windings must be solidly
earthed.
 Proper Lockout & Tag out procedure to be followed. Maintain proper logbook
about the handing over.
10.0) CHECKLIST FOR TAKING OVER FROM MAINTENANCE
 Check whether the root-cause was identified correctly.
 Check if the problem reported has been resolved and tested.
 Collect reports of all the tests carried out after the maintenance work.
 Record the details of root cause analysis in the Logbook.
 Check for proper fitting of all the accessories.
 Inspect the entire assembly for any leakages or breakages.
 Check the oil level in conservator tank.
Page | 28
 Check the Buchholz relay valve.
 Carry out all the Pre-start up checks as listed above in Clause no. 4.0.
11.0) DO'S / DON'TS
DO’s
 Always increase or decrease the load on the transformer in a smooth manner.
 All the jobs related to transformer operation to be carried out by authorized person
only.
 Always ground the bushing before starting any work using discharge.
 Examine the bushing for dirt deposit on coats, and clean them, periodically.
 If inspection covers are opened or any gasket joint is to be tightened, then, tighten
the bolts evenly, to avoid uneven pressure.
 Check the oil quality in case of oil filled transformers.
 The earthing (preferably double) for the equipment should be checked.
 The transformer yard fence should also be earthed.
 The transformer yard should be clean with sufficient illumination.
 The Oil level should be kept only up-to 3/4th level of the conservator tank.
 The Valves connecting the Buchholz relay should always be open.
 Sufficient lighting must be there while carrying out work.
DON’Ts
 Do not touch a live transformer.
 Do not re-energize the transformer without conducting all pre-commissioning
checks. The results must be comparable with results at works.
 Do not operate the off-circuit tap switch/tap links when the transformer is energized.
 Do not parallel transformer which do not fulfill the paralleling condition.
 Do not use low capacity lifting jacks on transformer for jacking.
 Do not overload the transformer other than the specific limits as per IEC 354.
 Do not leave any connection loose.
 Do not store transformer for long after reaching site. It must be erected and
commissioned at the earliest.
 Do not use PVC pipe to top-up the transformer.
Page | 29
CHAPTER 6-HT SWITCHGEAR
This chapter describes the Standard Operating Procedure for HT switch gear.
1.0) INTRODUCTION:
Paradip.
In crude location there is one 6.6 KV HT Panel receiving mains power from EPCM7. The HT
Panel feeds power to all the HT Motors and the Distribution Transformers.
In finished products location, there is one 6.6 KV HT Panel receiving mains power from
Power Transformer. The HT Panel feeds power to all the HT Motors and the Distribution
Transformers.
The switchgears are basically suitable for normal operating conditions for indoor
switchgears and Switch boards in accordance with IEC 60694. The following limit values,
among others, apply:
 Ambient temperature maximum + 40 °C
 Maximum 24 h average + 35 °C
 Minimum (according to “minus 5 indoor class”) - 5 °C
 Average relative humidity – 90%.
 The ambient air must not be significantly polluted by dust, smoke, corrosive and/or
flammable gases, vapours or salt.
 Anti-condensation heaters are provided for the Switchgears.
 Check the control / power supply availability indicated by LEDs.

 Check if all the protection parameters in the Numerical Relay and Mater Trip Relay
are enabled / reset.
 Ensure that the Breaker is in Service position by checking the indication LED.
 Ensure the readiness of the motor / other connected load before switching ON the
Breaker.
 Check for the ON position of control MCB.
Page | 30
 Check for communication with SAS and DCS.
 Ensure that the Emergency push button for the motor / Transformer is in released
position.
 Ensure that the “Spring charge” LED is ON.
 Ensure that the “Trip Circuit Healthy” LED is ON.
In addition to the above checks if the Breaker is being energized after a major
shutdown job, the following additional checks are to be carried out:-
 Check the general condition of the switchgear for any damage or defects.
 Visually inspect the switching devices, withdraw-able parts, isolating contacts,
insulating parts, etc.
 Check connection of the main earthing bar to the installation earthing conductor
(following the appropriate safety regulations)
 Check the paintwork for damage and, where necessary, touch up.
 Remove all residues of materials, foreign bodies and tools from the switchgear.
 Clean the switchgear, rubbing down insulating parts with a soft, dry, clean, non-
fraying cloth. Remove any greasy or sticky dirt.
 Correctly remount all covers etc. removed during assembly and testing procedures.
 Check whether incomer live terminals shrouded.
 Compartmentalization between live open terminals.
 Check the following facilities in switchgear:
 Power cables
 Auxiliary cables
 Switch gear space heater
 Auxiliary power source
 Control circuit and protection auxiliary supply for 110V DC
 Remote control system - SAS

 Complete earthing system
 Opening and closing operations with the withdraw-able part in the service position
should only be performed with the door closed.
 Operate the local or remote electrical control.
FOR TRANSFORMER FEEDERS
The Local / Remote operation of Vacuum Circuit Breaker can be selected from the
Numerical Relay REF 615.
Local Mode
Page | 31
The Transformer feeder Breaker can be closed using the Numerical Relay REF 615.
Remote Mode
The Transformer feeder Breaker can be closed using the SAS.
FOR MOTOR FEEDERS
The Local / Remote operation of Vacuum Circuit Breaker can be selected from the
Numerical Relay REM 615or Local Control Station at Pump House.
Local Mode
The Motor feeder Breaker can be closed using the Local Control Station push button at
Pump House.
Remote Mode
The Motor feeder Breaker can be closed using the SAS / DCS.
 An additional control mechanism fitted in the door of the circuit-breaker
compartment enables mechanical operation of the circuit-breaker with the door
closed and with the withdraw-able part in either position.
 Press the mechanical ON pushbutton on the front door, after having previously
turned the knob on the front door clockWise.
 Observe the switch position indicator.
After a major shutdown work has been carried out, the following procedure must be
followed:-
Insertion of VCB from the service truck into the test / disconnected position:
 Position service truck with guide pins of the adjustable bench top at the correct
height facing the panel front, and allow catch to engage.
 Press release lever on the truck and release the service truck from the trolley.
 Move sliding handles inwards against the springs to release withdraw-able part,
draw the withdraw-able part out onto the service truck and secure it in the catches
on the truck.
 Control wiring plug must be connected.
 Close the door of the circuit-breaker compartment.
Manual insertion of VCB from the test/disconnected position to the service position:
 Fit hand crank on square spigot of the spindle mechanism, after opening the hole
for them by turning slide.
 Turn the crank clockWise (approx. 20 turns) until the stop is reached and the
withdraw-able part is in the service position.
 Observe the position Service position LED indicator.
 Remove hand crank.
 It must be considered that the spring loaded pin head will lie completely on the rear
Page | 32
side of the panel door when the hand crank is moved from square spigot 18.1 of
spindle mechanism 18. This ensures that the rear part of the pin head has been
shifted onto the hexagonal cap of the spindle and prevents unintentional
wrenching of the spindle during panel service. Wrenching may lead to the circuit-
breaker blocking.
Note:
The VCB must not be left in any intermediate position in the travel range between
the service and test/disconnected position.
 Carefully inspect doors, enclosure sides for evidence of excessive heat. As a

general rule during operation, any temperature which the pain of the hand can't
stand for about 3 seconds may indicate trouble.
 A check for any abnormal conditions should be carried out immediately on entering
the substation and if any danger is suspected then the inspection should be
aborted. Typical warning signs are:
 High temperature in switch-room

 Presence of smoke
 Audible discharges or arcing
 Smell of ozone
 All the critical parameters viz. Current, Voltage, frequency etc. must be checked
and ensured to be within limits in Numerical Relay or inSAS.
 All the LEDs indicating healthy operation of the system must be monitored.
6.0) STOPPING ACTIVITY:
 Inform the concerned officers about the stopping activity.

 Operate the local or remote electrical control to open the VCB.
 Ensure that the “Breaker OFF” LED is glowing.
 Ensure that the “Spring Charge” LED is glowing.
Manual withdrawal of Breaker from the service position into the test/disconnected
position:
 Ensure that the apparatus is in the OFF position.
 Turn the knob on the panel front door.
 Fit operating lever.
 Put operating lever pointed upwards or downwards on the hexagonal shaft so that
there is sufficient room for movement of the operating lever even if space is limited
Page | 33
at the sides.
 Turn the lever clockWise through approx. 180° until the stop is reached to close the
earthing switch, or anticlockWise until the stop is reached to open the earthing
switch.
 Observe the mechanical/electrical switch position indicator.
Withdrawal from the test/disconnected position onto the service trolley:
 Open the door of the circuit-breaker compartment.
 Release control wiring plug and place it in the storage position on the withdraw-
able part.
 Position service truck with guide pins of the adjustable bench top at the correct
height facing the panel front, and allow catch to engage.
 Move sliding handlesinwards against the springs to release withdraw-able part, draw
the withdraw-able part out onto the service truck and secure it in the catches on
the truck.
 Press release lever (at the front underneath the bench top) and release the service
truck from the switchgear panel.
 Secure the position of the shutters with padlock.
To prevent the hazardous situations and erroneous operation, there is a series of

interlocks to protect both personnel and equipment.
 The VCB can be moved from the test/disconnected position to Service position
(and back) only if the enclosure is closed and the auxiliary supply is available.
 The circuit breaker can only be switched on when the withdraw-able part is in the
test or service position. In the intermediate position, the switch is mechanically
interlocked.
 Connecting & disconnecting the control wiring plug is only in the test/disconnected
position of the withdraw-able part. It cannot be done when the Breaker is in Service
position.
 The apparatus compartment door cannot be opened if the circuit breaker is in
service or in an undefined position.
 Access to the circuit-breaker racking slot can be restricted with a padlock.
 Access to the circuit breaker compartment and the cable compartment can be
with a padlock.
 Anti-pumping devices are provided for all the Breakers.
 The following indications are given by LED on the Switchgear
Page | 34
 Circuit Earthed.
 Circuit breaker tripped
 Circuit Breaker closed
 Circuit Breaker open
 Trip Circuit healthy
 Spring charge
 Breaker in Service position
 Numerical Relays for the feeders are linked to SAS and can be monitored through
SAS.
REM-615 RELAY FOR MOTOR FEEDER
REF-630 RELAY FOR INCOMER AND BUS COUPLER
REU-615 RELAY FOR RESTRICTED EARTH FAULT
REF -615 RELAY FOR TRANSFORMER FEEDER
8.0) HANDING OVER TO MAINTENANCE:

 Isolate the feeder from electrical supply.
 For the feeder being handed over to maintenance, ensure that the connected
load is entirely transferred to the spare feeder.
 Proper Lockout & Tag out procedure to be followed.
 Maintain proper logbook about the handing over.

10.0) DO'S / DON'TS:
DO's
 Make sure that the Switch Gear area is clean.
 Make sure all the meters are working properly.
Page | 35
 Check the condition of the protection relays.
 Ensure that no loose cable is there.
 Ensure proper earthing connections are made.
 Periodically inspect the condition of the circuit-breaker.
 Make sure that all power to the device is switched off before you open the covers
of the device. Failure to do so may cause danger to persons or damage the
equipment. All covers of the device must be closed before switching the power on
again.
 Ensure that anti-condensate space heater circuit is always working.
DON'TS
 Do not by-pass any protection systems.
 Do not operate the Breaker in Local mode, when Auto mode is in working.
 Do not work in Switchgear without proper PPEs and safety measures.
 Do not change numerical relay settings.
CHAPTER 7-AIR CIRCUIT BREAKER
This chapter describes the Standard Operating Procedure for air circuit breaker.
1.0) INTRODUCTION:
Paradip.
In crude location there is two 6.6 KV HT Panel receiving mains power from EPCM7. The
Distribution Transformers secondary output is given to PMCC switchgears.
In finished product location there is four 6.6 KV HT Panel receiving mains power from GIS-
313. The Distribution Transformers secondary output is given to PMCC switchgears.
Air Circuit breakers are installed in feeders having connected load from 55KW to 160KW.
Air Circuit Breakers can operate under the following temperature conditions:
The electrical and mechanical characteristics are stipulated for an ambient
Temperature of -5C to +70C. Circuit-breaker closing is guaranteed down to -35C.
 Remote control system – SCADA system healthiness or ready.

 Ensure all the protection scheme parameters are enable condition.
 Ensure the readiness of the motor / other connected load before switching ON the
Page | 36
Breaker.
When energising after a major shutdown maintenance work has been carried out
on the Breaker, the following checks are to be carried out:-
 Check the general condition of the switchgear for any damage or defects.
 Visually inspect the switching devices, withdraw-able parts, isolating contacts,
insulating parts, etc.
 Check connection of the main earthing bar to the installation earthing conductor
(following the appropriate safety regulations).
 Remove all residues of materials, foreign bodies and tools from the switchgear.
 Clean the switchgear, rubbing down insulating parts with a soft, dry, clean, non-
fraying cloth. Remove any greasy or sticky dirt.
 Check the following facilities in switchgear:
 Power cables
 Auxiliary cables
 Switch gear space heater
 Auxiliary power source
 Control circuit and protection auxiliary supply for 110V DC
 Check complete earthing system

 Switch room conditions. Like rubber mat, PPE’s and safety equipment.
To close the ACB (ON position):

 Charge the Breaker operating mechanism by pulling down on the lever seven times
until a Clack is heard. The charged indication is displayed.
 Ensure that power supply receiving end is ready.
ACB Starting
All the ACB’s will start three methods. Any one the method use ON/OFF the breaker.
 Select the breaker is local or remote.
 Press the ON push button in breaker. In case of push button is padlock condition
removing the screw.
 The ON indication is displayed.
 Insert the breaker control switch key; turn the handle to close position.
 Click the electrical SCADA screen on the ACB section. Ensure that breaker tag
number.
Page | 37
 A check for any abnormal conditions should be carried out immediately on entering
the substation and if any danger is suspected then the inspection should be
aborted. Typical warning signs are:
 High temperature in breaker section or bus bar.

 Presence of smoke
 Audible discharges or arcing
 Smell of ozone
 Current, Voltage must be checked and ensured to be within limits in Numerical

Relay or in SCADA.
 All the LEDs indicating healthy operation of the system must be monitored.
ACB STOPING:
All the ACB’s will stop three methods. Any one the method use OFF the breaker.
 Select the breaker is local or remote.
 Press the OFF push button in breaker. In case of push button is padlock condition
removing the screw.
 The OFF indication is displayed
 Insert the breaker control switch key, turn the handle to open position
 Click the electrical SCADA screen OFF the ACB section. Ensure that breaker tag
number.
Numerical Relays for the feeders are linked to SAS and can be monitored through
SAS.
REM-615 RELAY FOR MOTOR FEEDER

REF-630 RELAY FOR INCOMER AND BUS COUPLER
REU-615 RELAY FOR RESTRICTED EARTH FAULT
REF -615 RELAY FOR TRANSFORMER FEEDER


 Isolate the feeder from electrical supply.
 For the feeder being handed over to maintenance, ensure that the connected
Page | 38
load is entirely transferred to the spare feeder.

10.0) DO'S / DON'TS:
DO's
 Make sure that the Switch Gear area is clean.
 Make sure all the meters are working properly.
 Check the condition of the protection relays.
 Ensure that no loose cable is there.
 Ensure proper earthing connections are made.
 Periodically inspect the condition of the circuit-breaker.
 Make sure that all power to the device is switched off before you open the covers
of the device. Failure to do so may cause danger to persons or damage the
equipment. All covers of the device must be closed before switching the power on
again.
 Ensure that anti-condensate space heater circuit is always working.
DON'TS
 Do not operate local mode when Auto mode is in working.
 Do not work in Switchgear without proper PPEs and safety measures.
 Do not change numerical relay settings.
CHAPTER 9–MOTORS
This chapter describes the Standard Operating Procedure for motor.
Page | 39
1.0) INTRODUCTION
Paradip.
Both HT and LT Motors are being provided for transfer of Crude and Products.
In Crude Area, there are 07 no’s of HT Motors and 10 no’s of LT Motors.
In finished products area, there are 30 no’s of HT Motors and 47no’s of LT Motors.
Page | 40
2.0) DATA SHEETS
CRUDE AREA HT MOTORS
Rated Full load From
Sl.N Rating in Type of
Tag No. Speed in current Substation Make Service Mounting
o. kW cooling
RPM in Amps feeder
Panel 02
201-PM-
001A
Panel 03
201-PM-
001B
Ansaldo Crude
Panel 04
1 201-PM- 1300.00 1487 Sistemi, Charge Vertical TETV
131.50
001C
Italy Pump
Panel 13
201-PM-
001D
Panel 14
201-PM-
001E
201-PM- Panel 5 Crude

002A Inter
BHEL,
tank
2 285.00 1484 32.00 Bhopal Horizontal TETV
201-PM- Panel 15 Transfer
Pump
002B
Page | 41
CRUDE AREA LT MOTORS
Rated Full load From Type of

Sl.N Rating in Mounting
Tag No. Speed in current Substation Make Service
o. kW cooling
RPM in Amps feeder
203 - PM – MCC 402

24 A 3F1 Oily
Crompton
Water Horizontal TEFC
1 18.50 1475 33.0 Greaves
Transfer
ltd.
203 - PM – MCC 401 Pump
24 B 3F3
203 - PM – MCC 403

25 A 3F3 Crompton Water
2 30.00 2960 53.0 Greaves Transfer Horizontal TEFC
203 - PM – ltd. Pump
MCC401
25 B
3F4
203 - PM – MCC 402

26 A 4F2 Skimmed
Crompton
Oil Vertical TEFC
3 11.00 2910 20.0 Greaves
Transfer
ltd.
203 - PM MCC 401 Pump
– 26 B 3F2
Steam
201 - PM – Crompton
MCC 401 condens Horizontal TEFC
4 102 A 30.00 2925 51.60 Greaves
2F3 ate
ltd.
Transfer
Page | 42
Pump
201 - PM –
MCC 402
102 B
2F2
201 - PM – MCC 401

110 A 4F3
Melting
Siemens Horizontal TEFC
5 37.00 734 66.60 Pit Pump
201 - PM – MCC 402
110 A 4F4
PRODUCT AREA HT MOTORS
Sl. Rated Full load From Type of

Rating in Mounting
No Tag No. Speed in current Substation Make Service
kW cooling
. RPM in Amps feeder
Panel 10
205 - PM – 002 A
Panel 30 Naphtha
205 - PM – 002 B
BHEL, Export Horizontal TETV
1 1100.00 991 120.50
Panel 29 Bhopal Supply
205 - PM – 002 C Pumps
205 - PM – 002 D Panel 11
Page | 43
205 - PM – 003 A Panel 08
MS
Regular
supply
BHEL, Horizontal TETV
2 205 - PM – 003 B 180.00 1480 21.00 Panel 43 Pumps
Bhopal
(Marketi
ng)
205 - PM – 003 C
Panel 44
TETV
205 - PM – 004 A
Panel 01
MS
BHEL, Horizontal
3 280.00 1484 31.00 Regular
Bhopal
Pipeline
205 - PM – 004 B
Panel 36
205 - PM – 005 A Panel 07
MS
205 - PM – 005 B Panel 40 BHEL, Horizontal TETV
4 1060.00 991 116.0 Premium
Bhopal
jetty
205 - PM – 005 C Panel 41
205 - PM – 006 A Panel 03 DPK

BHEL, Supply Horizontal TETV
5 1120.00 1487 120.00
Bhopal Pump
205 - PM – 006 B Panel 04 (Jetty)
Page | 44
205 - PM – 006 C Panel 38
DPK
Panel 02 Supply
205 - PM – 007 A
BHEL, Pump Horizontal TETV
6 300.00 2976 32.00
Bhopal (Pipeline
205 - PM – 007 B Transfer)
Panel 37
205 - PM – 008 A Panel 31

HSD
BHEL, Domestic Horizontal TETV
7 205 - PM – 008 B 1120.00 1487 120.0 Panel 32
Bhopal Supply
(Jetty)
205 - PM – 008 C Panel 12
Diesel
205 - PM – 009 A Panel 13 Domestic
Supply
BHEL, Horizontal TETV
8 250.00 2972 26.00 Pump
Bhopal
(Pipeline
205 - PM – 009 B Panel 33 Transfer)
205 - PM – 010 A Panel 14

Diesel
Export
205 - PM – 010 B Panel 34 BHEL, Horizontal TETV
9 1120.00 1487 120.0 Supply
Bhopal
Pumps
205 - PM – 010 C (Jetty)
Panel 35
Page | 45
205 - PM – 018 A Panel 05
Diesel(Do
mestic)
205 - PM – 018 B BHEL, Supply Horizontal TETV
10 820.00 2976 84.0 Panel 39 Bhopal Pump
(Marketin
205 - PM – 018 C g)
Panel 06
11 DPK
205 - PM – 030 A Panel 09 Supply
BHEL, Pump
330.00 2975 35.00 Horizontal TETV
Bhopal (Marketi
205 - PM – 030 B ng)
Panel 42
PRODUCT AREA LT MOTORS

Full
Rated load Type of
Sl.N Rating in From Substation Mounting
Tag No. Speed curren Make Service
o. KW feeder cooling
in RPM t in
Amps
1 205 - PM – 132.00 216.00
LPG Transfer Vertical
001 A 1493 SG401 8F2 Crompto Pumps
n Greaves
205 - PM – Ltd.
001 B
SG401 9F2
205 - PM – SG401 21F2 TEFC
Page | 46
001 C
205 - PM –
001 D SG401 10F2
205 - PM –
SG401 23F2
001 E
205 - PM –
001 F SG401 24F2
203 - PM -
SG401 5F2 HDT HSD
006 A Crompto
2 75.00 1488 124.00 n Greaves Supply Horizontal TEFC
203 - PM - Ltd. Pumps
006 B SG401 25F2
205-PM-016 A MCC 401 8F4

Crompto
Sulphur Truck
n Greaves Horizontal TEFC
3 205-PM-016 B 30.00 2930 51.60 MCC 402 3F1 loading
Ltd.
Pump
205-PM-016
MCC 402 5F4
C
205-PM-017 A SG401 3F2

Crompto
SKO Supply Horizontal TEFC
4 125.00 3000 208.00 n Greaves
Pumps
Ltd.
205-PM-017 B SG401 22F2
Page | 47
205 - PM –
025 A SG401 7F2
Crompto
n Greaves MS
5 135.00 1481 226.00 Recirculatio Horizontal TEFC
Ltd.
205 - PM – n Pumps
025 B SG401 32F2
205 - PM –
SG402 5F2 Crompto
026 A Diesel
n Greaves
6 110.00 2960 180.00 Recirculatio TEFC
Ltd.
n Horizontal
205 - PM –
SG402 13F2
026 B
205 - PM –
MCC 401 9F3
027 A
Crompto Off spec

205 - PM –
7 7.50 1460 14.00 n Greaves LPG supply Vertical TEFC
027 B MCC 401 9F5
Ltd. Pumps
205 - PM –
027 C MCC 402 7F4
8 150.0 251.00 Crompto TEFC

205 - PM – 1490 n Greaves Vertical
028 A SG401 2F2
Ltd.
Page | 48
205 - PM –
SG401 30F2
028 B
Propylene
205 - PM – export Pumps
028 C SG401 31F2
205-PM-029 A MCC 401 6F2
Crompto
Propylene
205-PM-029 B n Greaves
9 45.00 2970 74.00 MCC 401 7F2 Supply Vertical TEFC
Ltd.
Pump
205-PM-029
MCC 402 6F2
C
Crompto Propylene
205-A-006- n Greaves Vapour TEFC
10 90.00 SG401 15F2 Horizontal
KM01 Ltd. Compressio
n Motor
11 205-PM-041
MCC 401 9F1
A
MS Dosing Horizontal TEFC
3.70 3000 6.90 KSB
Pump
205-PM-041
MCC 402 4F2
B
205-PM-042 Crompto Diesel dosing Horizontal TEFC

12 11.00 MCC 401 9F6
A n Greaves Pump
Page | 49
Ltd.
205-PM-042 MCC 402 5F2
A
Crompto
205-PM-043 n Greaves
A Ltd. Ethyl
Mercaptan
13 0.37 1500
Dosing
205-PM-042 Pump
B
Crompto
205-PM-101 MCC 401 8F3 n Greaves
A Steam
Ltd.
18.50 Cond. Horizontal TEFC
14
Transfer
205-PM-101 MCC 402 5F3 Pumps
B
205-PM-109
MCC 401 5F2 Crompto
A n Greaves
15 3.70 Vertical TEFC
Ltd.
205-PM-109
MCC 402 7F2
B Sanitary
Water
205-PM-110 Crompto Pump
MCC 401 9F4 n Greaves
A
3.70 Ltd. Vertical TEFC
16
205-PM-110
MCC 402 4F3
B
Page | 50
Crompto
n Greaves
MCC 401 3F3 Ltd.
241-PM-100 18.50 34.0 Vertical TEFC
17 2935
A
COC Pit
241-PM-101 Crompto Pump
MCC 401 4F3 n Greaves
A
18.50 34.0 Ltd. Vertical TEFC
18 2935
241-PM-101
MCC 402 2F2
B
Main
Cooling
205-A-006- Crompto Water Pump
19 3.70 MCC 401 8F2 n Greaves (Propylene Horizontal TEFC
PM-01A Ltd. Vapour
Compressio
n Package)
Crompton
Greaves Auxiliary
Ltd. Cooling
205-A-006-PM- Water Pump
20 3.70 MCC 401 6F1 (Propylene Horizontal TEFC
01B
Vapour
Compressio
n Package)
Crompton Auxiliary
205-A-006-PM- Greaves Lube Oil
21 1.10 MCC 401 7F1 Ltd. Pump Horizontal TEFC
02
(Propylene
Vapour
Page | 51
Compressio
n Package)
Crompton Agitator
Greaves
22 205-AGM-001 1.10 MCC 401 9F2 Ltd. Motor Horizontal TEFC
Water
Heater
Crompton
(Propylene
205-A-06-H01 3.00 MCC 401 2F1 Greaves Horizontal TEFC
23 Vapour
Ltd.
Compressio
n Motor
Package)
Oil Heater
Crompton (Propylene
205-A-06- 0.50 MCC 401 4F2 Greaves Vapour Horizontal TEFC
24 Ltd.
H02 Compressio
n Motor
Package)
Page | 52
Standard environment and site conditions for the installation of motors are usually set as
follows:
 Ambient temperature: -10~40ºC
 Humidity: Relative humidity below 90%RH for totally enclosed types, and below
80%RH for semi-enclosed types.
 Harmful gases, liquids, dusts, high moisture should be absent.
 Foundations should be strong and free of vibration.
Ventilation and space
 Installation area should be well ventilated.
 The installation space should be large enough to facilitate heat dissipation and
maintenance.
Foundation
 Use rigid and solid sole plate or common bed as foundation. For best motor
performance, it is advisable to use a sole plate or common bed, particularly when
using a shaft coupling.
 Ensure that the Motor-Pump coupling arrangement is intact.

 Ensure that the Emergency Push button in Local Control Station located in the Pump
House is in released position.
 Confirm with the concerned officer for starting the motor.
 Verify the Tag no of the Motor before starting.
 Ensure that all the protection systems for the motor are enabled and in order.
 Visually check for loose connections, if any.
If the Motor is being energized after a major overhauling job, the following
additional checks are to be carried out:-
 Make sure that the earthing connections are good.
 Ensure the frame and terminal box are grounded.
 Check the relay setting and the display readings in the Numerical Relay.
 Motor can be started using Local Control Switch positioned near the motor.
 Local control switch is located in the Pump House with a Push button JB.
 Switch ON the Control supply for the Motor.
Page | 53
Too frequent starts can be harmful to the motors. The following restrictions should be
observed:
 Motor can be restarted should the initial start fail. Two starts are generally permissible
when the motor is cold.
 Motor can be started only once when it is at normal running temperature.
 If the motor rotor fails to start turning within one or two seconds, shut off the power
supply immediately. Investigate thoroughly and take corrective action before
attempting a restart.
Possible reasons for not starting are:
 Too low a voltage at the motor terminals.
 The load is too much for the rotor to accelerate.
 The load is frozen up mechanically.
 All electrical connections have not been made.
 Single-phase power has been applied.
 Any combination of the above.
 Observe the direction of rotation of the Motor and ensure that it as per the
indication given on the Pump.
 Make sure that the anti-condensate heater is OFF while the motor is running.
 Ensure the voltage and frequency of the power source is identical to the ratings
shown on the nameplate.
 Voltage variation should be confined to within ±10% of the rating and the three
phase voltages should be in full balance.
 Ensure that the starting current is not more than 5 times the rated current of the
motor.
 Ensure the motor phase currents are within ±5% of the average values.
 Following the initial start-up, the bearing temperatures should be closely monitored.
If the rate of rise in temperature is excessive or if the motor exhibits excessive
vibration or noise, it should be shut down immediately and a thorough investigation
made as to the cause before it is operated again.
 The Bearing temperature and Winding Temperature of the motor in operation must
be monitored. The readings can be checked in the Motor feeder Temperature
scanner.
7.0) STOPPING ACTIVITY
 Inform the concerned officer about the stopping activity.
Page | 54
 If the operation is still going on, ensure that the operations will be continued using
other standby motor.
 Stop the motor using Local Control switch or DCS.
 Observe that the motor does not stop abruptly on giving the Stop command and
that it stops in a smooth manner.
 In case, the Local Control Switch does not function and only in case of emergency,
the Emergency Push Button can be used to stop the Motor.
8.0) AUTOMATION/INTER-LOCKING:
The motor feeder is interfaced with SAS/DCS and the following parameters / status
are monitored
 Abnormal rise in Bearing temperature / winding temperature.
 Running Hours of the Motor.
The motor will trip under the following scenarios
 When ESD is activated for that operational area.
 Due to occurrence of any Earth fault.
 Due to loss of load as a result of any de-coupling.
 When Supply voltage goes below / above the accepted variation of 10%.
 In case of locked rotor – Due to any jam while running.

 Isolate the Motor from electrical supply.

11.0) DO'S / DON'TS
Page | 55
DO’S
the bolts evenly, to avoid uneven pressure.
 Check the oil quantity of lubricant (grease or oil).
 The double earthing for the equipment should be checked.
 The motor surroundings should be clean with sufficient illumination.
 Always ensure that proper coupling guard is provided.
 Ensure that in case of outdoor motors, canopy is provided.
DON’Ts
 Do not touch the rotating parts.
 Do not re-energize the motor without conducting all pre-commissioning checks. The
results must be comparable with results at works.
 Do not operate the emergency push button for regular stopping activity.
 Do not run the motor with low lube oil.
 Do not bypass the safety interlocks.
CHAPTER 10-DIESEL GENERATOR

This chapter describes the Standard Operating Procedure for diesel generator.
1.0) INTRODUCTION
Paradip.
DG set is located near the Substation for Emergency lighting power supply in case of
failure of the main incomer supply. The DG set is synchronised with the main power via
AMF Panel and supplies the power at critical locations through Essential Services Board
located inside the Substation.
 Crude location has one 125 KVA DG set and the connected load to the DG set are as
under:-
 Emergency Lighting power for Substation building (SS 335AS), Cable cellar, DG shed
and the Transformer yard: 335AS-205-ELTG-501.
 Emergency Lighting power for Satellite Rack room (SRR 806): 806-205-ELTG-501.
 Emergency Lighting power for Operator’s Shelter building (485-2): 485-2 -205-ELTG-501.
 Emergency Lighting power for UPS in Satellite Rack room (SRR 806): 806-205-UPS-501
and 806-205-UPS-601.
Page | 56
 Emergency Lighting power for Battery Charger and DCDB system in Substation (SS
335AS): 335AS-205-BCH-701 and 335AS-205-BCH-702.
 Product location has one 350 kVA DG set and the connected load to the DG set are
as under:-
 Emergency Lighting power for Substation building (SS 312N), Cable cellar, DG shed
and Transformer yard: 312N-205-ELTG-501.
 Emergency Lighting power for Satellite Rack room (SRR 819): 819-205-ELTG-501.
 Emergency Lighting power for OM & S Control room (OMS801): 801-205-ELTG-501.
 Emergency Lighting power for Operator’s Shelter building (485-7): 485-7 -205-ELTG-501.
 Emergency Lighting power for Satellite Maintenance Building (492-3): 492-3 -205-ELTG-
501.
 Emergency Lighting power for UPS in Satellite Rack room (SRR 819): 819-205-UPS-501
and819-205-UPS-601.
 Emergency Lighting power for UPS in OM & S Control room (OMS801): 801-205-UPS-501
and 801-205-UPS-601.
 Emergency Lighting power for Battery Charger and DCDB system in Substation (SS
312N): 312N-205-BCH-701 and 312N-205-BCH-702.
2.0) DATA SHEET

PRODUCT AREA
1 Vendor’s name Jackson
2 Equipment reference number 312N-205-DG-501
3 Rated power 350 KVA
4 Rated voltage 415 Volts ± 5%
5 Frequency 50 Hz ± 3%
7 Recommended fuel HSD as per IS:1460
Fuel oil consumption (gms/kWh

8 under NTP) at 75% load and 0.8 58.2 Ltr/hr
power factor
Lube oil consumption (litres/kWh
9 0.092 Ltr/hr
under NTP) at 100% load
Page | 57
BATTERY
11 Make Cummins (Pulselite)
12 AH capacity 65 AH
13 Voltage 24 V, DC (each battery)
14 Quantity 02 Nos (connected in series)
ADDITIONAL FUEL TANK
15 Capacity of additional fuel tank 990 Ltr
CRUDE AREA
1 Vendor’s name Jackson
2 Equipment reference number 335AS-205-DG-501
3 Rated power 125 KVA
4 Rated voltage 415 Volts ± 5%
5 Frequency 50 Hz ± 3%
7 Recommended fuel HSD as per IS:1460
Fuel oil consumption (gms/kWh 20.8 Ltr/hr

8 under NTP) at 75% load and 0.8
power factor
Lube oil consumption (litres/kWh 0.03 Ltr/hr
9
under NTP) at 100% load
BATTERY
11 Make Cummins (Pulselite)
12 AH capacity 65 AH
13 Voltage 12 V DC
14 Quantity 01 No
Page | 58
ADDITIONAL FUEL TANK
15 Capacity of additional fuel tank 990 Ltr
3.0) OPERATING CONDITIONS

Operating Conditions for DG set
 Ambient temperature: Maximum + 40 °C.

 Maximum 24 h average + 35 °C.
 Minimum (according to “minus 5 indoor class”) - 5 °C.
 Room should be well ventilated.
Location
 Acoustic enclosure should be located considering wind direction ensuring that
there is no obstruction to natural wind flow and the prevailing wind do not enter into
the radiator / exhaust outlet.
 For humid / coastal atmospheric applications, anti condensation heaters are
mandatory for alternator.
 For aesthetic reasons, consider exhaust placement in relation to the building. Over a
period of time, exhaust gas carbon deposits will tend to accumulate on any nearby
wall or structure.
Enclosure placement / Enclosure room
 Ensure sufficient lighting / illumination at the installation space.
 Sufficient clearance must be available to open doors and to carry out any
maintenance activities both sides and rear.
 Also ensure sufficient overhead clearances are provided.
 The generator room / area around enclosure should not be used for storage
purposes.
 Do not the place enclosure beside heat generating equipment, or directly below
water or steam pipes or in the vicinity of corrosive substances or vapours, metal
particles and dust.
Normal precautions and safety
 The hot exhaust gas must never be directed towards hazardous area.
 Never operate the generator unless all guards, covers, shields and other safety items
are properly installed.
Ventilation
 Cross ventilation and free flow of cool, clean and fresh air should flow from
alternator end to engine.
Page | 59
Others
 All day tank must not be located inside the DG shed.
 Service storage tank should be located such that piping will have minimum and
controlled restriction
4.0) PRE-START UP ACTIVITIES
 Make a general visual inspection on the engine and alternator. Check if there is any
breakage, crack, indentation, leakage or looseness.
 Never operate the generating set before removing any fault, if any.
 Take out foreign materials such as keys, tools, cleaning wool, papers etc. on the
engine and the alternator.
 Check the engine oil level on the dip stick. Refill with an appropriate oil if it is low. Oil
level must be above the “L” mark and as close as possible to the “H” mark in the
dipstick. Never operate the Engine if the oil level is below the “L” mark or above the
“H” mark.
 Check the fuel level and top-up if necessary.
 Look at the water level by opening the radiator tap. If it is inadequate add more
coolant. Coolant level must be 30 mm. lower than the water filling neck.
 Engine cooling water must include antifreeze according to the coolest weather
conditions in the area. A mixture of 50% antifreeze and 50% water provides a good
protection in all area.
 Check the air filter gauge. Clean or replace the air filter, if necessary. Keep the inlet
opening open.
 Make sure that the generating set can easily take air from the environment.
 Check the battery connection cables. Take care to tighten the loosened battery
terminals with spanner and, cover with special substance and keep clean in order
to avoid oxidation.
 Ensure that the condition of all fuel filters, oil filters and air filters are good.
 Check if the circuit breaker switch is in OFF position.
 Make sure that the emergency stop button is not pressed.
 Make sure that all the relays in the AMF panel are reset.
 Make sure that the earthing of DG body, neutral, panel doors etc. are intact.
 Check that no loose materials are lying near generator set.
If the engine is being energized after a major overhauling job, the following
additional checks are to be carried out:-
 Ensure that insulation tests have been carried out for the power cables.
 Make sure that all the trip/alarm/annunciation systems have been checked.
Page | 60
 Ensure that all the metering systems have been checked.
 Check the tightness of all electrical connections.
 Check the tightness of all earthing connections.
 Ensure that all the earth pits are tested.
 Check if all the components in the circuit are as per the ratings.
5.0) START UP PROCEDURES:
Manual Operation
 Check the precautions and controls starting up the generating set.

 To initiate a start sequence in MANUAL, press the push on the DG Control Panel till
button and the start sequence is initiated.
 After fuel solenoid is energized, and then the starter motor is engaged.
 To prevent permanent damage to the cranking motor, do not cranked the engine
for more than 10 seconds continuously. If the engine fails to start after about three
successive attempts, with an interval of two minutes between successive starts then
the starter system should not be operated and the fuel system should be checked
for any faults.
 When the engine fires, the starter motor is disengaged and locked out at 50 Hz
measured from the Alternator output.
Automatic Mode of Operation Starting with PowerCom Controller and AMF
 At the time of Mains power failure, voltage monitoring relay will give feedback to
the control system that Mains supply has failed.
 After a delay of 15 seconds, the logical circuit will give start command to the DG
set.
 After the DG starts running, the neutral contactor will close automatically.
 This contactor’s contact completes the closing circuit of the DG contactor.
 Whether the start sequence is initiated by mains (utility) failure or remote input, the
following sequence is followed:
 After Start Delays the Fuel Solenoid is energized, then one second later, Starter
Motor is engaged the engine is cranked for 10 second period. If the engine fails to
fire during this cranking attempt then the starter motor is disengaged for a 10
second rest period. If this sequence continues beyond the 3 staring attempts, the
start sequence will be terminated and Fail to Start fault will be illuminated.
 When the engine fires, the starter motor are disengaged and “Safety On” Timer
activated.
Page | 61
 Check for any abnormal noise or vibration on the generating set.
 Check for any leaks in the fuel system, coolant system, lubrication system and the
exhaust system.
 Monitor the generating set operation by means of the gauges on the control panel.
 Check the engine temperature and oil pressure by means of the gauges on the
panel.
 The Oil temperature gauge should normally read between 167 deg F (75 deg C)
and 221 deg F (105 deg C). Under full load conditions, an oil temperature of 240
deg F (116 deg C) for a short period is not a cause for alarm.
 Engine Oil pressure must be indicated on the Gauge within 15 seconds after starting.
If the Oil pressure is not registered within 15 seconds, shut off the engine
immediately.
 Normal engine pressure at 221 deg F (105 deg C) should be between 3.0 and 7.0
kg./sq.cm.
 Water temperature should range between 75 deg C (167 deg F) and 95 deg C (203
deg F). Maximum engine coolant temperature should not exceed 95 deg C.
 The engine exhaust is a good indicator of engine operation and performance. A
smoky exhaust may be due to a poor grade of fuel, dirty air cleaner, over-fuelling or
other conditions. If the engine exhaust is smoky, corrective action should be taken.
 Monitor the generating set outlet voltage and frequency by means of the gauges
on the panel.
 Check on the voltmeter, if the voltage between phases is 415 V and between
phase and neutral is 230 V.
 Check that the frequency at idle is 50-51 Hz.
 There is an LED in the display which indicated that the Battery is not charging. So, if
the LED glows when the engine is running, it indicates that the charging alternator is
not generating voltage.
 Putting the generating set under load must be done as follows:
 Set the alternator outlet switch on the panel to ON position.
 Set the load switches (or fuses) on the distribution panel to ON position one by
one. This way, the generating set cannot be suddenly put under full load.
Otherwise, the engine stalling or alternator winding insulation deformation or
burning can occur.
 Never operate the generating set before removing any fault, if any.
Page | 62
Manual Mode:
 At the time of Mains power restoration, DG power contactor will be trip manually
through push button located on AMF Panel.
 After tripping DG contactor, Mains power contactor will close and feed Mains
power.
 Now, to stop the DG at the time of Mains restoration, stop push button will be
pressed manually.
 It is important to idle an engine for 3-5 minutes after a full load operation before
shutting it down. This allows the lubricating oil and water to carry away heat away
from the combustion chamber, bearings, shaft etc.
 If any Engine fault is there during running of DG Set, Controller will give trip
command to DG Set with annunciation at AMF Panel.
 In case of emergency, press the red colour Emergency stop button provided on the
DG body near the Control Panel and also on the AMF Panel.
Automatic Mode:
 When the Mains supply gets restored, the load transfer to the mains supply will be
done through logical circuit.
 Circuit will trip DG Power contactor and close mains power contactor
automatically.
 After the Mains power contactor is closed, the circuit will give stop command to DG
Set.
 DG will stop after cooling set time in controller.
 Before closing of any Power contactor, neutral contactor will close automatically
through logical circuits.
 If any Engine fault is there during running of DG Set, Controller will give trip
command to DG Set with annunciation at AMF Panel.
8.0) AUTOMATION / INTERLOCKING / PROTECTION:
Basic interlocks are given in DG both for the Engine and the Alternator for Protection
Purposes, and are mainly the relays / sensors which will give warning / cause the DG
Set to Trip.
ENGINE PROTECTION
 Over-speed shutdown: The engine over-speed default setting is 110% of the rated
engine speed nominal. The control includes time delay of 5 seconds to prevent
nuisance shutdown signals.
 Low Lube Oil Pressure Warning / Shutdown: The level is preset (configurable with a
PC based service tool or through the display panel menus) to match the capabilities
Page | 63
of the engine used. The control includes time delay of 5 seconds to prevent
nuisance shutdown signals.
 High Engine temperature Warning / Shutdown: The level is preset (configurable with
a PC based service tool or through the display panel menus) to match the
capabilities of the engine used. The control includes time delays of 5 seconds to
prevent nuisance shutdown signals.
 High Coolant temperature warning / Shutdown: This warning indicates that the
Engine coolant temperature is very high. For a temperature of 93 deg C (199 deg F)
it indicates a warning for a delay of 5 seconds and for a temperature of 96 deg C
(205 deg F) it shuts down the engine after a threshold time of 5 seconds.
 Low battery Voltage warning: This warning a battery charging system failure by
continuously monitoring the Battery voltage. The control includes time delays to
prevent nuisance warning signals.
 High battery Voltage warning: This warning a battery charging system failure by
continuously monitoring the Battery voltage. The control includes time delays to
prevent nuisance warning signals.
 Weak battery Voltage warning: The control system tests the Battery Bank each time
the Generator set is signalled to start. A warning is announced if the generator set
Battery indicated impeding failure. The control includes time delays to prevent
nuisance warning signals.
 Fail to Crank Shutdown: This Shutdown indicated that the controller signalled the
starter to crank the Engine, but the Engine did not rotate.
 Cranking Lockout: The control will not allow the starter to attempt engage or to
crank the engine, when the engine is rotating. (When the control senses the valid
engine RPM above the noise threshold value).
 Sensor failure indication: An out-of-range high of low diagnostic logic is provided on
the base control to detect analog sensors or interconnecting wiring failures.
ALTERNATOR PROTECTION
A Siemens Make Numerical Relay 7SJ80 is installed in the AMF panel for protection
of the Alternator.
 High/Low AC Voltage Shutdown: The high voltage default setting is 115% of the
rated voltage with a 5 seconds time delay. The instantaneous voltage default
setting is 130% of the rated voltage. The low voltage default setting is 85% of the
rated voltage with a 5 seconds time delay.
 Over-current warning/Shutdown: The default setting for the warning is 120% of the
rated current with a 05 seconds time delay.
Page | 64
 Under/Over-frequency: The under-frequency default is 85% of the 50 HZ frequency
with a 10 seconds time delay. The over-frequency default is 110% of the 50 HZ
frequency with a 05 seconds time delay.
 Earth Fault protection:
 Instantaneous Earth Fault 50N - The high set element is meant for instantaneous
operation at high values of fault current to limit the stress on the Alternator and may
have an operating time of about 20 milli-seconds.
 IDMT Earth Fault 51N - IDMT Earth Fault relays are inverse definite minimum time relay
which operate with a time delay at high values of fault current to limit the stress on
the Alternator.
AUTOMATION
The following status can be monitored from SAS as DG is interfaced with Substation
Automation System
 Emergency Generator ON
 Emergency Generator Fault
 Emergency Generator Prot relay (7SJ80) operated status.

 Isolate the DG from AMF Panel through Control supply.
 Before the DG being handed over to maintenance, ensure that alternate
arrangement has been made for power supply in case of Mains failure.
10.0) TAKING OVER FROM MAINTENANCE:

 Check the oil level in tank.
 Check Battery conditions.
Page | 65
 Check for proper functioning of AMF panel and protective relays, by running the
DG on No-Load as well as On-Load Conditions.
11.0) DO’S & DON’TS:
The below mentioned are the general safety instruction and Do’s & Don’ts which
one must follow during operation / maintenance of DG set.
DO’S:
 Make sure that the work area around the equipment is dry, well lit, ventilated free
from cluster, loose tools, parts, ignition sources and hazardous substances.
 Check the Engine and its compartment visually before operating and after the
Engine is stopped. This will help in detecting any leaks.
 Always wear protective glasses, protective shoes, and ear muff while working on the
Engine.
 Disconnect the battery (negative) Cable first and discharge before beginning any
repair works.
 If the engine has been operating and the coolant is hot, allow the engine to cool
before you slowly loosen the filler cap and relieve the pressure from the cooling
system.
 To avoid burns, be alert for hot parts and hot in lines, tubes and compartments.
 Always use tools that are in good condition.
 Make sure that the Engine compartment is lockable so that no unauthorised person
can operate the system.
 Keep your generator clean by wiping it periodically with a clean cloth.
 Check the exhaust system regularly for damage or leaks. Make sure the exhaust
pipe extends out at least one metre beyond the DG room’s perimeter.
 Check the air filter periodically and clean it by tapping it on a flat surface. Never
wash it in solvents or blow it out with an air hose.
 Make sure each operator is familiar with the important safety precautions.
DON’TS:
 Never operate the generating set before removing any fault, if any.
 Do not work on anything that is supported only by lifting jacks or hoist. Always use
proper blocks supports before starting any repair work.
 Do not wear loose fittings or torn clothing as rotating parts can cause cuts,
mutilation or strangulation.
 Do not attempt to rotate the crankshaft by pulling or prying the fan. This practice
can cause serious personal injury, property damage and damage to fan blade.
 Do not overfill the fuel tank. Close the fuel tank filler cap properly.
Page | 66
 Be alert for possible pressure when disconnecting any device from the system that
utilises pressure. Do not check for pressure leaks with your hands. Always use
protective hand gloves. High pressure Oil or fuel can cause serious injury.
 Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid
prolonged or repeated contact with your skin. Do not swallow internally. In case of
contact, immediately wash skin with soap and water.
 Always use the same fastener part number while replacing fasteners. Do not use
fasteners of lesser quality for replacements.
 Avoid inhalation of vapour, ingestion and prolonged contact with used Engine oil.
 Do not under any circumstance smoke or use naked flame or sparks in the vicinity of
the battery as it can cause explosion.
 Do not open the coolant filler cap while the Engine is running. Steam or hot coolant
can spray out and cause burns.
 Do not run the Engine with low oil pressure.
 Do not put the engine at full load immediately after starting at Manual mode.
 Do not shut down the engine at full load immediately after starting at Manual
mode.
 Do not run the generator for long periods of time without using it to power
appliances. It wastes fuel and may cause the engine to misfire.
 Do not run your generator set with the door panel open.
CHAPTER 11 – UPS
This chapter describes the Standard Operating Procedure for UPS.
1.0) INTRODUCTION
Paradip.
UPS system is located in Control Room building for feeding uninterrupted power supply to
Instrumentation, Communication system and Work stations.
Crude location has one 35 KVA UPS and one 15kVA UPS and the connected load are as
under:-
15kVA UPS (806-201-UPS-501) – 220 Volts AC:
 CCTV
 LAN Communication
 Work Station in Control Room SRR 806, Substation 335AS and Operator Shelter 485-2.
Page | 67
 Access Control
 PA system
 Fire Alarm system
 Distributed Control System
 Tank Gauging system
 Emergency Shutdown system
 Crude Oil Blending Skid
 MOV Master Station
 Auto Sampler
Product location has UPS system in Control Room 819 and OM&S room 801.
Control room SRR 819
 CCTV
 Work Station in Control Room SRR 819, Substation 312N and Operator Shelter 485-7.
 Access Control
 PA system
 Fire Alarm system
 Tank Gauging system
 Analyzer Room
 OM&S room 801
 CCTV
 Work Station in OM&S Technology building 497 and Satellite Maintenance building
492-3.
 Access Control
 PA system
 Metering Station – I, II and III.
Page | 68
 Sulphur loading
 Analyzer
 Weighbridge
 Admin building
 LCD-205-A-006
Page | 69
2.0) DATA SHEET
35kVA UPS
1 Make Emerson Network
819-205-UPS-601
2 Equipment Tag No.
806-205-UPS-601
3 Rating 35 kVA
4 Voltage 110V AC ±10 %
5 Frequency 50Hz ±2 %
Ni-Cd
6 Type of battery to be provided
7 Number of Cells 320
8 Float voltage 454.4 V
9 Boost voltage 464 V
10 Operating Temperature 0 – 50 deg C
11 Protection Level IP 42
15kVA UPS
801-205-UPS-501
2 Equipment Tag No. 819-205-UPS-501
806-205-UPS-501
3 Rating 15 kVA
Ni-Cd
Page | 70
125kVA UPS
2 Equipment Tag No. 801-205-UPS-601
3 Rating 125KVA
Ni-Cd
Temperature
 UPS systems are designed to operate at a constant ambient temperature of up to
40ºC without the need to de-rate them. For optimum battery life it is recommended
that the ambient around the UPS should be 20ºC. If the ambient temperature
exceeds this recommendation the batteries will not perform to their design life
expectations.
Humidity
 The maximum humidity the UPS is subjected to must not exceed 90% (non-
Page | 71
condensing).
Ventilation
 Ensure that all of the UPS ventilation grills are left clear and free from obstructions.
 Ensure that no equipment is placed inside the UPS room.
 Ensure that adequate ventilation using exhaust fan is provided in Battery room for
battery gassing.
 The forced ventilation is provided by internal intake fans.
Access
 UPS should be easily accessible both on front and rear sides.
 No obstruction in the way to emergency buttons.
Illumination
 Sufficient illumination must be there inside the room. The recommended range of
illumination is 150 – 200 lux in UPS room and 150 lux in Battery room.

UPS UNIT
 Ensure that all the outgoing feeders are in OFF.

 Check the availability of all the three power sources
 From PMCC to Servo Voltage Controlled Stabilizer.

 From Essential Service Board to UPS 1 and UPS2.
 Check if the HVAC diffusers are open and system is in order.

 All the annunciation systems should be checked and reset.
In addition to the above checks, following checks to be carried out after a major
maintenance work has been carried out:-
 Clean the cubicles and bus bars with vacuum cleaner.
 IR test for all the cables and the charger circuit.
 Ensure the correctness and tightness of all wiring.
 All the cable terminations are done as per drawings.
 Any opening or the door at the bottom should be closed.
 Tightness of earthing for panels, battery switch.
BATTERY BANK
 Ensure that the Cells have not developed any crack/damage/leak.
 Corrosion problems (especially to terminals), if any.
 Ensure that battery cells are filled with electrolyte.
 Check the condition of vent plug for any blockage.
 Cleaning of battery bank to be done to remove any dust.
Page | 72
In addition to the above checks, following checks to be carried out after a major
maintenance work has been carried out:-
 Condition of acid proof flooring.
 Ensure correct polarity of the cells.
 Working condition of the following :-
 Smoke detectors
 Exhaust fan
 Check whether the emergency eye wash hand wash provision available or not.
PROCEDURE FOR UPS START-UP WITHOUT POWER INITIALLY SUPPLIED TO THE LOAD
This procedure should be followed when turning on the UPS from fully powered
down condition i.e. where the load is not being initially supplied at all.
 The external power isolators should be in closed position.
 Open the UPS doors to gain access to the main power switches.
 Close the Rectifier Power Switch (Q1).
The Module Mimic LED’s will indicate input supply a.c. present (2 -steady green) and
after approximately 20 seconds the Inverter output healthy (4- steady green) and
Battery unavailable (3) will light and also red led (13) will illuminate.
“Initializing Window”
 After first connecting power to the UPS and closing the Q1 isolator, the “Initializing
Window” message will appear on the LCD screen. It persists for about five seconds
while the control firmware is loaded. It is followed by a screen showing various
messages with the time and date on the bottom line.
NOTE:
If input power is present but the display remains blank, then the Micro Controller is
not working.
The following action will apply power to load the equipment -
 Close the UPS output power switch Q4.
The Module Mimic LED’s will change so that the Load on Inverter (5 - steady green)
and Battery unavailable (3) will light and also red led (13) will illuminate.
 Close the Bypass input power switch Q2.
Bypass input led (1-steady green) will light, after 20 second the inverter synchronizes
with the mains bypass.
 Before closing the battery circuit breaker check the d.c. bus-bar voltage. From the
Page | 73
above window press the ENTER key:
The Main Menu Window will display:
 Select MEASUREMENT and press ENTER key.

 Select BATTERY and d.c. bus-bar voltage will be displayed:
 If the voltage indicated is satisfactory (a.c. system, 446V d.c. for 400V a.c.
system and 459V d.c. for a 415V a.c. system) press the Escape key
repeatedly until the display returns to the original window.
 Manually close the battery circuit breaker. This is located inside the battery room
adjacent to the battery racks.
The Module Mimic indicator (3) Battery unavailable should extinguish. Several LED’s
on the Battery state of charge bar-graph (17) will illuminate showing the battery
state of charge when the battery circuit breaker has been closed and the inverter
has stabilized the screen will change to the default window.
 The message shown below will be seen on the default screen whenever the UPS is
operating normally:
The UPS is operating normally with its Inverter supplying the load.
PROCEDURE FOR UPS START-UP WITHOUT INTERRUPTING POWER TO THE LOAD
This procedure will describe how to start the UPS and the how to transfer the load
from the external maintenance bypass to the UPS inverter.
 The external power isolators should be closed.
 Open Q3 Maintenance Bypass switch and external switch (inside Maintenance
Bypass) to load.
 Close the output power switch Q4 and the Bypass power switch Q2.
“Initializing Window”
 After first connecting power to the UPS and closing the isolator, this“Initializing
Window” message will appear on the LCD screen. It persists for about five seconds
while the control firmware is loaded by ascreen showing various messages with the
time and date on the bottom line.
The Module Mimic indicators Bypass supply healthy (1) and after 20 seconds Load
on Bypass (6) will flash and red led (13) will illuminate.
The Display window will show the present status of the UPS.
 Close the Rectifier input power switch Q1.
Wait for 20 seconds then close the battery circuit breaker. This is located inside the
battery room adjacent to the battery racks. The Module Mimic indicator (3) Battery
Page | 74
unavailable should extinguish. Several LED’s on the Battery state of charge bar-
graph will illuminate showing the battery state of charge.
The rectifier will ‘walk-in’ and stabilize at float the voltage.
 Open the Maintenance Bypass power switch Q3 and fit lock.
The Module mimic indicator Load on bypass (6) will flash amber.
The Display window will show the present status of the UPS.
After 5 seconds the Module Mimic LED’s will change so that the Load on inverter (5)
will light steady green and the Load on Bypass (6) will extinguish.
The message shown here will be seen on the Default screen whenever the UPS is
operating normally.
The UPS is operating normally with its Inverter supplying the load
PROCEDURE FOR SWITCHING THE UPS INTO A MAINTENANCE BYPASS CONDITION
FROM NORMAL OPERATION
The first part of this procedure details how to select the Inverter OFF and power the
load from the bypass mains via the Static Switch. This procedure should be followed
to transfer the load from the UPS inverter output to the maintenance bypass system.
This may be required during UPS maintenance procedures.
Follow the procedure below to transfer the load from the output to the
Maintenance Bypass of UPS.
The following window allows the operator to select the UPS inverter ON or OFF.
 Before making this operation, read messages on display to be sure that bypass
supply is regular and the inverter is synchronous with it, not to risk a short interruption
in powering the load.
 Press the INV switch on the left side of the operator control panel.
Confirm this operation as instructed at the display:
Press ENTER for 1 second to confirm INV OFF
Press ESC for 1 second.
If ENTER is pressed:
The Module Mimic indicator Load on Inverter (5) will extinguish and the Load on
Bypass indicator (6) will flash amber, and also the red led (13) will flash and normally
will accompany by an audible alarm.
 Pressing the Alarm Silence Switch cancels the audible alarm but leaves the warning
message displayed until the appropriate condition is rectified.
 The UPS inverter will not shut down and the load will transfer to the Bypass supply.
The Module Mimic indicator Load on Bypass (6) will flash amber and the Load on
Inverter (5) indicator will extinguish.
Page | 75
 Your load is now powered via the Static Bypass system.
 Unfasten the lock; release the internal safety bar and close the maintenance
bypass power switch Q3.
 Open the Rectifier input power switch Q1, the Output power switch Q4, the bypass
power switch Q2 and the Battery circuit breaker. The unit will power down but the
load will continue to be supplied by the manual bypass.
 Wait 5 minutes for the internal D.C. bus-bar capacitors to discharge.
 The following points will be live within the UPS:
 Bypass a.c. input supply terminals.

 Maintenance Bypass power switch.
 Static Bypass power switch.
 UPS output terminals.
 Input and Output terminals remain protected by a metallic cover.

 Your load is now powered from the maintenance bypass system and the UPS is
completely shutdown.
PROCEDURE FOR CARRYING OUT A RESET AFTER A RECOGNIZED CONTROLLED
TRANSFER TO BYPASS/EPO ACTION.
When the necessary action to correct the problem has been taken, this procedure
should be followed to restore the UPS back to its normal operating condition
following, a controlled transfer to bypass or when the Remote Emergency Power Off
has been activated.
A recognized controlled transfer to bypass is activated by the following problems:
 Inverter Over-temperature
 Cut-off Overload
 Battery Over voltage
 Press the ENTER key.

 Select FUNCTION and press ENTER key.
 When the PASSWORD has been completed press the ENTER key.
 Select the NEXT key and press ENTER key.
 Press ENTER key.
 Select RESET alarm and press ENTER key.
 Return the Display window to normal by repeatedly pressing the ESCAPE key back
through the various windows until the default screen is displayed.
 This operation resets the logic circuitry to enable the rectifier, inverter and static
switch to operate normally.
Page | 76
NOTE
When the remote EPO switch has been activated it is necessary to manually close
the battery circuit breaker.
 When the EPO system incorporates a trip facility of the external input a.c. power
supply circuit breaker, the RESET switch would have no affect on it. First close the
external input a.c. supply circuit breaker, the UPS can be started in the normal
manner, as the logic circuits will automatically reset on return of the power supplies.
PROCEDURE TO COMPLETELY SWITCH ON THE UPS AT THE UPS DISPLAY CONTROL
PANEL
 From the Default window, press the ENTER key
 TheMain Menu window will display:
Select FUNCTION and press ENTER key:
 Before being allowed into the FUNCTION windows you are requested to enter a
password. This is achieved by pressing the UP arrow key repeatedly until the first digit
displays the character required, you then press the DOWN arrow key once to move
on to the second digit. This action is repeated for all eight digits. When the
PASSWORD has been completed press the ENTER key.
 This operation gives the operator access to modify UPS's operating mode. You have
now access to all function windows.
 Press the DOWN arrow key until the cursors have selected.
NEXT PAGE – press the enter key.
 Press the DOWN arrow key until the cursors have selected ON/OFF UPS CONTROL.
 Press the enter key.
 The following window allows the operator to select the UPS inverter ON or OFF,
select the rectifier ON or OFF, select the rectifier to manual or float voltage and a
switch OFF the line (bypass) voltage to the load.
 Ensure INVERTER is selected by the cursors and press the ENTER key.
 The OFF selection will be highlighted, using the UP arrow key, rotate between the
selections offered (in this case it will be ON or OFF) select ON. Press the ENTER key to
execute your order.
 After approximately 20 seconds, the Module Mimic will change so that the Load on
Inverter (5) will light steady green and the Load on Bypass (6) will extinguish.
 Return the Display window to normal by repeatedly pressing ESCAPE key back
The UPS is operating normally with its Inverter supplying the load
PROCEDURE TO SWITCH ON THE INVERTER AT UPS DISPLAY CONTROL PANEL
Page | 77
 This operation gives the operator access to modify UPS’’s operating mode. The
display window will show the present status of the UPS for normal operation.
 Confirm this operation as instructed at the display:
 Press ENTER for 1 second to confirm INV ON
 Press ESCAPE for 1 second to exit.
After 20 second the Module Mimic LEDS will change so that the local or the inverter
(5) will light steady green and the load on bypass (6) will extinguish.
 Return to the normal window.
 During normal operation, i.e. when the UPS input supply is present and within
specification, both the rectifier and inverter sections are active and the static switch
is turned on to connect the inverter output to the critical load bus. The battery
circuit breaker is also closed and the battery is therefore permanently float charged
at the d.c. bus voltage level.
 As the unit outputs are connected in parallel, the System checks that the inverter
control circuits are perfectly synchronized with one another and with the Bypass
Mains in terms of both frequency and phase and that they have the same output
voltages. Current supplied to the load is automatically divided among UPSs. A
warning message appears while synchronization is in progress. A module's static
switch cannot close until these conditions are satisfied.
Page | 78
LED
NORMAL
N0. INTERPRETATION – ACTION
STATE
If this green led is OFF, it signifies a problem with the Bypass input a.c.
Check the following –
 Bypass input power switch Q2 is closed.
 Input Supply voltage is within 10% of nominal
1 ON
 Power supply fuses are OK – on the a.c. Power supply board will
extinguish if either fuse is ruptured.
 If the above checks prove unsatisfactory then seek qualified
assistance.
If this led is OFF, a problem exists in the Input power supply or in a part
of the rectifier. An alarm message is visible at the display.
 The rectifier input isolator (Q1) is closed.
 The input voltage is within the limits of normal operation.
2 ON
 The phase sequence of the mains input is correct.
 Verify that condition leading to an emergency stop has not
happened, in which case a Reset must be carried out.
 If these checks do not give a positive result, request qualified
assistance.
If this yellow led is ON it signifies that the battery is not available. This
could be due to the battery circuit breaker being open or that the
d.c. busbar voltage is below the figures stated in the item(2)
specifiedabove.The battery circuit breaker will open automatically if
the d.c. voltage falls below these levels.
3 OFF  Check that the conditions for LED(2) are satisfied.
 DC busbar voltage – if not above 320V, then carry out checks as
for led(2) – mains rectifier failure above. If d.c. busbar voltage is
above 320V but you are unable to close the battery circuit
breaker then seek qualified assistance.
 Battery circuit breaker is closed.
 If the above checks prove unsatisfactory, then seek qualified
Page | 79
assistance.
If this green led is OFF, it signifies that the inverter is not producing its
correct output voltage.
 If [OVERTEMPERATURE] or [OVERLOAD] alarm messages are active
then (after allowing the UPS to cool / checking that the load
current on the Bypass line is not excessive) use the procedure to
carry out the reset
4 ON
 Check that the conditions for LED(2) are satisfied.
 Check that the Inverter LED(8)- yellow – is OFF, otherwise follow
Inverter switch ON procedure.
 Check that no conditions exist which will prevent switching the INV
ON (e.g. PC command).
 Verify that condition leading to an emergency stop has not
happened, in which case a Reset must be carried out.
If this green led is OFF, then it signifies that the load has been
transferred to the Static bypass supply. If this is an automatic change
5 ON
over it will be accompanied by a fault warning on the display panel.
Take the appropriate actions for the display indication
This led is mutually exclusive to LED(5). If this amber led is ON, the load
has been transferred to the Bypass mains supply. Verify the cause by
6 OFF
following the alarm indications at the LCD display panel. If the above
checks prove unsatisfactory then seek qualified assistance.
This red led will flash ON and OFF and indicates that the UPS has
detected fault, it will be accompanied by a message on the display
panel, take the required actions for the display panel message This
13 OFF
will be accompanied by an audible warning. Pressing the Alarm
silence switch (14) stops the audible alarm, but leaves the warning
If this yellow led is ON it signifies that the battery voltage is low and
16 OFF that the end of battery discharge is near. This will be accompanied
by audible warning.
This is a bargraph indicating the battery charge state and would

17 N/A
normally have four or five of the leds ON.
Page | 80
When the unit runs on battery, this bargraph changes to give an
indication of the time remaining on the battery.
This is a bargraph indicating the % of the total load that is being

18 N/A
applied to the system.
If this yellow led is ON it signifies that the applied load has exceeded
the maximum. It will be accompanied by all five load bargraph leds
19 OFF being ON (item 18), the Alarm warning indication flashing RED (item
13) and an OVERLOAD messages on the visual display. This will be
accompanied by an audible warning. Reduce the load immediately.
 Inform the concerned officers about the stopping activity.

 Before stopping or switching OFF a UPS unit, ensure that the entire load is transferred
to the other unit or to the Bypass system.
PROCEDURE FOR SWITCHING THE UPS INTO A MAINTENANCE BYPASS CONDITION
FROM NORMAL OPERATION
The first part of this procedure details how to select the Inverter OFF and power the
load from the bypass mains via the Static Switch. This procedure should be followed
to transfer the load from the UPS inverter output to the maintenance bypass system.
This may be required during UPS maintenance procedures.
Follow the procedure below to transfer the load from the output to the
Maintenance Bypass of UPS.
Press ENTER for 1 second to confirm INV OFF
Press ESC for 1 second.
Bypass indicator (6) will flash amber, and also the red led (13) will flash and normally
will be accompanied by an audible alarm.
 Pressing the Alarm Silence Switch cancels the audible alarm but leaves the warning
 The UPS inverter will not shut down and the load will transfer to the Bypass supply.
Page | 81
The Module Mimic indicator Load on Bypass (6) will flash amber and the Load on
Inverter (5) indicator will extinguish.
 Your load is now powered via the Static Bypass system.
 Unfasten the lock; release the internal safety bar and close the maintenance
bypass power switch Q3. Open the Rectifier input power switch Q1, the Output
power switch Q4, the bypass power switch Q2 and the Battery circuit breaker. This is
located inside the battery cabinet (if used) or is otherwise located adjacent to the
battery racks. The unit will power down but the load will continue to be supplied by
the manual bypass.
 WARNING
 Wait 5 minutes for the internal D.C. busbar capacitors to discharge.
 WARNING
 The following points will be live within the UPS:
 Bypass a.c. input supply terminals.

 Maintenance Bypass power switch.
 Static Bypass power switch.
 UPS output terminals.
 Input and Output terminals remain protected by a metallic cover.

 Your load is now powered from the maintenance bypass system and the UPS is
completely shutdown.
This procedure should be followed to completely power down the UPS and LOAD.
All power switches, isolators and circuit breakers will be opened and there will be no
load power.
 The following procedure will switch off all power to the load equipment.
 Open the Battery circuit breaker and the Rectifier input power switch Q1.
Bypass indicator (6) will flash amber. The Battery not available indicator (3) will light
amber and the battery bargraph LED’s will all extinguish.
 The display window will show messages reflecting the actions taken (i.e. Load on
Bypass; Battery Breaker open; Rect. Switch open; etc).
 Open the Output power switch Q4 and the bypass power switch Q2.
All operator LED indications and messages will extinguish as the mains driven internal
power supplies decay.
 To completely isolate the UPS from the a.c. supplies, the main external power input
isolator (both isolators, where separate supplies are provided for rectifier and
Page | 82
bypass) should be opened.
 On the primary input distribution panel, which is often located distant from the UPS
area, a label should be posted advising service personnel that the UPS circuit is
under maintenance.
 Wait 5 minutes for the internal D.C. busbar capacitors to discharge.
 The UPS is now completely powered down.
IMPORTANT
 The Maintenance Bypass Power switch may be operated at any time when the UPS
is powered down to connect the load to the maintenance bypass supply if
required.
 The load equipment is not protected from normal supply aberrations when
operating in the maintenance bypass mode.
Procedure to completely switch OFF the UPS at the UPS Display Control Panel
 From the Default window, press the ENTER key: the
 Main Menu window will display:
Select FUNCTION and press ENTER key:
Before being allowed into the FUNCTION windows you are requested to enter a
password. This is achieved by pressing the UP arrow key repeatedly until the first digit
displays the character required, you then press the DOWN arrow key once to move
on to the second digit. This action is repeated for all eight digits. When the
PASSWORD has been completed press the ENTER key.
 This operation gives the operator access to modify UPS's operating mode, it is
advised that only trained qualified personnel should attempt to do that.
 You have now access to all function windows.
Press the DOWN arrow key until the cursors have selected
NEXT PAGE – press the enter key.
Press the DOWN arrow key until the cursors have selected ON/OFF UPS CONTROL.
Press the enter key.
The following window allows the operator to select the UPS inverter OFF, select the
rectifier OFF, select the rectifier to manual or float voltage and a switch OFF the line
(bypass) voltage to the load.
 Ensure INVERTER is selected by the cursors and press the ENTER key.
 The ON selection will be highlighted, using the UP arrow key, rotate between the
selections offered (in this case it will be ON or OFF) select OFF. Press the ENTER key to
execute your order.
 After approximately 20 seconds, the Module Mimic will change so that the Load on
Page | 83
Inverter (5) will light steady green and the Load on Bypass (6) will extinguish.
 Return the Display window to normal by repeatedly pressing ESCAPE key back
The UPS is operating normally with its Inverter supplying the load.
Procedure to switch OFF the inverter at UPS display control panel
 Press ENTER for 1 second to confirm INV OFF
Press ESCAPE for 1 second to exit.
The Module Mimic indicator Load on Inverter (5) will extinguish and the load on
bypass indicator (6) will flash amber, and also the red led (13) will light and normally
will be accompanied by audible alarm. Pressing the Alarm Silence Switch cancels
the audible alarm. Pressing the Alarm Silence Switch cancels the audible, but leaves
the warning message displayed until the appropriate condition is rectified.
 Press the INV switch on the operator control panel to start up the INVERTER.
NORMAL OPERATION
 After 20 second the Module Mimic LEDS will change so that the local or the inverter
(5) will light steady green and the load on bypass (6) will extinguish.
 Return to the normal window.
EMERGENCY STOP – It is housed beneath a safety cover to prevent inadvertent
operation. When the emergency stop switch is pressed it disables the static switch
block entirely (so removing load power). It also disables the rectifier and inverter,
and trips the battery circuit breaker. Under normal circumstances it does not
remove UPS input power since this applied through a manually controlled external
isolator; however, if the UPS input supply is connected via a circuit breaker having
an electrical trip facility, another section of emergency power off can be used to
drive the external circuit breaker’s trip.
 Mains Failure
If the Mains power fails or is out of tolerance, the rectifier will go off automatically,
while the Inverter will continue to operate on power from the battery for a period of
time which depends on the load and the capacity of the battery. If the mains
supply has not returned within this time, the Inverter will go off automatically and an
alarm message will appear on the UPS operator control panel display. Critical load
Page | 84
will not be interrupted in the event of a drop or return of the AC power mains.
 Return of power mains
When the mains return within the required tolerance, the Rectifier will start up again
automatically and gradually (power walk in), supplying power to the Inverter and
recharging the battery at the same time. There will be no interruption of the critical
load.
 Off-Battery
If the battery system only is taken out of service for maintenance, it is disconnected
from the rectifier/ charger and inverters by means of (an) external disconnect
breaker(s). The UPS shall continue to function and meet all of the specified steady-
state performance criteria, except for the power outage back-up time capability.
 UPS Module fault
 In the event of an Inverter fault, the Static Transfer Switch will automatically
transfer the load onto the Bypass Mains with no interruption. In such an event,
request qualified technical assistance.
 In the event of a fault in a unit, the unit's Static Transfer Switch will automatically
exclude the unit from the system. If the system is still capable of providing the
required load, the remaining units will continue to supply the load with no
interruption. When the units still present in the system are no longer capable of
fulfilling power requirements, the load will automatically be transferred onto the
MSS Bypass Mains. The load will be transferred with no interruption if the Inverters
are synchronised with the network; if this is not the case, there will be an
interruption lasting about 20 milliseconds.
 Overload
 In the event of an overload at the Inverter output which lasts longer than the
typical time/ current, the Inverter will shut down and the Static Transfer Switch will
automatically transfer the load onto the MSS Bypass Mains with no interruption. If
the overload falls within the typical time/ current that has been specified, the
load will be returned to the inverters when the power drops to a level which can
be supported by the number of active units in the system.
 In the event of a short circuit in the output, the load will normally be transferred
onto the MSS Bypass Mains, which will cause the Inverter to shut down; this switch
is determined above all by the features of the protective devices in use in the
system. In either case, an alarm message will appear on the UPS operator control
panel display.
 The control logic system constantly monitors load requirements and controls the
Page | 85
power supplied by the UPS modules. In the event that an overload condition is
sustained for greater than a preset time, the load will transfer to the mains bypass
supply, when the number of active modules is unable to satisfy load
requirements. The load returns to the inverter supply if the power is reduced it a
value that can be sustained by the number of active modules in the system.
 Maintenance Bypass
A second bypass circuit contained in the UPS cabinet, identified as the
'Maintenance Bypass' line is included to enable a 'raw' mains supply to be made
available to the load while facilitating a safe working environment for carrying out
scheduled UPS system maintenance or troubleshooting. The circuit is manually
selected by the Maintenance Bypass Isolator which can be padlocked in the OFF
position.
WARNING
The internal maintenance bypass must not be used when the UPS system is
comprised of more than two UPS modules in parallel.
CAUTION
If an automatic circuit breaker device is not present in the input distribution panel,
there remains a dangerously high voltage at the output bus-bars of the UPS module
that is switched off.
 The annunciation / alarm system comprises of the following
Sl.No. Display Message / Interpretation
Alarm
Over temperature is sensed by a
normally- closed thermostat (90 deg C
operating) fitted to each inverter heat
1 INV. OVERTEMPER. sink. If an over temperature condition
arises, the audible alarm will accompany
this message; the inverter stops and load
transfers to Bypass after 3 minutes.
This message informs the operator that
the inverter has been switched OFF and
OVERTEMP.
2 that the load has been transferred to
SHUTDOWN
Bypass due to an Inverter over
temperature.
The inverter overload has an inverse
3 OVERLOAD PRESENT
load/time characteristic – i.e. it will accept
Page | 86
125% overload for 10 minutes and 150%
overload for 60 seconds. If this
characteristic is exceeded the load
transfers to the bypass supply, the inverter
stops and the overload alarm
annunciates. The [OVERLOAD PRESENT]
alarm will annunciate as soon as the load
exceeds 100% of the UPS rating, and the
load will transfer to Bypass some time later,
depending on the degree of overload
present.
This message informs the operator that the
OVERLOAD
4 load has been transferred to bypass due
SHUTDOWN
to an inverter overload.
Battery discharge has continued beyond
a preset value. The inverter will shut down;
the system will attempt a transfer to
5 BATTERY :E.O.D.
bypass. If bypass is not available, any load
connected to the UPS will be without
power.
The RECT. OFF alarm is active whenever
the battery charger (rectifier) is not
producing its correct output voltage. This
can be caused by an operator selection
6 RECT. OFF
to OFF, an Input supply failure, an open
rectifier a.c. input power switch or an
internal fault which may be accompanied
by one of the fault conditions.
The UPS is interfaced with Substation Automation System and the following
parameters
 Bypass failure
 Maintenance Bypass open
 Low battery
 Load on Bypass
 Load on Inverter
Page | 87
 Load on Maintenance Bypass
 Low battery pre-alarm

 Electrical work permits to be issued.
 For the UPS unit being handed over to maintenance, ensure that the connected
load is entirely transferred to the other unit.
 Isolate the UPS from electrical supply.
 Isolate the UPS from Battery bank.
 Maintain proper logbook about the handing over of the UPS system.

 Inspect the entire assembly for any physical damage.
11.0) DO'S / DON'TS
DO’S
 Ensure that the location of the UPS is clean, where the unit will not be exposed to
dust or foreign bodies.
 Ensure that no items are left on top of the UPS that may cause a problem (e.g. tools,
drinks, etc).
 Only use tools with insulated handles to work in battery bank.
 Wear rubber gloves and a rubber apron when handling batteries.
 Incorrect wiring may lead to damage of battery and charger. Be sure that the
wiring is as per the drawings before charging.
 Always disconnect negative terminal first and positive terminal last for battery
connections.
 Always keep the panel doors fully closed.
 Keep close supervision in the UPS operation.
Page | 88
DON’Ts
 Do not obstruct ventilation holes on the UPS. These holes dissipate the heat
generated during the operation. Obstruction of these holes will affect the overall life
span of the battery.
 Do not leave items that may pose a tripping hazard on the access route to the UPS.
 Do not touch any live battery terminals.
 Do not touch electrolyte with bare hands.
 Do not use CRC to clean battery links when the battery bank is ON.
 Do not take metallic structures like Aluminium ladder inside the battery room.
 Do not place any equipment within 1M from Battery bank or directly above it, in
which hot surfaces of sparks may occur.
 Do not store any goods inside the battery room.
Page | 89
CHAPTER 12-BATTERY CHARGER SYSTEM
This chapter describes the Standard Operating Procedure for battery charger system
1.0) INTRODUCTION
Battery Charger Unit with battery Bank is located in the Substation for uninterrupted DC
power supply to all Numerical protection relays and for critical DC lighting inside
buildings. The Battery Charger system has a DC Distribution Board through which the DC
supply is distributed.
Crude location has one 110V and one 220V Battery charger set and the connected
load are as under:-
110V DCDB:
 Uninterrupted 110V DC supply to all the Numerical Relays and Control circuits in
HT & LT switchgears and AMF panel.
220V DCDB:
i) Critical DC lighting inside Substation SS 335AS.
ii) Critical DC lighting inside Control Room SRR 806.
Finished products location has one 110V and one 220V Battery charger set and the
connected load are as under:-
110V DCDB:
i) Uninterrupted 110V DC supply to all the Numerical Relays and Control circuits in
HT & LT switchgears and AMF panel.
220V DCDB:
ii) Critical DC lighting inside Substation SS 312N.
iii) Critical DC lighting inside Control Room SRR 819.
iv) Critical DC lighting inside Control Room OMS 801.
2.0) DATA SHEET
110V BATTERY CHARGER (PRODUCTS AREA)
1 Make Mass-tech Controls
312N-205-BCH-701
2 Equipment Tag No.
3 Rating 415AH
Page | 90
4 Output Voltage 110V DC
5 Mains Input Voltage 415V ±10%
6 Frequency 50Hz ±5%
7 Float mode DC output Voltage 120 Volts
8 Float mode DC output current 150A
9 Boost mode DC output Voltage 134 Volts
10 Boost mode DC output current 83 A
11 Ambient Temperature 50 degC
BATTERY DETAILS
12 Type of battery Ni-Cd
13 Voltage of each cell 1.2 Volts
14 No. of cells 86 nos
110V BATTERY CHARGER (CRUDE AREA)
335AS-205-BCH-701
2 Equipment Tag No.
3 Rating 166AH
Page | 91
BATTERY DETAILS
220V BATTERY CHARGERS (PRODUCTS AREA)
312N-205-BCH-702
2 Equipment Tag No.
3 Rating 41AH
BATTERY DETAILS
Page | 92
220V BATTERY CHARGERS (CRUDE AREA)
335AS-205-BCH-702
2 Equipment Tag No.
3 Rating 26 AH
11 Ambient Temperature 50 deg C
BATTERY DETAILS
3.0) OPERATINGCONDITIONS
Location
 The Panels should be placed in a dust free environment in a positive pressure
system.
Ventilation
 Install the Charger at Indoor place suitably ventilated.
Page | 93
 Ensure that all of the Panel ventilation grills are left clear and free from obstructions.
 Ensure that the space heater and thermostat are as per the environmental
conditions.
 The forced ventilation is provided by internal intake fans.
Access
 Always ensure that the Battery Charger and Battery Bankare easily accessible (front
and rear).
 Sufficient clearance must be available to open doors and to carry out any
maintenance activities both sides and rear.
 Always provide adequate space around the cable connections points of the
Battery Charger and DCDB.
 Always provide adequate space around any switches or buttons that may need to
be accessed in the event of an emergency.
 Always ensure that the visual display panel of the Battery Charger and DCDB is
easily accessible.
illumination is 150 – 200 lux.
Battery Bank
 Ensure that the ambient temperature is 50 deg C max.
 The light fittings in the Battery room should be flame proof.
 The battery room is provided with acid resistant tile floor and painted with acid
resistant paint up to 1M height in walls.
 Emergency eye wash hand wash provision should be available.
 Ensure that adequate ventilation using exhaust fan is provided for battery gassing.
illumination is 150 lux in Battery room.
4.0) PRE-START UP ACTIVITY
For Battery Charger unit the following activities to be carried out:

 All the annunciation systems should be checked and reset.
 All the outgoing MCBs should be kept in OFF position.
 Ensure that the Battery Charger is selected to operate in AUTO mode.
When the panel is energized for the first time or after a shutdown job the following
activities are to be carried out
 Panel earthing connections tightness must be checked.
 All the cable terminations are done as per schedule.
Page | 94
 Ensure the correctness and tightness of all wiring.
 IR test for all the cables and the charger circuit.
 Clean the cubicles and bus bars with vacuum cleaner.
For Battery Bank the following activities to be carried out:
 Ensure that battery cells are filled with electrolyte.
 Ensure correct polarity of the cells.
 Check the condition of vent plug for any blockage.
 Cleaning of battery bank to be done to remove any dust.
 Corrosion problems (especially to terminals), if any.
 Connect battery cables with proper polarity to charger terminal board TB2.
When the Battery Bank is energized after a shutdown job the following activities are
to be carried out
 Condition of acid proof flooring.
 Working condition of the following :-
 Sprinkler system
 Smoke detectors
 Exhaust fan
 Check whether the emergency eye wash hand wash provision available or
not.
 Ensure that the Cells have not developed any crack/damage/leak.
 Availability of thermometer, hydrometer and cell tester.
5.0) START UP PROCUDURES
The procedure given below is for Battery Charger Unit “A”. The same procedure can
be used for Battery Charge unit “B”
Auto mode
 Switch ON the selector switch SW5A for DC output.
 Select position of SW4A for operating the Charger unit in Auto Mode.
 Always keep SW4A Auto mode and use Manual mode only when Auto mode is not
functioning.
 The AC mains supply switch SW2A is to be switched on.
 Then check the AC input voltage by the AC Voltmeter selector switch SW1A in
Voltmeter VM1A. Check all the three phases.
 Check the DC output voltage VM2A – 110V or 220V.
 Press push button PB1A for float charging mode.
 Press the selector switch SW3A for float charging of Battery bank.
Page | 95
 Check the ammeter AM1A for the Battery Bank charging current reading.
 Switch ON the MCCB 1A in DCDB.
 Switch on the respective MCBs for connected loads.
 Ensure that the indication lamp against the respective load is glowing.
Manual mode
 Before switching ON any charger in manual mode ensure minimum position of
potentiometer RV3A for charger A.
 Switch ON the selector switch SW5A for DC output.
 Select position of SW4A for operating the Charger unit in Auto Mode.
 The AC mains supply switch SW2A is to be switched on.
 Then check the AC input voltage by the Ammeter selector switch SW1A in
Voltmeter VM1A. Check all the three phases.
 Check the DC output voltage in VM2A – 110V or 220V.
 Press push button PB1A for float charging mode.
 The procedure given is for Charger A. The same procedure may be adopted for
Charger B.
For Cell Booster
 Connect the Battery cable with proper polarity to terminal TB2 of Cell Booster.
 Switch ON SW1, MCCB1 and adjust charging current by REG1 as per requirement.
 Process of Battery charging will start.
 Charging voltage & current can be seen on VM2 & AM1 respectively.
6.0) OPERATIONAL MONITORING
The following parameters are to be monitored during the operation of the Battery
charger system
 AC Input Voltage – The input voltage should be 415V +/- 10%.
 DC Charging Voltage –
 For 110V system – Float Mode

The output voltage of the charger is maintained at 120V +/- 1% (1.4 V/cell). The
output voltage should remain stabilize within ±1% for AC input variation of 415V
±10%, also for load variation from 0-100%.
 For 110V system – Boost Mode
The charge voltage in Boost mode should be set at 134V (1.55 V/cell).
The output voltage of the charger is maintained at 241V +/- 1% (1.4 V/cell). The
output voltage should remain stabilize within ±1% for AC input variation of 415V
Page | 96
±10%, also for load variation from 0-100%.
The charge voltage in Boost mode should be set at 267V (1.55 V/cell).
 DC Charging Current
The charger is capable to supply continuous load of 60A while trickle charging
current to the battery. It is to be ensured that the current is within the limit.
The charger is capable to supply continuous current of 33A for Boost charging the
battery. It is to be ensured that the current is within the limit.
The charger is capable to supply continuous load of 20A while trickle charging
current to the battery. It is to be ensured that the current is within the limit.
The charger is capable to supply continuous current of 8A for Boost charging the
battery. It is to be ensured that the current is within the limit.
 Mode of charger – To monitor whether the charger unit is in Float or Boost mode.
 Abnormal rise in temperature of the unit.
 Abnormal noise or vibration in the unit.
The following parameters are to be monitored during the operation of the Battery
room
 Formation and accumulation of any gas inside the room.
 Overheating of any cell in the Battery bank.
 Temperature and specific gravity of the electrolyte, in case of any abnormalities.
 Functioning of ventilation system.
 Spillage of any electrolyte.
Battery Charger Unit

 While taking Charger unit “A” out from service, ensure that Charger “B” is in ON.
 First switch OFF its AC input SW2A and then switch OFF DC output SW5A.
Battery Bank
 The Battery cut off switch in the Battery switch box in the Battery room should be
Page | 97
operated.
For Cell Booster
 After completion of charging bring REG1 to its minimum position and switch OFF
SW1 and MCCB.
 Disconnect the Battery cell from the Cell Booster.
8.0) AUTOMATION / INTERLOCKING / PROTECTION
PROTECTION:
 AC input voltage surges: Surge suppresser
 Diode/SCR against voltage surge: RC Surge suppresser
 Control circuit: HRC Fuse
 Output short circuit: SCR controller, MCCB
 Battery Current Limiting Circuit: CLC Battery current limit protection is also provided
in this charger. During Float charging, if battery draws more current than the set
value, output voltage of both the Chargers will decrease and thus limit the Battery
current. During Boost charging this protection will get bypassed.
INTERLOCK:
 Normally both the chargers will be ON in Float mode and supply station load as well
as trickle charging current to the battery. At this time both the chargers & battery
are in parallel across the load. Hence, if one charger fails other charger will feed
total load of the system without any interruption.
 When AC Input supply of both the charger fails, battery bank will feed DC load of
the system through DC contactors C2A & C2B and get discharged.
 After resumption of AC supply of both the chargers, they will switch ON in Float
mode automatically and starts feeding Load as well as charging current to the
Battery. The scheme is so designed that at a time only one charger can be select
for Boost charging.
 If battery requires Boost charging, shift any one charger to Boost mode manually by
pressing push button (PB1A/PB1B and PB2A/2B). Also, charger A will shift in Boost
mode only if Charger B is healthy and switch ON in Float mode. During Boost
charging DC Contactor C2A will get energize and the system load gets isolated
from charger A. Thus Charger B will feed the system load and Charger A will charge
the battery. After set time of Timer T1A, Charger A will shift to Float mode
automatically.
 If during Boost charging if Charger B fails, Charger A will shift to float mode
automatically. Thus DC Contactor C2A will drop out automatically and charger A
Page | 98
gets connected with the system load and takes the system load.
 If power fails during Boost charging, DC contactor (C2A/C2B) will get de-energized
automatically and full Battery voltage will appear across the load. The continuity of
DC supply to the DC bus is maintained even for a short period of 150 to 300
milliseconds (contactor closing time) through a silicon diode i.e. tap diode MR3
connected to appropriate tap cell - 70th cell of the battery bank in case of 110V
Charger and 139th cell in case of 220V Charger.
 Charger A & Charger B will trip due to DC output over voltage. If DC output voltage
of any charger exceeds the set value, respective charger will trip. Press push-button
PB3A/PB3B (CH. Reset) to restart the charger.
ANNUNCIATION:
 CHARGER AC MAINS FAIL – In case of failure of Mains incomer power supply.
 CHARGER AC I/P FUSE BLOWN – In case the fuse Mains AC input fuse FS 4A/5A/6A
fails.
 CHARGER RECTIFIER FUSE BLOWN - In case the Rectifier output fuse FS8 10A/B fails.
 CHARGER CONDENSOR FUSE BLOWN – In case the Charger condensers fuse FS 11A
fails.
 CHARGER DC O/P VOLTAGE FAIL – In case the Charger DC output fails.
 CHARGER DC O/P FUSE BLOWN - In case the Charger DC output fuse FS 12A/13A
fails.
 BATTERY FUSE BLOWN – In case the Battery protection fuse FS 16 to 18 is blown.
 DC U/V – In case the output voltage is less than a preset reference voltage.
 For 110V system: Actuating Voltage – 99V.
Resetting Voltage – 110V
 DC O/V - In case the output voltage is more than a preset reference voltage.
 BATTERY E/F – For both 110V and 220V system the earth fault current range is 1-7mA.
INDICATION:
 AC Input ON for Charger.
 FLOAT mode ON for Charger.
 BOOST mode ON for Charger.
Page | 99
 DCDB - 1 & 2 ON.
METERING:
 AC Input Voltmeter Charger.
 DC output Voltmeter & Ammeter for Charger.
 Battery Charge/Discharge Ammeter.
SAS INTERFACE –
The Battery Charge system is interfaced with Substation Automation System. The
following faults are indicated in SAS
 DC Supply Charger failure – “A” failure

 DC Supply Charger failure – “B” failure
 Charger trouble
 Earth Fault
 Battery discharged

 Shut down and isolate the Battery Charger unit from electrical supply.
 While taking one Charger out of service, ensure that the other Charger is ON and
that the connected load is transferred to the other Charger.

 Inspect the entire assembly for any physical damages.
11.0) DO’S AND DON’TS
DO’s
 Ensure proper phase sequence before connecting AC input supply to Charger
terminal board TB1A and TB1B.
Page | 100
 Always use HRC fuses of proper rating.
 Boost mode should be used only for Boost charging the battery.
 Keep inside of the charger clean. Use vacuum cleaner twice in a week.
 Keep close supervision in Manual mode for regulation.
 Ensure that sufficient clearance is maintained around battery bank for ease of
maintenance.
 Always use PPE like acid resistant gloves, goggles while working on Battery bank.
 Always keep the panel doors fully closed.
 Cable connections are made with recommended lugs.
 Always use non-sparking tools for battery bank connections.
 Use petroleum jelly in battery terminal links to protect from corrosion.
 Always deploy trained person aware of the hazards to work in Battery bank.
 Ensure that no foreign particles are kept inside the panels before box up.
 Always disconnect negative terminal first and positive terminal last.
DON’Ts
 Do not operate the Charger unit in Manual mode, unless the Auto mode is not
working.
 Do not touch any live battery terminals.
 Do not touch electrolyte with bare hands.
 Do not use CRC to clean battery links when the battery bank is ON.
 Do not take metallic structures like Aluminium ladder inside the battery room.
 Do not place any equipment within 1M from Battery bank or directly above it, in
which hot surfaces of sparks may occur.
 Do not store any goods inside the battery room.
Page | 101
CHAPTER 13-HIGH MAST
This chapter describes the Standard Operating Procedure for high mast lighting.
1.0) INTRODUCTION
 High masts are for the illumination purposes in Tank Farm and adjacent areas. The
high Mast is 30m high and has 08 light fittings in each Mast. Each high mast has 60 m
dia. Illumination coverage area.
 There are two different locations for Crude and finished products storage facility at
Paradip. In Product location 28 nos of High Masts are there and in Crude location 21
nos are there.
2.0) DATA SHEET
Bajaj Electricals Ltd.

1 Make
205 - LTM – 401 to 428

2 Tag No.
Tank Farm lighting

3 Service
30 mts
4 Height of Mast
415V ± 6% Volts
5 Input supply Voltage
3
6 Phase
50 Hz ±3%
7 Frequency
Power 4800 Watts

8
BGENF 22R 2x400W SV( +)

9 Type of fitting / fixture
750 kilos including carriage and 12

10 Load carrying capacity of carriage
luminaries
11 Capacity of winch motor 1.5 HP
Page | 102
12 Speed of winch motor 895 RPM
13 Type of lubricant SAE 90 / SAE 140
14 Type of aviation fixture BLAOL-1
15 Max. Wind speed 65m/sec
 The structure is hot dip galvanized & robust .It can withstand all climatic conditions,
but in case ,if any pre-warning of cyclone is available, it is recommended to lower
the overhead lantern carriage to the base position to minimize the windage area at
the top and prevent any possible mishap , if wind speed exceeds more than the
specified speed.
 The opening or the door at the bottom should be closed.

 No loose or un-identifiable wire should be there.
 Check the main breaker status (ON/OFF) at feeder panel in substation.
 Ensure that there is no abnormal wavering of the lantern carriage.
 Check the healthiness of control fuses.
 Check the winch motor gear box and check the lubricate oil level.
When the High Mast is energized after a shutdown job the following activities are to
be carried out
 Check for the availability of double Earthing.
 Check the armour wire earth continuity.
 Set the electronic timer setting.
 Check the internal steel rope wire condition and tightness.
 Check for the proper functioning and for proper anchoring of the winch motor.
 Switch ON the space heaters in the Feeder pillar during rainy season.
 Check the direction of winch motor.
The High Mast has to be either started on Auto mode or Manual mode.
Page | 103
Auto mode
 An electronic timer is provided in the High mast in the feeder pillar. The High mast
will operate as per the setting of electronic timer. The timer gives a signal to the
contactor through a switch and the contactor will pick up and the luminaries will
glow.
Manual mode
 In manual mode, the electronic timer setting is disabled and the High Mast can be
Turn ON directly by the respective M.C.Bs (Miniature Circuit Breakers) in the High
Mast feeder pillar.
 Monitor the load Current in each phase. It can be monitored at Feeder pillar.
 Monitor the supply voltage across all the phases.
 Ensure that all Luminaries are lit.
 Check for any abnormalities in the assembly of Luminary carriage.
 Working of both the aviation obstruction lights.
 Check for any abnormal heat in the feeder pillar.
 Ensure that there is no abnormal wavering of the lantern carriage.
contactor through a switch and the contactor will pick up and the luminaries will be
OFF.
Manual mode
 In manual mode, the electronic timer setting is disabled and the High Mast can be
Turned OFF directly by the respective M.C.Bs (Miniature Circuit Breakers) in the High
Mast feeder pillar.
8.0) AUTOMATION/INTERLOCKING/PROTECTION
contactor through a switch and the contactor will pick up and the luminaries will be
ON/OFF.
 MCBs, fuses and Over load Relays are provided for protection in case of over-
current and short-circuit.
 A lightning finial 1.2 m long is provided with double earthing on the top of the High
Page | 104
Mast to protect against lightning strike.

 Isolate the High Mast JB from electrical supply.

11.0) DO'S / DON'TS
DO's
 If any pre-warning of cyclone is available, it is recommended to lower the overhead
lantern carriage to the base position to minimize the windage area at the top and
prevent any possible mishap.
 Proper earthing connections should be ensured.
 The operation of the High-mast is to be clone by only trained technicians under the
supervision of a qualified Engineer/Supervisor.
 Rest the lantern carriage on the rest pads before starting the maintenance of
luminaries.
 Always use only recommended grade of lube oil (SAE20) for winch motor.
DON'Ts
 Do not raise or lower the Lantern Carriage if the Wind speed is more than 15 Km/h.
 No loose connections of luminaries or wires should be there.
 Only skilled and trained workmen should be allowed to climb the High Mast with
proper safety harness.
 Do not operate the Winch motor without sufficient quantity of gear oil in the sump.
Page | 105
CHAPTER 14-SELF REGULATING HEAT TRACING
This chapter describes the Standard Operating Procedure for electrical heat tracing
in self-regulating methods.
1.0) INTRODUCTION:
Electric heat tracing cables are used to maintain temperature of cargo in pipelines.
In Crude area Heat Tracing principle is used to maintain the temperature of High
viscous Crude in the pipeline to ensure that it is in liquid state. The principle of
Electrical Heat Tracing used is “Self Regulating Heat Tracing”.
The lines for which Electrical heat Tracing have been provided are as under:
 All tank outlet lines - 36 inches dia. size
 All Thermal expansion lines – 2 inch dia. size
 All tank ITT outlet lines and Header line – 32 inch dia. size
 Crude charge pump inlet / outlet lines
2.0) DATA SHEET
Thermon Engg.
1 Make
HTSX
3 Type
4 Model HTSX-20-2-OJ & HTSX-15-2-OJ
16awg Bus Wire, NPC (nickel plated

5 Bus Wire
copper)
Fluor polymer based, semi conductive
6 Primary Insulation
matrix
7 Metallic Braid Tinned Copper
8 Over jacket Fluoropolymer
9 Over all dimension (mm) 11.2 x 5.2 width x thk
10 Operating voltage 240Vac
Page | 106
E4X/7-35235 (flame proof/weather
13 Thermostats type
proof
 Operating Voltage is 240 Volts.

 There must be no abnormal fluctuation in the input power.
 The outer cladding must not be subjected to any mechanical stress.
4.0) PRE STARTUP ACTIVITIES:
 Before starting electrical heat tracing systems mean time clearance taken from
maintenance team.
 Visually inspect pipe line hot insulation.
 Check the power supply availability at field panel.
 Check the volt meter readings (all three phase).
 Check the all sub-feeders in OFF condition before start-up.
 Check that all the protection relays in the substation are in order and enabled.
When the Heat tracing system is energized after a shutdown job the following
additional activities are to be carried out
 Check the thermostat temperature setting 40 °C.
 Earthing connection tightness for Panels, JBs and end termination JBs.
 Ensure that all cable connections and electrical wiring connections should be
sealed against moisture.
 Ensure that all the tracer cables are insulated properly.
 Ensure that water ingress cladding on the outer barrier is not damaged.
 Check that the fuses are of proper rating as per the design.
 Check for any pitting of the contacts inside the panels.
5.0) START UP ACTIVITIES:
After completion of all the pre start-up activities,, the following activities following to
be done:
 Switch ON the main feeder from Substation.
 Switch ON the main incomer line for field panel.
 Check the indication light (RYB) are glowing.
 Switch on (65 Amps feeder) one by one for safe manner.
Page | 107
 Check the starting current (initial time).
 Check the running current (after starting heat tracing system 15 minutes).
 Check for any abnormal rise in temperature in Bus-bar in field panels.
 Observe for any smoke emitting from any section of the pipeline.
 After starting heat tracing system. At mean time visually inspection all the panels
and tracer line.
 Visual checks for functioning of all panel indication lamps (indicating tracer circuit
healthily condition).
 Check for the Current reading of each circuit and ensure that the reading is normal.
 Check for the voltage drop at the farthest end of tracer.
 Check for any annunciation.
 Inform the concerned officers about stopping of the system.

 Switch off the sub feeder one by one. Do not switch off main incomer line first.
8.0) INTER LOCKING:
 Thermostat cut in / out for set temperature - The thermostat sensor is set for a
temperature of 40 deg C. If the temperature goes below 40 deg C, then the
thermostat gives a signal to the contactor to switch ON the Electrical heat Tracing
circuit. If the temperature goes above 40 deg C, then the thermostat gives a signal
to the contactor to switch OFF the Electrical heat tracing circuit.
 Overload relay for over current protection – Each circuit is designed for a particular
load and a relay is incorporated in the circuit. A particular current is set in the relay
and when the load current goes beyond the set value, the relay trips and isolates
the power supply.
 Earth fault protection – Earth fault protection relay is provided in the Panel in the
Sub-station to protect the system from any earth fault.

 Isolate the system from electrical supply.
Page | 108
 Inspect the entire assembly for any damages or breakages.
11.0) DO’S AND DON’T:
DO’s
 Before starting the heat tracing must be visually inspect the all lines and its
corresponding panel
 Junction box and power splice connector inspect any loose connection and any
water ingress present or not.
 Properly calibrate required temperature
 Check the voltage range. Minimum 216 Volt required.
DON’Ts
 Do not walk over the electrically heat tracing lines.
 Do not open hot insulation during rain.
 Do not by-pass the thermostats.
 Don’t set values more than 40°C temperature.
 Do not make any at-site modification in the Weather proof JBs.
Page | 109
CHAPTER 15-SKIN EFFECT HEAT TRACING
This chapter describes the Standard Operating Procedure for electrical heat tracing in
skin effect methods.
1.0) INTRODUCTION
Skin effect Heat Tracing system is used in finished products area for Sulphur lines. The
operating principle of a skin effect heating system is based on two phenomena:
proximity effect and skin effect. The heating device is a carbon steel pipe called a
"heat tube" with a specially designed skin effect conductor inside. The heat tube
and insulated conductor are joined together at one end, while at the opposite end
the heat tube and the conductor are connected across an AC voltage source
When the system is energized, current flows through the conductor to the end point,
then is concentrated toward the inner surface of the heat tube by the skin effect
phenomenon and the attendant proximity effect. This electromagnetic interaction
ensures that the return current travels on the inner surface of the heat tube with
virtually no measurable voltage on the outer surface. The current flow through the
impedance of the inner skin of the heat tube generates heat.
2.0) DATA SHEET

Heat Tracing Transformer
Thermon Engg.
1 Make
312N-205-HTTR-01
2 Tag No.
3Ph-2Ph DW Scott
3 Type
Connected Transformer
4 Cooling ONAN
5 Input supply Voltage 415V ± 10% Volts
6 No. of Phase 3
7 Frequency 50 Hz ±3%
8 Output voltage 727 Volts
9 No. of Phase 02
10 Ingress Protection IP 55 min
Page | 110
250kVA
11 Capacity
Maximum ambient
12 50 deg C
temperature
13 Primary Current 348 Amps
14 Secondary Current 172 Amps
TRACING ELEMENTS
15 Insulation type Mineral wool
16 Insulation thickness 65mm
17 Conductor / Tube size 6 AWG – 0.75” tube
18 Conductor type Fluoropolymer
19 Tracer type A 106
Maintenance
20 138 deg C
temperature
21 Thickness of Al cladding 0.12
For Heat Tracing Transformer

Maximum Ambient : 50 deg C
Temperature
Minimum Ambient : 5 deg C
Temperature
: 50 deg C
Design Ambient Temperature
Relative Humidity : 90%

: < 1000 M above sea level
Altitude
Environment : Tropical, dusty and corrosive

System Voltage : 415 Volts
: 50kA for 1 sec (Primary side
Fault level
fault level)
For Skin Effect Heat Tracing System
Page | 111
Ambient Temperature : 11 deg C
Wind Speed : 40km/hr
Weather Barrier : Aluminum (0.12)
 Ensure that the bus wires are not twisted at either end of the heater cable.
 Visually inspect the stretch of the pipeline for any abnormality.
 Visual inspection of system grounding points.
 Visual inspection of thermal insulation system.
When the Heat tracing system is energized after a shutdown job the following
additional activities are to be carried out
 Ensure that all cable connections and electrical wiring connections should be
sealed against moisture.
 The metal sheath of the heater cable must be connected to a suitable ground
path.
 Conductor insulation test to done and resistance not less than 50 M-ohms.
 Visual inspection of RTD temperature sensor location.
 Visual inspection of field Junction boxes is properly wired and all terminals are tight.
 Visual inspection of Control / Power Panel is properly wired and all terminals are
tight.
 Visual inspection of Transformer properly wired and all terminals are tight.
 Check the thermostat range setting.
 Check whether the JB are earthed.
 Get the clearance from the Operations department for commissioning of Heat
Tracing system.
 Energize the Heat Tracing Transformer.
 Then energize the Heat Tracing Panel in the Substation.
 Finally, energize the field Heat Tracing Junction Box.
 Observe the voltage and current readings.
 Visually inspect the stretch of the pipeline for any abnormality.
 Visual checks for functioning of all panel indication lamps (indicating tracer circuit
healthily condition).
 Temperature measurements at inspection points.
Page | 112
 Ensure that the heater cables are not exposed to temperature above their
maximum ratings.
 Current reading of each circuit and check for any blown out fuse.
 Check for tripping of any Over-load Relay.
 Check for any abnormality in the insulation like physical damage, any smoke etc.
7.0) STOPPING ACTIVITY / SHUTDOWN:
 First inform the concerned department about the de-commissioning of the Heat
Tracing system.
 Switch off the field distribution boards of the Heat Tracing system, in a sequential
manner.
 Switch off the Heat Tracing Panel in the Substation.
 Finally, de-energize the Heat Tracing Transformer.
 The RTD Temperature Sensor is installed on the process pipe with attachment bands.
 The maintenance temperature of the system is 138 deg C. Once the temperature of
the system reaches 138 deg C, the RTD will sense the temperature and sends a
signal to the contacts. The contact isolates the supply to the respective circuit.
 Once the temperature of the system fall below 138 deg C, the RTD will sense the
temperature and sends a signal to the contacts. The contact will restore the supply
to the respective circuit.
 The transformer in case of overload will trip.

 Isolate the system from electrical supply.

Page | 113
11.0) DO'S / DON'TS
DO’s
 Before energizing the Heat Tracing system, visual inspection of JBs, pipeline
insulation, earthing, tightness of connection to be checked.
 Ensure that the incoming supply voltage is within the acceptable range as per data
sheet.
 Check the set range of RTDs.
DON’Ts
 Do not walk on the insulated pipeline.
 Do not open the Panel or the inspection cover during rainfall.
 Do not open the panel in energized condition.
 Do not remove the insulation in energized condition.
 Do not use non-calibrated RTD for temperature detection.
 Do not operate the Tap changer switch in the Transformer.
Page | 114
CHAPTER 16-HVAC SYSTEM
This chapter describes the Standard Operating Procedure for heating ventilation and air
conditioning
1.0) INTRODUCTION
The HVAC system is used in Satellite Rack Room building to control the temperature
using Air Handling Units in conjunction with Air Cooled Chillers Unit. The inside of
building will be positive pressurized relative to the outside of the building. Auto
Pressure relief dampers are fixed on the buildings to release excessive pressure build
up inside
2.0) DATA SHEET

AIR COOLED CHILLER – 56.0 TR capacities
Page | 115
1 Make BLUE STAR
2 Tag No. ----------
196.9kW/ 56.0
3 Nominal cooling capacity
TR
4 Input Power supply 415V,3phase,50Hz
5 Total current at rated load 128 Amps
6 Power consumption at rated load 69.7 kW
Condensate fan motor nos
7 Quantity 03
8 Input Power supply 415 Volts,3phase,50Hz
9 Speed 910 RPM
10 Power consumption at rated load 1.9kW
AIR COOLED CHILLER – 74.0 TR capacities
Page | 116
1 Make BLUE STAR
2 Tag No. ----------
260.75kW/
3 Nominal cooling capacity
74.0 TR
4 Input Power supply 415V,3phase,50Hz
5 Total current at rated load 170 Amps
6 Power consumption at rated load 91.2 kW
Condensate fan motor
7 Quantity 03
8 Input Power supply 415 Volts,3phase,50Hz
9 Speed 910 RPM
10 Power consumption at rated load 1.9kW
Standard environment and site conditions for the installation of motors are usually set
as follows:
 Ambient temperature: -10~40ºC
 Humidity: Relative humidity below 90%RH for totally enclosed types, and below
80%RHfor semi-enclosed types.
 Harmful gases, liquids, dusts, high moisture should be absent.
 Foundations should be strong and free of vibration.
 Ensure input voltage is within specified range (380 - 420 volts).

 Ensure all valves on the waterlines are in open condition.
 Check water level in expansion tank.
 Be certain all control sensor bulbs are inserted completely in their respective thermo
wells.
 Check that the recommended fuses are in the power circuit disconnect switch and
then close the switch.
 Ensure crankcase heater supply is connected before disconnect switch as shown in
Page | 117
wiring diagram.
Additional checks to be carried out after a shutdown work has been carried out
are as under
 Check the inside of the unit and duct work to make sure that no loose nuts, bolts,
trash, sheet metal parts etc. have been left behind, which may be sucked into fan
and result in permanent damage.
 At the same time, check to make certain that air filters have been placed in the
filter section, with fill pieces in place.
 Recheck the tightness of the mounting hardware, set screws and locking collars on
the bearing, and motor mount adjustment nuts.
 Check the bearing for proper lubrication.
 Be sure all door latches (locks) are secured before starting unit.
 After 24 hours of satisfactory operation, shut down the equipment and check all
foundation bolts, shaft bearing and drive set screws and tighten wherever required.

The start-up procedure for Chillers unit is as under:-
 Start the chilled water pumps.

 Start the Air Handling Unit.
 Set chilled water thermostat to the desired water temperature.
 ‘Switch on’ the chillers from the micro computer panel located on the chillers.
 Check the current drawn by motor with an ammeter. Do not exceed maximum
speed or amperage.
 If an unusual noise is heard on starting, and there is no change in suction pressure
and discharge pressure, the direction of rotation of compressor is wrong. Reverse
the wiring terminals of the compressor and again check for noise, and suction &
discharge pressures. This can be eliminated with the provision of a safety electrical
device on the control panel, which provides the unit reverse polarity protection and
single phase protection.
 When compressor starts, a flow of liquid will be noted in the liquid indicator. After
several minutes of operation, the bubbles disappear and full flow of liquid occurs
when the unit is operating normally.
 Check the operation of the safety control switches and indicating lights on the
Page | 118
control panel to be sure that they function to stop compressor motor in case the
settings are exceeded.
 Check compressor suction superheat after steady operation has been established
and leaving chilled liquid has been pulled down to the required temperature.
 Inform the concerned officer about the stopping activity.

 Before stopping a unit, ensure that the other unit is put in operation.
 Switch off the chillers by pressing ON/OFF switch only.
 Stop chilled water pump.
 Stop air handling equipments.
 The building with installed HVAC system shall be provided with HVAC controls like
Temperature, RH%, room pressure and common fault alarm which shall be
connected with DCS system and shall be interlocked with the fire and gas detection
system.
 The HVAC control is interlocked with the fire and gas detection system. In the event
that a building’s fire protection system detects smoke/fire in any zone, the fire alarm
panel shall be set up to shutoff all hvac equipment and dampers associated with
them.
 Ambient temp and humidity controller is required for operation control.

 Isolate the Motors and Power panels from electrical supply.
10.0) CHECKLIST FOR TAKINGOVER FROM MAINTENANCE

Page | 119
11.0) DO'S / DON'TS
DO’S
 Examine the units for dirt deposit and clean them, periodically.
 If inspection covers are opened or any joint is to be tightened, then, tighten the
bolts evenly, to avoid uneven pressure.
 Check the oil quantity of lubricant (grease or oil).
 The motor and AHU surroundings should be clean with sufficient illumination.
DON’Ts
 Do not re-energize the motor or AHU without conducting all pre-commissioning
checks. The results must be comparable with results at works.
 Do not run the motor with low lube oil.
CHAPTER 17-PRESSURISATION SYSTEM

This chapter describes the Standard Operating Procedure for substation pressurisation
system
Page | 120
1.0) INTRODUCTION
The Pressurisation system is used to maintain a dust free environment inside the
Substation building. The inside of building will be positive pressurised relative to the
outside of the building. Auto dampers are fixed on the buildings to release excessive
pressure build up inside.
Standard environment and site conditions for the installation of motors are usually set
as follows:
(a) Ambient temperature: -10~40ºC
(b) Humidity: Relative humidity below 90%RH for totally enclosed types, and below
80%RHfor semi-enclosed types.
(c) Harmful gases, liquids, dusts, high moisture should be absent.
(d) Foundations should be strong and free of vibration.
 Checkall the entry / exit door in substationare closed.
 Check all the panel doors closed and cable gland plates is fully closed.
 Check that all the excess air relief dampers (3 no’s)are dust free and well lubricated.
 Ensure that pressurization duct is properly fixed and anchored.
 Verify the supply air grill (25 no’s) are open and free from any obstruction.
 Check the main air inlet valve open in suctionairline.
 Check the condition of fine filter and it is not choked.
 Ensure the free rotation of air blower motor.
 Carry out visual inspection for Air handling unit for belt condition, air fan blade
condition.
 Check if the duct entry points are properly sealed to avoid leakage of air.
 Check the availability of three phase supply.
 Check the earthing tightness.
 Check the interlock with fire alarm system.
 Ensure that the air suction line and discharge duct (supply air grill) are open.
 Switch ON the all the control supply.
 Switch ON the motorized damper. Verify opening f the same.
 Switch ON the air inlet inertia filter motor.
 Switch ON the Centrifugal air handling unit motor.
 Switch ON the centrifugal fan.
Page | 121
 Check the motor current, voltages on the main control panel placed at
pressurization room.
 Check the motor temperature and vibration of inertia motor and blower motor.
 Check the positive air pressure inside substation building.
 If positive pressure is not maintained inside the substation building, check the motor
speed by using Tachometer.
 Check noise level by using sound level meter.
 Check the sand filter condition.
 Monitoring the motor (centrifugal fan) bearing temperature by using thermometer.
 Monitoring the annunciation signals.
 Switch OFF the air intake motor power supply.
 Closed the hand operated valve by manually in air intake chamber.
 Switch OFF the Air handling blower motor power supply.
 Switch OFF damper motor control supply.
 Switch OFF the main input power supply from power distribution panel.
Pressurization system control panel has interlocks with Fire Alarm Control Panel.
The following cause and effect are presented in pressurization panel.
SL.NO. CAUSE EFFECT
1.Inertia filter stop (Air inlet system motor)

1 Fire signal coming 2. All motorized valve closed by automatic.
from FACP 3. Centrifugal Fan (blower) motor are stopped
1.Inertia filter stop (Air inlet system motor)
Gas signal 2. All motorized valve closed by automatic.
3. Centrifugal Fan (blower) motor are stopped.
2
Fire indication All the system shut off
3 switch gear room

Page | 122
 Isolate the Motor from electrical supply.
9.0) CHECKLIST FOR TAKINGOVER FROM MAINTENANCE
10.0) DO'S / DON'TS
DO’s
the bolts evenly.
 The motor surroundings should be clean with sufficient illumination.
 Use proper PPE’s.
DON’Ts

 Do not open the service rolling shutter when the system is in operation.
 Do not close supply air grill / suction airline while running.
 Do not open the door in air handling blower.
 Do not disturb the torque setting in fire damper grill.
 Do not re-energize the motor without conducting all pre-commissioning checks. The
results must be comparable with results at works.
 Do not run the motor with closed suction/discharge airline.
Page | 123
CHAPTER 18-CATHODIC PROTECTION
This chapter describes the Standard Operating Procedure for Cathodic protection.
Page | 124
1) INTRODUCTION
Cathodic protection (CP) is a technique used to control the corrosion of a metal surface
by making it the cathode of an electrochemical cell. Cathodic protection system is
being used for corrosion prevention in storage tanks,mounded bullets and underground
pipelines.
In finished product location, Impressed Current Cathodic Protection system is used for
Storage Tanks and Mounded Bullets and Sacrificial Anode Cathodic Protection system is
used for underground pipelines.
In Crudelocation, Impressed Current Cathodic Protection system and Sacrificial Anode
Cathodic Protection system is used for Storage Tanks and Sacrificial Anode Cathodic
Protection system is used for underground pipelines.
2) DATA SHEET
CATHODIC PROTECTION TRANSFORMER- RECTIFIER UNIT for Storage Tanks in Crude

Location
1 Tag No. 201-CPTR-401 to 411
2 AC input Voltage 240V ± 10%, 1 Ph., 50 Hz, AC
3 A.C. Input Current 40 A
4 D.C. Power Output 1500 W
5 KVA rating of Transformer 3.0 KVA
6 D.C. Output Voltage 0 to50 V
7 D.C. Output Current 0 to 75 A
CATHODIC PROTECTION TRANSFORMER- RECTIFIER UNIT for Storage Tanks in product

Location
205-CPTR-404 to 408
205-CPTR-411 to 419
205-CPTR-422 to 427
1 Tag No.
205-CPTR-438
205-CPTR-451
203-CPTR-417
Page | 125
6 D.C. Output Voltage 0 to50 V
CATHODIC PROTECTION TRANSFORMER- RECTIFIER UNIT for Mounded Bullets in

product Location
205-CPTR-V-403
1 Tag No. 205-CPTR-V-412
205-CPTR-V-406
6 D.C. Output Voltage 0 to 50 V
3) OPERATING CONDITIONS
 Transformer Rectifier Unit is Air cooled cabinet.
 The control cabinet has cooling heat sinks for electronic control circuits.
 Transformer Rectifier Unit is weather proof and suitable for outdoor installation.
4) PRE-START UP CHECKS
 Check the proper earthing connection with the TRU and Junction boxes.
 Check and sure about the incoming cable termination with TRU.
 Check the connection details as per the vendor drawing of AJB, CJB and Tank exit
cable.
 Check the TRU proper accumulate for easy operation.
5) START-UP PROCEDURE
 Switch ON the AC supply and ensure by indicating lamp glow.
 Vary the auto transformer knob on the operation panel up to required output
voltage.
 Check the ammeter reading on the operation panel. It should not exceed the rated
amps.
 Note the reading of the corrosion voltmeter.
6) OPERATIONAL MONITORING:
Page | 126
 Check for any abnormalities like heat, sound in the TRU.
 Monitoring of the impressed current is done to maintain the desired structure to soil
potential.
 Check and note the DC Voltmeter, DC Ammeter and input AC Voltmeter readings.
7) STOPPING ACTIVITY
 Vary the auto transformer knob on the operation panel up to Zero voltage.
 Switch OFF the input AC supply and ensure that the indicating lamp indicates that
supply is OFF.
8) AUTOMATION/INTER-LOCKING:
 The Transformer Rectifier Unit has a Remote Monitoring Unit provision by which the
status can be monitored from DCS. This facility can be used in future.
9) HANDING OVER TO MAINTENANCE
 Isolate the CPTR / JB unit from electrical supply.
10) CHECKLIST FOR TAKINGOVER FROM MAINTENANCE
11) DO'S / DON'TS
DO’S
 If JB or TRUdoors are opened or any gasket joint is to be tightened, then, tighten the
bolts evenly.
 The JB/TRU surroundings should be clean with sufficient illumination.
DON’Ts
 Do not operate the Auto transformer knob unless required.
Page | 127
 Do not touch any live part inside TRU with bare hands.
Page | 128
Section: 03
Annexure
2.ABBREVIATION
Page | 129
S. SHORT TERMS EXANSION
NOS
ACB
1) Air circuit Breaker
ATS
2) Automatic transfer scheme.
AC/DC
3) Alternative current / direct current
AMF
4) Auto main failure
BCH
5) Battery charger
CCTV
6) Closed circuit television
CLC
7) Current limit control
CPTRU
8) Cathodic protection transformer rectifier unit
CRC
9) Cleaning solvent
DOL
10) Direct online
DCDB
11) Direct current distribution board
ELTG
12) Emergency lighting
EOD
13) End of discharge
EPCM-7 Engineering procurement consultant
14)
management
EPO
15) End of power
FACP
16) Fire alarm control panel
HV/ LV
17) High voltage / Low voltage
HVAC
18) Heating ventilation and air conditioning
ICCP
19) Impressed current cathodic protection
IDMT
20) Inverse define minimum time lag
IEC
21) International electro technical commission
IP
22) Ingress protection
KVA
23) Kilo volt ampere
LAN
24) Local area network
LED
25) Light emitting diode
Page | 130
MCCB
26) Molded case circuit breaker
MOG
27) Magnetic oil gauge
MFM
28) Multifunction meter
MOV
29) Motor operating valve
MCB
30) Miniature circuit breaker
MCC
31) Motor control center
MVA
32) Mega volt ampere
ONAF
33) Oil natural air force
ONAN
34) Oil natural air natural
OTI/WTI Oil temperature indicator /winding
35)
temperature indicator
PA
36) Public address
PMCC
37) Power motor control center
PRV
38) Pressure Relief Valve
PVC
39) Poly vinyl chloride
RPM
40) Revaluation per minute
SCADA
41) Supervisory control and data acquisition
SAS
42) Substation automation system
TEFC
43) Totally enclosed fan cooled
TETV
44) Totally enclosed tube ventilated
UPS
45) Uninterrupted power supply
VCB
46) Vacuum Circuit Braker
Page | 131
HVAC
Manual mode shut down and startup sequence

AIR-COOLED SCROLL CHILLER
The chiller is intended for evaporation of R-407C gas at lower pressure and thereby
absorbed in heat from surrounding cooling medium. Liquid refrigerant from condenser
at reduced pressure through expansion valve is extended inside tube which has inner
star and outer integral extended fin for more surface area and the water in the shell
comes into contact with the tube and thereby gets chilled. Heat from water is taken
form the refrigerant gas and sent back to the compressor. The chiller consists of a
bundle of tubes header through which gas passes and water inlet and outlet
connection in the shell.
 Chiller should be provided with 2 sets of thermostats:

 1 set for controlling compressor capacity so that water temperature remain
within the specified limit
 1 set of anti freeze thermostat to prevent forming of ice. The setting of
temperatures of thermostats should be checked at the earlier interval for
healthy performance of the chiller.
 Soap bubble test in the header should be carried out at regular intervals for
checking of leakage of refrigerant.
If leakage is found following activities should be carried out :
 Tightened the fasteners .
 Check gasket condition, if leakage is through gasket, change the gasket
.
 If tube leakage is suspected, then either plug the tube or re-expand with
higher expander.
Air-cooled Chiller Systems
Starting the system
 Ensure that the crankcase heater is always ‘ON’ when the compressor is ‘OFF’.
 Ensure input voltage is within specified range (380 - 420 volts).
 Ensure all valves on the waterlines are in open condition.
 Check water level in expansion tank.
 Be certain all control sensor bulbs are inserted completely in their respective
thermo wells.
 Check that the recommended fuses are in the power circuit disconnect switch
and then close the switch.
 Ensure crankcase heater supply is connected before disconnect switch as shown
in wiring diagram.
 Start the chilled water pumps.
 Start AHUs, or other airhandling equipments.
 Set chilled water thermostat to the desired water temperature.
 ‘Switch on’ the chiller from the micro computer panel located on the chiller.
Page | 132
 In case of scroll compressors, if an unusual noise is heard on starting, and there is
no change in suction pressure and discharge pressure, the direction of rotation
of compressor is wrong. Reverse the wiring terminals of the compressor and
again check for noise, and suction & discharge pressures. This can be eliminated
with the provision of a safety electrical device on the control panel, which
provides the unit reverse polarity protection and single phase protection.
 When compressor starts, a flow of liquid will be noted in the liquid indicator.After
several minutes of operation, the bubbles disappear and full flow of liquid occurs
when the unit is operating normally.
 Check the operation of the safety control switches and indicating lights on the
control panel to be sure that they function to stop compressor motor in case the
settings are exceeded.
 Check compressor suction superheat after steady operation has been
established and leaving chilled liquid has been pulled down to the required
temperature. Compressor suction superheat is the difference between the
actual temperature of the main refrigerant gas entering the compressor and the
saturation temperature corresponding to the suction pressure as shown in a
standard pressure-temperature table for R407C. Compressor suction superheat is
directly related to evaporator (cooler) superheat, which is controlled by thermal
expansion valve adjustment. A low compressor suction superheat indicates a
low cooler superheat (approaching flooding condition of the evaporator) and
vice versa.
 The thermal expansion valve is factory-set to control at 5.5oC superheat,which, in
normal operation, produces a compressor suction superheat of approx. 6oC. It is
not recommended to adjust thermostatic expansion valve in the field.
 Check setting of controls as under (New Saginomia Preset Type) LP Cutout - set
at 35 psig (Check with gauge) HP Cutout - set at 450 psig (Check with gauge)
Antifreeze - set at 5 degree Centigrade (Check with thermometer) Thermostat -
set as per requirement
Stopping procedure
 Switch off the chiller by pressing ON/OFF key only.
 Stop chilled water pump.
 Stop air handling equipments.
Page | 133

Operating Manual Consolidated - 02.01.2017

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Operating Manual Consolidated - 02.01.2017

Hochgeladen von

Copyright:

Verfügbare Formate

OPERATING MANUAL

1.1 Overview of Paradip BOOT Terminal............................................ 6

1.2 Purpose .............................................................................................. 6

1.3 Scope and Applicability............................................................... 10

2.0 Design Basis ................................................................................ 14

2.1 Design Basis for Electrical equipment’s...................................... 12

3.0 Electrical Facilities ...................................................................... 17

3.1 Crude Location .............................................................................. 31

3.2 Finished Products Location .......................................................... 32

4.0 Roles & Responsibilities ................................................................. 46

Section – 2 (Standard Operating Procedures)

5.0 Transformers ..................................................................................... 19

6.0 Diesel Generator ............................................................................. 26

7.0 HT Switchgear .................................................................................. 39

8.0 Air Circuit Breaker........................................................................... 45

9.0 Motor ................................................................................................. 49

10.0 UPS .................................................................................................... 67

11.0 Battery Charger and DCDB ......................................................... 89

12.0 High Mast ..................................................................................... 100

13.0 Self Regulating Heat Tracing..................................................... 104

14.0 Skin Effect Heat Tracing ............................................................. 108

15.0 HVAC System .............................................................................. 112

16.0 Pressurization .............................................................................. 118

17.0 Cathodic Protection System .................................................... 121

1 Log sheet ..............................................................................................

2 Abbreviation ...................................................................................... 125

 Zero breakdown for all Electrical equipments.

SCOPE AND APPLICABILITY

Sl.No. Equipment / System Tag No. Rating / Type Qty

1 Distribution Transformers 335AS-201-TR-401/402 2.5MVA ;6.6kV/415Volts 2

2 Bus Duct 335AS-201-BD-401/402 4000A 2

3 Diesel Generator 335AS-201-DG-501 125kVA 1

4 AMF Panel 335AS-201-PA-501 415 Volts; 400Amps 1

5 HT Switchgear 335AS-201-SG-301 6.6kV 1

6 LT Switchgear (PMCC) 335AS-201-SG-401 415Volts 1

10 806-201-UPS-601(R/N) 110 Volts / 40KVA 1

15 Inter-Tank Transfer Pump 201-PM-002 A/B 285 kW 2

21 High Mast ----- 30M / 6.4 kW/ Each 21

C Cathode Junction Box 201-CJB-701 to 711 ----- 11

25 HVAC system For SRR 806 ----- 01

Power Panel for HVAC 806-201-PP-401 / 402

B AC Scroll Chilling Unit SRR 806 56TR 2

C Air handling unit SRR 806 200000 CFM Double skinned 2

26 Pressurisation System SS 335AS ------- 1

A Pressurisation Panel 335AS-205-PV-401 415 Volts 1

31 Earth pit ------- 103

32 Welding Socket 201-WS-401 to 413 415 Volts / 63 Amps 13

3 Heat Tracing Transformer 312N-205-HTTR-401 250KVA 1

4 Booster Transformer 366N-205-TR-401/402 400KVA 2

7 Diesel Generator 312N-205-DG-501 415 Volts; 380 kVA 1

8 AMF Panel 312N-205-PA-501-P1 415 Volts; 400 Amps 1

9 HT Switchgear 312N-205-SG-301 6.6kV 1

10 LT Switchgear (PMCC) 312N - 205 -SG 401/402 415Volts 2

------- 800 Amps 44

13 Motor Control Centre 312N - 205 - MCC 401/402 415Volts 2

110 Volts / 40KVA

25 Naphtha Export MOTORs 205-PM-002 A/B/C/D 1100.00 kW 4

34 Off spec LPG 205-PM-027 A/B/C 7.50 kW 3

Sulphur Truck Loading

36 Propylene Supply MOTOR 205-PM-029 A/B/C 45.00 kW 3

38 241-PM-100 A/B 18.50 kW 2

43 MS Dosing MOTOR 205-PM-041 A/B 3.70 kW 2

44 Diesel Dosing MOTOR 205-PM-042 A/B 11.00 kW 2