Industrial Visit Reports: College of Engineering Trivandrum
Industrial Visit Reports: College of Engineering Trivandrum
Submitted by
K B ANANDU
B-Tech
Electrical and Electronics Engineering
University Register No: 14400055
ACKNOWLEDGEMENT
K B ANANDU
CET
1. SABARIGIRI 24-05-2017 4
HYDROELECTRIC POWER
STATION, MOOZHIYAR
SABARIGIRI
HYDROELECTRIC POWER
STATION
Moozhiyar, Pathanamthitta, Kerala,
South India
HYDROELECTRIC POWER
SABARIGIRI POWERHOUSE
Two reservoirs contribute the water required for operation of the project.:
1. PAMPA RESERVOIR
This reservoir is formed by the Pamba dam constructed across Pamba
river. The water from this reservoir is flowing to the Kakki reservoir
through an underground tunnel of length 3.21 km.
2. KAKKI RESERVOIR
The Power Station was commissioned during 1966 -67 with six
generators having vertical shaft pelton turbine as the prime mover. After
power generation, water from the power station is released to the
Moozhiyar reservoir.
DETAILS
U1 50 MW 18.04.1966
U2 50 MW 14.06.1966
U3 50 MW 29.12.1966
U4 50 MW 22.06.1967
U5 50 MW 09.09.1967
U6 50 MW 26.11.1967
RMU works were undertaken in the Power Station from 2005 to 2009 .
During renovation work unit No. 4 was also up rated to 55 MW and put
into service on 11-2-2007. In a fire accident that happened 16-5-2008,
unit No 4 was completely destroyed. The whole machine parts were
dismantled and new machine was erected with an enhanced capacity of
U1 55 MW 03.12.2009
U2 55 MW 07.02.2009
U3 55 MW 17.03.2008
U4 55 MW 06.05.2014
U5 55 MW 05.05.2006
U6 55 MW 0.1.07.2005
The 300 MW Sabarigiri Hydro Electric Project, which was added to the
Kerala System in 1966, enjoyed the special status of having a capacity
higher than the capacities of all the other projects (including Sholayar
which was also in the final stages of commissioning in 1966), in the
Kerala system put together. Sabarigiri also elevated Kerala to a power
surplus state in 1966.
ALTERNATOR
The hydro electric generators have vertical shaft and are salient pole
synchronous generators. The alternator were made by Allis Chambers.
Technical Specifications
Rated Power : 55 MW
Phases :3 Φ
Frequency : 50 Hz
No. of Poles : 12
CONCLUSION
BRAHMAPURAM DIESEL
POWER PLANT
Kochi, Kerala, South India
INTRODUCTION
The DG hall houses the entire prime mover alternator set. The
prime mover used at BDPP is SEMT Pielstick diesel engines. It is a 4-
stroke turbo charged and inter cooled engine with direct twin fuel
injection. The engine uses two fuels - primary fuel being LSHS. Diesel is
used for starting and stopping purposes.
A1-B8-A7-B6-A4-B3-A2-B9-A8
B5-A6-B1-A3-B7-A9-B4-A5-B2
The piston reciprocates in these cylinders with a stroke length of 580 cm.
each cylinder has a set of valves – inlet valve and exhaust valve and a
fuel injection system. A cam mounted on a cam shaft operates these
valves. The cam shaft is coupled to the crank shaft with asset of gears.
The profile of the cams is arranged suitably for the perfect timing of the
operation of the valves. Cam shaft is composed of a number of cams
connected together to form a single shaft. This arrangement provides an
economic method for replacement of individual cams during faults. The
fuel injection system can be broadly divided into two parts -pressurizing
unit and atomizing unit. Pressurizing unit consists of a plunger which
reciprocates in a cylinder called barrel. These together forms a fuel
pump which pressurize the fuel to about 450 bars. Atomizing units are
nozzles which provide a fine spray of fuels into the cylinder. Two
nozzles–main nozzle and pilot nozzle are present in each cylinder. A
cam provides the up and down motion of the plunger in the barrel.
The speed of the engine is maintained constant even when the load on
the alternator varies. This is attained with the help of a governor. It
adjusts the fuel input to the cylinder with load, which more fuel is
supplied when the load is high and less fuel when the load is low. The
quantity of fuel is controlled by providing a helical groove on the plunger.
The relative angular position of the groove with spill pot determines the
amount of fuel injected to the cylinder. This angular displacement is
obtained by a rack and pinion arrangement.
A mechanical over speed trip device is fitted at one end of the cam shaft.
A centrifugal force which comes to play at high speeds of the shaft
activates the device and the fuel supply is cut off. This device is set for a
speed of 565 rpm. A safety valve is provided at the top of the cylinder. It
is set for a maximum pressure of 240 bars. To improve the efficiency of
the engine a turbocharger is provided which is a turbine- compressor
system. The turbine is driven by the exhaust gas which in turn drives the
compressor. Hence the air is compressed to about 3 bars. The
compressed air is cooled to maintain a particular temperature using HT
water. The turbocharger works at 15000 rpm. For every 150 hrs the
turbine is washed which is known as turbo wash.
STARTING
1. Start
Maximum over speed of the machine is limited such that engine will
electrically trip at 555 rpm and if the relay is not operated mechanical
tripping occurs at 565 rpm. The signal voltage corresponding to 555rpm
is 8.46 volt.
: 2bar trip
ALTERNATOR
N= 120f/p
P= no of poles=12,
N= speed in rpm=500
Specification of exciter
· RPM : 500
· Frequency : 66.7
· Capacity : 59.1 KW
· Connection : Star
GENERATING TRANSFORMER
Specifications
● Type : outdoor
● No. of winding per phase : 3
● Cooling : ONAF
● Rating : 38 MVA
● Voltage : 11/110 KV
● Current : 1996.85 A at LV
: 199.68 A at HV
STATION TRANSFORMER
The 4 ST's installed in the plant provide the low voltage of 433V for
the station purposes. Its capacity is 2000KVA with 11000/433V rating.
There is one standby station transformer
MV SWITCH GEAR
LV SWITCH GEAR
BATTERY ROOM
In the battery room, there are 55 cells of 2 volts each, giving 110V.
It has a capacity of 300 Ah. It is a float rectifier cum boost charger. The
battery supplies the necessary dc voltage for display and lighting
purposes at emergency
It is provided to prevent the plant shut down during the grid failure.
It is an AC generator Specification of generator are given below.
● Rating : 500KVA
● Voltage : 415
● Current : 695.6
● Speed : 1500 rpm
● Rotor : Salient pole
● Excitation : Self excited ac
Parallel Operation
● Fuel system
● Lubricating oil system
● Compressed air system
● Cooling water system
● Charge air and exhaust gas system
While starting, diesel is passed into the engine and after the load
reaches 30% of engine capacity of 21.32MW (i.e. about 6.5MW), the fuel
is switched to LSHS. Diesel is used when the plant is shut down for a
long period for maintenance. LSHS is flushed out and diesel is fed in
using a selector valve. The use of LSHS here can cause it to clog the
pipes as it solidifies unless the temperature is maintained at a critical
temperature.
The HFO feeder pump pumps the fuel to the HFO booster unit at a
pressure of around 4 to 5 bar. From here, fuel passes to the fuel oil unit
and finally to the engine.
1. Unloading pump
5. HFO separator
LFO System: The fuel, which is diesel in this case, is brought by BPCL
and stored in their LFO storage tanks using an unloading pump. There
are two storage tanks of 450kl capacity each. The LFO transfer pump
pumps diesel to LFO day tank. Purifiers are not necessary here as diesel
is a clean fuel. There is no chance of contaminations. The LFO day tank
has a capacity of 200kl. The LFO feeder pump supplies LFO to the
booster unit and finally to the engine.
The Booster unit is an important part of fuel system. There are four
booster units, one for two engines. The booster unit starts with a three-
way change over valve. The two inlets are the LFO &HFO from their
respective day tanks. The type of fuel required can be selected using
this valve. The selected fuel is then passed through an auto filter; the
impurities up to 300 microns are removed. The fuel then approaches the
de aeration vessel were air present in it are removed. The fuel which has
to enter the engine requires a pressure of 7-9 bars. Much pressure is
lost as the fuel travels from the day tank to the booster unit. A booster
pump in the booster unit gives the necessary pressure to the de aerated
fuel. The fuel is pumped to steam heaters and then to a viscosity meter.
There is a particular range of values of viscosity which the fuel must
have for the proper functioning of the engine. This valve is adjusted by
the combined action of steam heaters and viscosity meters. Viscosity of
a fuel depends on temperature. As temperature increases viscosity
decreases. Thus, a proper temperature is given to the fuel to adjust the
viscosity. The viscosity of LSHS is 730 CST at 50 degrees Celsius and
about 80-22 CST at 100-110 degree Celsius. This is the working
temperature, viscosity and necessary adjustments are made. The fuel is
finally ready for use and is send to the engine as required through the
fuel oil unit.
LFO FUEL
1. Unloading pump
8. Diesel engine
For small diesel engines a dc motor is used for starling. The diesel
engine used at BDPP is started with compressed air. Here, the air used
is compressed to a pressure of 13 to 30 bar and is stored in air vessels.
This highly compressed air is supplied to the engine for starting it. When
this high-pressure air enters the cylinder, the piston is pushed
downwards. By timing the supply of air to different cylinders, the piston is
made to reciprocate within the cylinder. The timing of air supply to the
engine is attained by means of a cam mechanism driven by a shaft
coupled with the engine shaft.
Compressed air system is also used for sudden stopping of the engine.
The high-pressure air from the air vessel throws the fuel governor to stop
position when the engine is to be stopped suddenly. The compression of
air is attained with the help of two compressors. The compressed air is
then stored in air vessels nearby the engine. The compressed air system
can be broadly divided into two parts:
Starting air system: This system is concerned with the starting of the
diesel engine. To start the engine, the air pressure must be well above
18 bars. Thus, the air pressure is always maintained in between 18 and
30 bars. This high-pressure air is supplied to the engine during starting
time. Working air system: This system is concerned with sudden
stopping of the engine end controlling of the pneumatic valves at
different locations in the plant. The pressure required in the working air
system is about 7 to 8bar. Any fault for this system causes the complete
shutdown of the plant as almost all of the valves are controlled by this
system and it is required for the emergency operations in the plant.
P= PmALN/n, N in rps
Exhaust gas from the engine is at very high temperature. By using this
high temperature exhaust gases for other purpose the overall efficiency
of the plant can be increased. At BDPP, the exhaust gas from the engine
is used for a number of purposes. Exhaust gas from each engine is used
to drive the charge air system of that engine. Steam or the steam system
is generated by boilers which use the exhaust gas for boiling water.
Such boilers are connected to engines 4, 5 and 8
DEMINERALIZING PLANT
1. NaOH
2. Bore well
3. Air pumping
4. Storage tank
5. Iron RF
6. Dual RF
7. Cartridge filters
8. Softeners
9. Softeners
11. Tank
BOILER UNITS
There is a spring loaded safety valve with 13bar operating pressure. Two
pressure gauges for the steam pressure and hydracell water- pressure.
A steam separator is used for separating the steam and the condensate.
The condensate is then fed to the steam rator. A pressure regulating
valve operating at 4 bars is also provided. The range of feed water is 8.2
-9.0 pH, which ensures enough alkalinity to prevent corrosion. The
working pressure is about 7 bar.
Once the diesel engine is started there is no need of steam rator. The
exhaust flue gas from the machine is used to produce the required
steam in a Exhaust Gas Boiler [EGB] The exhaust gas input to the EGB
is controlled by a actuator-damper arrangement. The actuator used to
CONTROL ROOM
The whole plant is controlled -from the control room. There are 8
control cubicle for each alternator engine set namely
CFC1,CFC2........CFC8.The details such as voltage generated, power
factor, frequency, load current, engine rpm etc for each set is shown in
these cubicles display panel. Generator synchronization can be done
from the control room. The control system employed is PLC (Program
Controlled Logic). All the functions and operations at BDPP are
completely automated through the PLC (Programmed Logic Control)
system. This is a completely automated system which runs 24 hours and
lakes note of all the details concerning the operation of the plant. PLC
used at BDPP is programmed in COCEPT. The PLC system consists of
a number of panels which contains modules that are responsible for
some functions. The control room in the power plant houses the main
panels of the PLC system. Power plant control system consists of a
number of sub systems each of which takes care of a specific part of the
plant. All subsystems are coordinated by a central system located at the
control room. The control system has two parts - one located at the
central control panel in the control room and the other part at the
location of control i.e. near the engine. This part is called Genset control
panel. Such a panel is provided for each engine.
The sensors and transducers are connected to the input module of the
local control panel. The input module transfers the data to the processor
which consists of the logic sensor and program. The output from the
processing section is fed into the output module. A single module can
accept up to 64000 inputs. A number of such modules are used to
handle all the control and coordination operations of the plant. The
modules are connected to a back plain. One such back plain contains
modules handling inputs, CPU, RIO head or drop and power supply. RIO
head is present at the central control panel of each section. To this, lines
from RIO drops from each individual panel are connected. RIO taps are
provided to take multiple lines from a single RIO head. The RIO head
then sends the data to the CPU. The CPU processes the data and gives
necessary signals to the concerned section
In this unit all necessary equipment driving forced water is provided for
fire extinguishing. It consists of motors for driving water pumps. When
the cortisol bulb in transformer bursts the surrounding water outlet points
sprays water automatically. In a fire unit there are 2 main motor pumps
of 90 KW rating. There is a jockey pump of 11kw. Main motor pumps are
used for 4 to 7 bar water spray. Diesel engine pump is used for 5 to7
bar. Jockey pump is used for 6 to 7 bar pressure. There are various
outlets across the power plant for fire extinguishing purposes. CO2 and
foam extinguishers are also employed.
CONCLUSION
BDPP is the one of the major power plant in Kerala. It forms the
main power back-up solution for the increasing load demands there.
Being a diesel-plant it has to assure perfect cleanliness. The plant is
designed for continuous working and as per international standards. The
plant setup is done by MAN B&W, Germany. All the important parts, the
working and maintenance of the plant have been studied.
KELTRON EQUIPMENT
COMPLEX
Karakulm, Thiruvananthapuram,
Kerala, South India
INTRODUCTION
Keltron is India’s first and the largest electronics corporation in the State
sector. Keltron has been a catalyst in making electronics work in almost
every aspect of our daily life, since 1973.
Management
PRODUCTION CENTRES
All production centres and business units of Keltron are ISO 9000
certified.
POWER
ELECTRONICS
GROUP(PEG)
SPECIAL
SECURITY PRODUCTS
SYSTEM GROUP(SPG)
GROUP(SSG)
KELTRON
EQUIPMENT
COMPLEX
SPACE
IDCP,Training ELECTRONICS
&Data Entry GROUP(SEG)
iTAC
12 pulse charger
IP 31 protection
COMPONENTS OF UPS
Battery: this is the power storage section and is kept charged either by
the rectifier or a separate charger.
Static Switch:Its purpose is to switch the load between the inverter and
the utility mains supply. This arrangement ensures that if the inverter
experiences an overload situation or battery under voltage, it will
transfer the load to the more resilient mains supply. Also a fault on the
inverter will cause the load to be transferred.
FABRICATION SHOP
The importance of iron & steel among other materials is well known for
industrialization and national economy. Metal fabrication is the group of
entire processes employed to shape the metals into the desired form by
melting & casting down to hot/cold working, joining by welding, brazing,
A seven tank process is being used for the processing. After every basic
process the material is dipped in a water tank to remove the excess
chemicals. The basic processes involved are:
1. DEGREASING:
In the fabrication of metal components the parts often contain
residual machining lubricants which need to be cleaned before
being surface tested or coated. Consequently, metal component
degreases are widespread throughout the manufacturing sector.
Two common methods of degreasing are liquid solvent cleaning
(cold cleaning) and vapor degreasing. Cold cleaning consists of a
dip tank containing a solvent based cleaning solution at room
temperature. The component is dipped in the tank with a varying
residence time and then removed often with drag out.
2. DERUSTING:
This process removes only the rust from the part; all other exposed
metal along with their tolerances will not be affected. Afterwards,
all types of rust inhibitors are applied to the part for rust protection.
3. PHOSPHATING:
Phosphate coating s are used on steel parts for corrosion
resistance, lubricity, or as a foundation for subsequent coatings or
painting. It serves as a conversion coating in which a dilute
solution of phosphoric acid and phosphate salts is applied via
spraying or immersion and chemically reacts with the surface of
the part being coated to form a layer of intrinsic crystalline
phosphates. Phosphate conversion coatings can also be used on
aluminum, zinc, cadmium, silver and tin.
4. PASSIVATION:
The passivation of stainless steel is a process performed to make
a surface passive, i.e., a surface film is created that causes the
surface to lose its chemical reactivity. Stainless steel passivation
unpotentializes the stainless steel with the oxygen absorbed by the
metal surface, creating a monomolecular oxide film. Passivation
can result in the very much-desired low corrosion rate of the metal.
The passivation of stainless steel is performed when free iron,
oxide scale, rust, iron particles, metal chips or other nonvolatile
deposits might adversely affect the metallurgical or sanitary
condition or stability of the surface, the mechanical operation of a
part, component or system, or contaminate the process fluid.
Passivation is performed on clean stainless steel, providing the
surface has been thoroughly cleaned or descaled.
Zinc plating
(b) Silver plating
(c) Zinc yellow plating
ANODIZING
Anodizing is an electrochemical process that converts the metal
surface into a decorative, durable, corrosion-resistant, anodic oxide
finish. Aluminum is ideally suited to anodizing, although other nonferrous
metals, such as magnesium and titanium, also can be anodized.
PAINTING
After all the above process, the machine part is kept in oven and
gets heated for some time. After that it is painted to prevent corrosion of
the material. Usually spray painting is preferred. Plating, painting, and
the application of enamel are the most common anti-
corrosion treatments. They work by providing a barrier of corrosion-
resistant material between the damaging environment and the structural
material. Aside from cosmetic and manufacturing issues, there are
tradeoffs in mechanical flexibility versus resistance to abrasion and high
temperature.
TOOL ROOM
1. ENGRAVINGMACHINE:
2. LATHE MACHINE
It is known as mother of all machines. It has five parts – head stock, tail
stock, lathe garage, chuck (3 jack and 4 jack). A lathe is a machine tool
which rotates the work piece on its axis to perform various operations
such as cutting, sanding, knurling, drilling, or deformation, facing,
turning, with tools that are applied to the work piece to create an object
which has symmetry about an axis of rotation.
3. SHAPING MACHINE:
It is used for edge shaping and filing. The given aluminum work piece is
held still and the tool is moving. At a time only 5mm of metal is removed.
It is used for drilling out non circular shapes- square, rectangle, triangle
etc. This machine has got motion in all directions. The drill rotates on its
axis giving a straight cut on the metal piece.
It uses permanent magnets to hold the work piece. It is used for finishing
the surface of metal.
These are used for drilling grooves for screws in the work piece. Drill bits
of different types are used to obtain the required radius. In radial type,
both clockwise and anti-clockwise motion of the machine is possible,
thus helpful for large work piece.
Assembling section
Products
Electromagnetic Log and Re Transmission Unit
Search and Rescue Beacon
Echo sounder
Underwater Telephone
Processor Based Ground Mine
Expendable Bathy Thermograph
Modular Interface for Ship Borne System
Radar Interface Unit
Underwater Wireless Acoustic Communication System
ELECTROMAGNETIC LOG
The process is
Advantages
No moving parts
cheaper
Disadvantages
ECHO SOUNDER
a transducer located near the keel of the ship which serves (in most
models) as both the transmitter and receiver of the acoustic signal; the
necessary oscillator, receiver, and amplifier which generate and receive
the electrical impulses to and from the transducer; and a recorder or
other indicator which is calibrated in terms of the depth of water.
SGCS are used to move the ship in the desired directions in the sea by
controlling the rudder position. The technology courtesy is to Brown
Brothers, UK.
XBT probe
OPERATION
There are two modes of activation for the search and rescue beacon-
manual mode and water activation mode.
The manual mode consists of two switches- test switch (green) gets
automatically turned off when an output signal is produced. Alert switch
(red) keeps on producing the output signals continuously so that there is
no difficulty in locating the person in danger. It is also known as
Emergency Position Indicating Radio Beacon (EPIRB).
The water activation mode produces a signal that is sent to the satellite
when the search and rescue beacon falls into salty water at a depth of
atleast 4m.
CODING:
partnered ISRO through the history of India’s space program. Right from
the inception of the early SLV/ASLV program through the successful
PSLV and GSLV launch vehicles, and the historic Chandrayan mission -
right up to the present time through the development of the heavy GSLV
Mark III to launch 4 ton satellites into geostationary transfer orbits.
The circuit design and PCB fabrication is done by ISRO. Production and
testing of the circuit on PCB is done by KELTRON. Dedicated facilities
established at KEC, Karakulam meet the specialized and sophisticated
requirements of ISRO for GLSV and PSLV.
CONCLUSION: