2.2.

Training at Ceylon Electricity Board

I think Ceylon Electricity Board is the best place to train as an electrical engineering trainee. The Ceylon Electricity Board (also abbreviated as CEB), is the largest electricity company in Sri Lanka. With a market share of nearly 100%, it controls all major functions such as electricity generation, transmission, distribution and retailing in Sri Lanka. 2.2.1. My Work Sites I had two months Training in Ceylon Electricity Board. Information on worksites that I worked during the training period is mentioned below in the table with names and designations of key training personnel involved and time periods spent in each section.

Table 2.1 Information on Worksites Training Place Kothmale Power Station Kelanithissa Power Station Kelanithissa Combined Cycle Power Station System Control Centre Generation Planning & Design Transmission Operation & Maintenance (Anuradhapura Region) Mr. Hettiwattaa (Chief Engineer, Transmission Operation & Maintenance - Anuradhapura Region) From 28/06/2010 To 11/07/2010 Key Training Officer Mr. T.M.S.K. Thilakarathna (Chief Engineer, Kothmale Power Station) Mr. Hendahewa (Chief Engineer, Kalanithissa Power Station) Mr. N.A.F.G. Jayamaha (Chief Engineer, Kelanithissa Combined Cycle Power Station) Mr. Lakshitha Weerasinghe (Chief Engineer, System Control Center) Mr. S.H. Midigaspe (Chief Engineer, Generation Planning & Design) Time Period From 17/05/2010 To 30/05/2010

From 31/05/2010 To 06/06/2010

From 07/06/2010 To 13/06/2010

From 14/06/2010 To 20/06/2010

From 21/06/2010 To 27/06/2010

21 | P a g e

2.2.2. Kotmale Hydro power station

2.2.2.1. Introduction Kotmale hydro power station is one of the major power stations in the Mahaweli project. It is an underground power station.

Figure 2.13 Power house, Kotmale. The arrangement of basic components of the power station. It consists of three generators 67 MW each.

2.2.2.2. Surge Chamber

The length of the tunnel is 7 km. It connects with the penstock which is 120 m long. There is a surge chamber in between the tunnel and the penstock, which is there to protect the penstock and the tunnel from high pressure situations. These high pressure situations occur when shutting down a machine. In a machine tripping off, this situation is even worse. When the main inlet valve closes the water pressure increases, then the water level in the surge chamber increases and releases the extra pressure from the penstock and the tunnel.

22 | P a g e

The power house consists of 3 Main Inlet Valves of cylindrical type for three

generators. A hollow cylinder is there to open or close the water flow. When the cylinder is at horizontal position the water flows through the cylinder and flow is opened. When the cylinder is at vertical position water flow is closed. It is operated using hydraulic pumps.

Figure 2.14 Surge Chamber

2.2.2.3. Turbines

Francis type turbines are used in the power house and they are designed for a head of 201.5 m. The water comes through the penstock is directed to a spiral way with circular cross section, whose diameter

decreases gradually. On the way the water goes out of the spiral way to hit the turbine through guide vanes. There are 24 guide vanes in each turbine. Those guide vanes are controlled by the governor with the help of two servo motors. The action of servo motors can be clearly seen when the machine is given the frequency controlling task. Figure 2.15 Turbine

23 | P a g e

2.2.2.4. Generators

Rated output of a generator 90000 kVA with power factor of 0.85. Generation voltage is 13.8 kV. One generator consists with a brushless exciter whereas the other two generators consist with conventional static exciters. Table 2.2 Comparison between Static and Brushless Exciters Static Exciter Quick in response Carbon dust Maintenance is difficult Deterioration Brushless Exciter Slower in response No Carbon dust Easy to maintenance

Brushless exciter is an AC machine, placed on top of the generator. It has a rectifying circuit in its rotor. The power needed for excitation is taken from the rotating part itself, so no brushes needed. But brushless exciters have brushes for protection purposes.

2.2.2.5. Transformer Yard

There are 9 single phase transformers in the transformer yard. The three generators are equipped with three transformers for each. The secondary sides of the transformers are connected in a way such that a star connection is formed. Using single phase transformers other than one three phase transformer is suitable, because maintaining becomes easier and also the replacing procedure is economical in some cases.

The ratings of the transformers are as follows.

Rated capacity - 30 MVA Rated voltage - HV side 220 kV LV side 13.8 kV Rated current - HV side 20.54-248.6 A LV side 2174 A
24 | P a g e

Figure 2.16 The transformer yard

2.2.2.6. The Switchyard

Kotmale switchyard consists with 2 switchyards. One is 220 kV switchyard and the other is 132 kV switchyard which is presently not in use. In the switchyard SF6 circuit breakers and minimum oil circuit breakers are used. We could observe a repairing procedure of a minimum oil circuit breaker. The most important thing in this switch yard is that the power that goes to Biyagama through Kotmale Biyagama line starts from here. Figure 2.17 The Switchyard

25 | P a g e

That line transfers a huge amount of power; therefore a fault in this line may be a reason for a blackout. So the maintenance of this switchyard is very important.

The switchyard consists with following main power lines. Incoming 220kV double circuit line from Victoria. Outgoing 220k double circuit line to Biyagama. Outgoing 220k single circuit line to Anuradhapura. 220 kV Double circuit line to Upper Kotmale. (Proposed.)

2.2.2.7. MW/Mvar Control A synchronous generator has a capability curve of operation. When the generator violates the curve, it trips off. So, variation of MW/Mvar must be done inside the curve. Amount of active power is controlled by the governor. Reactive power is controlled by controlling the output voltage. Automatic Voltage Regulator (AVR) is responsible of voltage control.

2.2.2.8. Maintenance of the Power Station Maintenance of the power station is mostly done according to the specifications of the manufacturer. There are maintenance programs held monthly, quarterly, half yearly and annually. I got an explanation on maintenance from the ES (maintenance). 2.2.2.9. Synchronization Before connecting any power plant to an electricity network, the output must be synchronized. It means two waveforms of both sides must overlap. To synchronize, the voltage, frequency, phase angle and the phase sequence of two waveforms must be identical. Required voltage can be achieved by exciting. Frequency can be controlled by the governor. So the phase angle and sequence must be checked when synchronizing and the supply must be connected exactly at the correct point.

26 | P a g e

2.2.3. Mini Hydro Power Station at Nillambe On 21/05/2010 I visited Nillambe mini hydro power station which adds 3.2 MW for the national grid. There are two sets of machine units. Turbines are of Francis type designed for a head of 110 m. The generator produces a rated output of 1.6 MVA with the generation voltage 6.3 kV at 0.8 power factor. Voltage is then step-up to 33 kV and connected to the distribution network. Figure 2.18 The Nilambe Power Station

2.2.4.

Kelanithissa Power Station

We learned about 20 MW gas and 115 MW gas turbines. Also we studied about, Compressor Combustion Process Turbine Generator & Excitation Methods

Description of 20 MW gas turbine, Output Voltage 11 KV Power 26690 KVA Fuel Diesel Turbine Speed -5100 rpm Generator Speed 3000 rpm 2 pole, Cylindrical rotor

27 | P a g e

2.2.4.1. Kelanithissa Combined Cycle Power Station Combined Cycle Plant is a combination of gas turbine and steam turbine generator (110MW+55MW). Inlet air drawn from air filters compressed and moved. Then air and fuel are fired. Turbines are rotating from the use of hot gas. After that the exhaust gas goes to the heat recovery steam generator (HRSG). Then HP and LP turbines rotates from the use of hot exhaust gas.

2.2.5 System Control Center A major disadvantage of Electricity, while comparing with the other types of energy is that it cannot be stored in large amounts. So that the conventional and easiest way of supplying electricity to the consumers is generate the needed energy at the same time they are consumed. So it is essential to maintain the condition that demand equals supply. This is the major function done by the System control centre. CEB purchases power from private power producers. So it is important to select the suitable power station to run at the suitable time, considering so many conditions. Economic, agreements, irrigation and so on. System control centre consists with three main sections. System Operations Branch controls power generation to match instantaneous demand. Supply and demand balancing is achieved by maintaining system frequency within the range 49.5 50.5 Hz. I observed addition and rejection of generator units during day time. Plant additions are done according to the weekly plan issued by the Water Management Secretariat. Normally, base load is supplied by thermal power plants due to their low flexibility. I studied the Sri Lankan Power System network at the System Control Center. There are two main hydro complexes in Sri Lanka, named Mahaweli complex (based on Mahaweli River) and Laxapana Complex (based on Kelani River). Also there are some other hydro power plants. The capacities of the plants are given below.

28 | P a g e

Table 2.3 Hydro power plants & Capacities

Hydro plant Mahaweli Complex Victoria Kotmale Randenigala Rantambe Ukuwela Bowatenna Mahaweli Total Laxapana Complex Wimalasurendra Canyon Old Laxapana New Laxapana Polpitiya Laxapana Total Other Hydro plants Samanalawewa Kukule Udawalawe

Installed Capacity (MW)

70 67

x3 x3

210 201 123 50 40 40 664

61.5 x 2 25 20 40 x2 x2 x1

25 30

x 2 x 2

50 60 49.9 100 75 334.9

(8.3 x 3)+(12.5 x 2) 50 x2

37.5 x 2

60 35 2

x2 x2 x2

120 70 4

29 | P a g e

Inginiyagala Nilambe Other Hydro Total Hydro Total 1.6

12 x2

12 3.2 209.2 1208.1

Power stations of Mahaweli and Laxapana complexes are arranged in a cascade system and a proper illustration with a diagram is given in Annex E and Annex F. Due to the cascade arrangement the maximum usage of the potential of water is taken. The main objective of Mahaweli complex is supplying water for agricultural purposes. But the main objective of Laxapana complex is generating electricity.

Now Sri Lanka has a Thermal based generation system. The capacities of the plants are given below Table 2.4 Thermal power plants owned by CEB

Thermal plant KPS GT KCCP Sapu STG 1 Sapu STG 2 Sapu STG 3

Installed Capacity(MW) 20x5 + 115 108(GT) + 55(ST) 16x4 9x4 9x4 215 163 64 36 36

30 | P a g e

Table 2.5 Private Thermal power plants

Thermal plant Lakdanavi Asia Power Barge Aes Ccp Ace Matara Ace Horana Ace Embilipitiya Heladanavi West Coast Total

Installed Capacity (MW) 22.5 48 60 163 24 24 100 100 300 1355.5

2.2.5.1. Operations Planning Section Operations planning section is responsible for planning the short term operations of the power system. Before any maintenance process starts the system control centre must be informed about it. So such processes are scheduled for certain duration.

2.2.5.2. Maintenance

Annual Maintenance processes are conducted on all the power stations to make sure the power supply is reliable and safe. But if too many power stations are maintained simultaneously, problems may occur due to the insufficient capacity. So these maintaining processes are scheduled by system control centre such that there may not be any problem with the capacity.
31 | P a g e

The condition of power stations also must be checked. Such process is called Routine Maintenance. They are also must be scheduled. Forced outages occur due to unexpected break downs. Those power plants need repairs, but they cannot be planned. So there should be a plan in system control centre to face such situation without doing harm for the consumers.

Apart from the power stations, the transmission system also must be repaired from time to time. Also faults in the transmission system must be expected. So system control centre has plans to face such situations and repair the faults as soon as possible.

2.2.6. Generation Planning & Designing

2.2.6.1. Introduction

Electricity demand keeps increasing in Sri Lanka. So new supply enhancing projects must be there to meet those requirements. In addition, depreciation and retirement of existing power stations is also a reason for planning the generation projects in future. Ultimately the capacity of the country is to be increased according to the plans. The generation plan is prepared considering those factors and with the intention of supplying electricity to the consumers in a reliable, stable and affordable manner. An econometric model is used in preparing the plan, rather than thinking only about the financial benefits of selling electricity. A good generation plan ensures a reliability of the entire power system. The Long Term Generation Expansion Plan is prepared annually, and the planning horizon covers fifteen years. In that process studies are done considering next twenty years.

Load forecasting, pre feasibility studies, feasibility studies, site surveys, finding funds are also done in this branch in addition to generation planning.

2.2.6.2 Main Objectives of Generation Planning To investigate the feasibility of new generating plants for addition to the system in terms of the plant and system characteristics.

32 | P a g e

To specifically investigate the future operations of the hydro-thermal system in order to determine the most economical operating policy for reservoirs, hydro and thermal plants.

To conduct system simulation studies to determine the economically optimum mix of generating plants to meet the forecast demand and the acceptable reliability levels in the 15 year period ahead.

To investigate the robustness of the economically optimum plan by analyzing its sensitivity to changes in the key input parameters.

2.2.6.3 Demand Forecast

Demand forecasting is done to identify the changes in electricity demand and to identify the related economic side of it. Three main sectors are considered in demand forecasting. They are Domestic sector, Industrial and General Purpose sector and the other sector (Religious Purpose and Street Lighting). Forecasting for the other sector is based on past demands. But in domestic sector and Industrial and General Purpose sector some other independent variables are considered. The data necessary for forecasting are taken from Central Bank, Department of Census and Statistics and statistical unit of CEB. Those variables are Gross domestic production per capita, past demand, Average electricity price, Gross domestic production, Number of consumer accounts, previous year GDP.

2.2.6.4 Load Forecast scenarios

Forecast with demand side management. Low load forecast. (Low population and low GDP growth; -1.2%) Base Load forecast. High load forecast. (High population and low GDP growth; +1%)

2.2.6.5 WASP Package The software used in the generation planning branch is WASP (Wien Automatic System Planning)-IV. It is internationally recognized software, distributed in over eighty countries and fifteen international agencies.
33 | P a g e

2.2.7 Transmission Planning 2.2.7.1. Introduction

In Sri Lanka majority of the power stations are located in remote places with respect to Colombo and other load centers. Therefore the energy generated must be transmitted to a long distant in an optimum way. The energy loss should be very low, and the voltage and the frequency of the receiving end must not approach the undesired values. Stability and the reliability are also very important in a transmission system. Presently in Sri Lanka 132 kV and 220 kV transmission lines are used. The transmission planning branch is responsible for planning and developing this transmission system. The planning horizon of the transmission plan is 10 years.

2.2.7.2. Objectives of Transmission Planning Finding out the transmission developments required to ensure reliable and stable power system for the period of consideration and the planned implementation dates. Estimating the investment cost for these transmission developments.

2.2.7.3. The Importance of Transmission Planning Transmission planning is important basically in following situations. The components of the existing transmission system are expected to be expired in recent future. Connecting of a new power source to the system. Connecting of a new huge load to the system. To face the fault conditions in a better manner. To make the system more stable and reliable. To face the situations where the existing transmission system is expected to be incapable of maintaining the desired voltage levels at the relevant points.

34 | P a g e

2.2.7.4. Planning Criteria To ensure quality and reliable supply under normal operation and under contingencies following criteria are considered. 2.2.7.5. Voltage Criteria Voltage Criteria defines the permitted voltage deviation at any live bus bar. Table 2.6 Voltage Criteria Allowable Voltage Variation. (%) Bus Bar Voltage. Normal. 5 10 Single Contingency. -10 to +5 10

220 kV 132 kV

Single Contingency - Outage of any one element of the system. Double Contingency Condition - Simultaneous outages on two generator units, two transformer units, two transmission lines or a combination of them. 2.2.7.6. Thermal Criteria

The transmission network should not overheat due to overloading at steady state conditions. The following steps are taken to maintain the network according to the criteria. Enhance the grid substation capacities and construct new grid substations Excess loads are transferred to adjacent grid substations, but those grid substations must be capable of withstanding new loads.

2.2.7.7. Security Criteria

In this criteria the performance of the system under contingency conditions are considered. At such situations the system must be able to withstand it without violating the voltage criteria.

35 | P a g e

2.2.7.8. Stability Criteria Stability criteria considers about the system stability during and after a system disturbance. Transmission system should be able to withstand in following situations. Three phase fault at any one overhead line terminal Loss of any one generator unit, load rejection by loss of any transformer

2.2.7.9. Short Circuit Criteria This criterion defines the maximum three phase circuit currents at the bus bars of grid substations in order to protect the network. Table 2.7 Short Circuit Criteria Bus Bar Voltage. System. Overhead 132 kV and above Under ground Overhead 33 kV Under ground Under ground Maximum Three Phase Fault Level. 40.0 kA 40.0 kA 13.1 kA 16.0 kA 20.0 kA

11 kV

2.2.7.10. PSS/E Software (Power System Simulator for Engineers) PSS/E is the software is used for transmission planning. Using that software the system is analyzed for the following four situations. Then the optimum results are identified. Hydro Maximum Day Peak Thermal Maximum Day Peak Hydro Maximum Night Peak Thermal Maximum Night Peak

36 | P a g e

2.2.8

Transmission Operation & Maintenance (Anuradhapura Region)

2.2.8.1.

Introduction

I was placed at Transmission operation and maintenance branch at Anuradhapura Region. I went to seven grid substations in this time period. Therefore I got a very good chance to go around the Sri Lanka. I visited Trinco, Valchchena, Pannala, Puttalam, Habarana, Old Anuradhapura & New Anuradhapura Grid Substations. Grid substation is a place where 220 kV or 132 kV lines interconnect and step down that voltage to 33 kV for distribution. I identified all the equipment, and also the functions of those equipments. I started to develop software for Transmission Operation & Maintenance Division to improve the communication of the way leaves process. I finalized the data entry form and data base form of the way leaves software with the use of Java platform

2.2.8.2.

Grid substation

Components of Grid Substation are, 2.2.8.3. Circuit Breakers Transformers Circuit Breakers Isolators Surge Arresters Current Transformer Potential Transformers Bus bars Feeders Protection Items

Circuit Breakers can be categorized under operating voltages, quenching medium and operating mechanism.

37 | P a g e

Table 2.8 Circuit Breakers Operation voltage of Circuit Breaker (kV) 220 132 33 SF6 SF6 SF6 or oil Spring charge Pneumatic or spring charge Spring charge Quenching medium Operating mechanism

Circuit breakers are located in both line bays and transformer bays to switch on/off the feeders purposely for maintenance or any other purposes and to ensure the protection of equipment and stability of the system by the auto operation of breakers. When closing, the circuit breaker pull rod goes up and completes the contact. 132 kV circuit breaker must complete contact within 30 ms. Circuit breakers can operate manually or remotely from control room. A huge electrical arc is produced at the operation of a circuit breaker and it is quenched by the quench medium. Due to high dielectric strength SF6 is used as quench medium. The transformer oil is also used for this but its dielectric strength is lower than SF6 and need a lot of maintenance like filtering and testing of dielectric strength due to formation of carbon. The spring operation mechanism moves pull rod using motor. But in pneumatic mechanism it moves using the pressure difference. 2.2.8.4. Isolator

Isolator is a simple switch that cannot be operated when the particular line is loaded or will be loaded with the operation of the isolator, since there is no medium of quenching the arcs generated at such instant. By looking at the circuit breaker one cannot say it is open or closed. But whether the line is closed or open can be seen by looking the isolator. Isolator should be opened after switching of the relevant circuit breaker and it should be closed before the circuit is originally closed by the circuit breaker as well. 2.2.8.5. Autotransformer

A transformer that contains an auto tap changer is called an autotransformer. The distribution voltage is maintained using autotransformers at grid substation.
38 | P a g e

Auto tap changer senses the secondary voltage of the transformer via a PT and changes the tapping of the secondary coil using a diverter switch. In auto transformer 33 kV windings are called Tertiary windings and they are connected in delta to reduce third harmonic effect. This winding also can be used to improve power factor by connecting capacitor bank to windings.

2.2.8.6.

Surge arrestors

Surges are generated due to lighting and switching operations. These surges damage high voltage equipments. These surges are ground by surge arrestors.

2.2.8.7.

Current Transformers

When a current is to be measured in a very high voltage circuit, an ammeter cant be connected directly to the circuit. In this case an ammeter is connected to the line through the current transformer, which steps down the high value to low value. In a CT the primary current isnt controlled by the condition of the secondary circuit. In usual practice the primary of a circuit is connected directly to one phase and the secondary is taken from the instrument. Current transformers are also used to supply current to the protection relays.

2.2.8.8.

Voltage Transformers

An instrument voltage transformer is small compared to the power transformer. Its used to connect the voltmeter for metering purposes. For voltages above 110 kV capacitor voltage transformers are used since electromagnetic type is very expensive.

2.2.8.9.

Protection

Another essential thing we came to know in Substation is Protection. We leant different protection schemes. Transformer Protection Bus bar Protection

39 | P a g e

2.2.8.9.1.

Transformer Protection

The transformer faults can be categorized as, Winding and terminal faults Sustained or unclear external faults Abnormal operating conditions such as over load, over voltage and over fluxing Core faults

The following relays are used in transformer protection scheme. Over current, Directional over current relays Earth fault, restricted EF, Standby EF relays Differential relay Over fluxing relay Winding/oil Temperature relays Buchholz relay

2.2.8.9.2.

Bus bar Protection

The standards construction for bus bars has been very high, with the result that bus faults are extremely rare. Most common bus bar protection schemes are, Differential protection Fault bus protection

40 | P a g e