STANDARD OPERATING PROCEDURE

For
Plant Electrical System

ESSAR POWER (Orissa) LIMITED, Paradeep

Prepared by Reviewed by Approved by

Mahadev Kovalli,
Name Manoranjan Pradhan
Designation Dy.Manager
Signature
Date

The effective implementation of procedures as per this Manual is responsibility of all

employees. While all due care has been exercised in preparing this Manual, however these
must not to be considered complete in all respect and additional safety measures as may
be required in different situations must be complied with.
 STANDARD OPERATING Format No.
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Revision No.
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Topics
Section Pages
Plant Electrical System
11 415 V Breaker Operating Procedure
11.01 415 V ACB Breaker Operating Procedure
11.02 Plant PMCC/MCC(USS-1&2, SSS-1&2,TGMCC-1&2)
11.03 NEDB
11.04 EDG(Emergency Diesel Generator)
12 6.6 KV Breaker Operation Procedures
12.01 Station Switch Board
12.02 Unit Switch Board 1A
12.03 Unit Switch Board 1B
12.04 Unit Switch Board 2A
12.05 Unit Switch Board 2B
12.06 CHP Switch Board
AC Generator or Synchronous Generator Operation
13 Procedure
13.01 AC Generator Fundamental and Protection's
13.02 AC Generator Excitation System
AC Generator Synchronization and Emergency
13.03 Handling Operation
14 Power Transformer Operation Procedures
14.01 Station Transformer 20MVA
14.02 Generating Transformer 40MVA
14.03 Power Transformer Cooling System
14.04 Power Transformer Protection System
15 220KV Switchyard Operation Procedures
15.01 Switchyard Equipment Details
15.02 GT-1 Transformer Line Breaker
15.03 GT-2 Transformer Line Breaker
15.04 ST-1 Transformer Line Breaker
15.05 CPP Out Going or PP bay Breaker
15.06 Line and Bus Isolators
15.07 220KV Bus-Coupler Breaker

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16 Plant DC System
16.01 220V Station Battery(1500Ah) System and Charger
16.02 220V Unit Battery(300Ah) System and Charger
16.03 UPS battery(500Ah) System and Charger
16.04 48V Switchyard Battery System and Charger
16.05 CHP Battery System Charger
17 Plant UPS startup and shutdown procedure
17.01 105KVA UPS system
17.02 Switchyard UPS system
17.03 CHP UPS system
17.04 DM Plant UPS system
19 Plant HVAC system
20 Plant Illumination System

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1.0 OBJECTIVE

To lay down the procedure for safe operation of man and property of Electrical
systems such as Transformers, Switchgears and to minimize the power
generation downtime.

LT Voltage Level- Up to 1.1KV

HT Voltage Level- Above 1.1KV and not exceeding the 33KV
EHT voltage Level- Above 33KV and up to 220KV

(As per IEC 60038:1983)

2.0 SCOPE

This SOP shall be applicable for all LT, HT and EHT electrical systems.

3.0 RESPONSIABILITY
3.1 Technician’s
3.2 Shift Engineer’s
3.3 Executive’s

4.0 ACOUNTABILITY
4.1 HOD Operation
4.2 Shift In charge

5.0 Electrical Terminology and Definitions

5.1 Synchronous Generator – It is a purely electrical device, it convert

the mechanical power from prime mover into an electrical AC power at a
particular voltage and frequency and it works on the principle of
“Faraday’s Laws of Electromagnetic Induction”.

5.2 Transformers – It is a purely electrical static device, it only transfer

the electrical energy from one circuit to the another circuit without change
in frequency through the process of electromagnetic induction. It most
commonly used for the change the voltage from higher level to the lower
level and vice-versa and it works on the principle of “Mutual Induction”.

5.3 UPS – An Uninterrupted Power Supply (UPS), it is a piece of electrical

equipment which can be used as an immediate power source to the
connected load when there is any failure in the main input supply.

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5.4 Battery – It is an electrical device that produces electrons through

electrochemical reactions, and it contains the one positive (+) and one
negative (-) terminals. A battery consists of one or more number of
electrochemical cells, which can transform stored chemical energy directly
into the electrical energy. The capacity of battery is measured in Ampere
Hours (AH).

5.5 Relay – A relay is automatic device which senses an abnormal

condition in electrical circuit, it closes the contacts and complete the
circuit breaker trip coil circuit hence makes the circuit breaker tripped for
disconnecting faulty portion of the electrical circuit from rest of the
healthy circuit.

5.6 Current Transformer – A current transformer (CT), it is an electrical

quantity measuring device to use the measure of current flow in the load
circuit.

5.7 Potential Transformer – A potential transformer (PT), it is an

electrical quantity measuring device to use the measure of the voltage or
electric potential difference in the electrical circuit.

5.8 EMVT – An Electromagnetic Voltage Transformer (EMVT), it is a type

of voltage transformer with a higher accuracy class and it is using for
metering and protection purpose.

5.9 CVT – A Capacitive Voltage Transformer, it is a type of voltage

transformer with a lower accuracy class comparatively EMVT. It is using
for Voltage measurement and protection purpose.

5.10 Circuit Breaker – An electrical circuit breaker is a switching device

which can be operated manually and automatically during the charging of
circuit for controlling and protecting an electrical power system.

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5.11 Isolators – An isolator is a manually operated mechanical switching
device which separates a parts of the electrical power systems. Isolators
are used to open a circuit during no load condition.

5.12 Bay – A bay in an electrical system it consists of a switching devices

are called Circuit Breakers, Isolators, current carrying conductor and
measuring devices for particular circuit.

5.13 KIOSK – It is a small house placed in outdoor area for protecting the
electrical and electronic devices from Sun light, Dust, and Rain also
maintain the constant room temperature by providing the Air Conditioner.
Intelligent Electronic Devices (IED) are using for continuous monitoring
and controlling the electrical parameters.

5.14 BCU – Bay Control Unit, it is a preprogrammed electronic device

consist of input and output terminals for SCADA system, for particular bay
to which continuous monitoring and controlling the electrical parameters.

5.15 SCADA – Supervisory Control and Data Acquisition (SCADA) is one of

the graphical user interface which remotely controls the operation of
switching devices such as CB’s, Isolators and Earth switches.

5.16 Switchyard – The switchyard consists of a electrical switching devices

are called a Circuit Breakers, Bus-coupler, Isolators, current carrying
conductor and measuring devices. The purpose of switchyard is to protect
the costly equipment’s like Power Transformers, Alternators and its
auxiliaries during abnormal condition.

5.17 Active Power – The power which is actually consumed or utilized in

an AC circuit is known as True Power or Active Power or Real Power. It is
measured in KW or MW.

5.18 Reactive Power – The power which flows back and forth that mean it
moves in both the direction in the circuit or react upon itself, is called the
reactive power or useless power. It is measured in KVAR or MVAR.

5.19 Apparent Power – The product of root mean square (RMS) value of
voltage and current in a circuit is known as apparent power. It is
measured in KVA or MVA.

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5.20 Power Factor – It is the ratio of the Active Power to the Apparent
Power is known as Power factor (cosФ). It has a unit less quantity and it
is totally depends upon the connected load.

5.21 Voltage – Voltage is the potential difference in electric potential

energy per unit charge between the two points in a circuit. It is measured
in Volts or Kilo Volts.

5.22 Current – Current is the flow of electrons in a circuit. It measured in

Ampere or Kilo Ampere.

5.23 Frequency – Frequency is defined as the number of cycles per second

completed in a given time period. It is measured in Hertz.

5.24 Insulator – Insulator is a very high resistive path through which

practically no current can flow. Porcelain suspension disc insulator are
used in substation, it’s having good dielectric strength (60KV/cm) as well
tensile strength (500Kg/sqr.Cm).

5.25 Conductor – Conductor means which is path between the source to

the connected load and it’s carries the desired current and voltage. ACSR
(Aluminum Core Steel Reinforced) moose conductor are used in
substation.

5.26 Earthing – The Earthing means the connection of non-current carrying

part of the equipment to the earth. Earth is conventionally considered as
a zero potential.

5.27 Grounding – In grounding, the current carrying parts are directly

connected to the ground. The grounding provides the return path for the
leakage current and hence protect the power system equipment form
damage.

5.28 BDV – Break down Voltage, it is the minimum voltage at which

transformer oil losses the insulating property and gives the sufficient
spark between conductor and insulating oil. The minimum value of
transformer oil BDV is 60KV. BDV is test to conduct once in every three
months or it depends upon the loading pattern of the transformer.

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5.29 Buchholz Relay – Buchholz relay is a safety device which is generally
used in oil immersed transformer rated above 5MVA. This relay is
provided between the main oil tank and conservator tank. It gives the
6protection against the internal faults such as core insulation failure,
turns insulation failure etc.

11. 415 V volt breaker operating procedures

11.1 This SOP is applicable for all PMCC/MCC, NEDB, ACDB and
EDG of LT breaker system.
11.2 Here we are using the ABCB (Air Blast circuit Breaker).
11.3 Ensure the all the wiring of breaker control and outgoing cables
connections are made properly.
11.4 Read the instruction manual which is provided by OEM for smooth
operation and maintenance of breakers.
11.5 Ensure the breaker should be tested and commissioned properly by
electrical skilled persons, keep the test report for future use.
11.6 Ensure the availability of AC and DC control supply for breaker.
11.7 Ensure the breaker panel should be grounded properly.
11.8 Ensure the remote and local operation of breaker prior to the
loading.
11.9 Check the AUTO mode operation of breaker.
11.10 Ensure the breaker housing is in clean and good condition, no arc
flashing marks.
11.11 Ensure the breaker spring charging is happening manually and
automatically.
11.12 Ensure the all indications are showing on breaker panel, such as all
three phase supply, breaker position, spring charge, trip circuit
healthy, synchro check, auto trip alarm, DC control supply healthy
etc.
11.13 Ensure the Breaker housing doors are in closed condition.
11.14 Ensure the all maintenance work is completed and work permit is
closed by electrical dept. prior to the taking in service.
11.15 Ensure you are standing on an insulating rubber mat while doing
visual inspection of breaker.
11.16 Operation for closing air circuit breaker

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11.17 Ensure the breaker in proper position inside the panel.
11.18 Ensure the trip circuit healthy indication appears on the panel.
11.19 Check the incoming voltage between the all three phases should be
415 volts to 430 volts showing in voltmeter.
11.20 Ensue the spring is in charge condition, if not then charge manually
by the TO and FRO movement (8 to 10 strokes) of the handle
provided on the breaker or it should be done automatically with the
help of motor. It takes the time for spring charge less than 10sec.
11.21 Ensure the spring is charged by yellow indication appears on
breaker.
11.22 Reset the all alarms appears in relay.
11.23 Close the breaker by help of TNC (Trip Neutral Close) switch turning
towards right side or by pressing the green button.
11.24 Procedure for breaker Isolation
11.25 Ensure breaker is not in service.
11.26 Control supply to be made “OFF”.
11.27 Release the interlock key.
11.28 Discharge the spring through press the TRIP button.
11.29 Remove the breaker horizontally by rotating the handle slowly and
observe the tightness or abnormal sound, if found stop the removal
process immediate and inform to the EMD. Don’t try to isolate
forcibly. This process can be done by manually only.
11.30 It must be tagged as “DON’T OPERATE”.
11.31 Procedure for Breaker Restoration
11.32 Ensure the maintenance job completion and work permit to be
closed and it counter signed by SIC.
11.33 Place the breaker horizontally by rotating the handle slowly and
observe the freeness and abnormal sounds.
11.34 Ensure breaker is placed properly.
11.35 Control supply made “ON”.
11.36 Ensure all the indications are showing on breaker panel is normal.
11.37 Ensure the spring is in charged condition.
11.38 Ensure the input power supply is available.
11.39 Remove “DON’T OPERATE” tag.
11.40 Inform to the CCR engineer is breaker is ready for service.

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11.41 Change-Over procedure for LT Breaker

11.41.1 415V BUS-COUPLER CLOSING AND INCOMER-1A BREAKER OPENING

Initial Checks for Bus-Coupler closing (415V)

a) Check the B/C is in service position and spring is in charged condition.

b) Check for lock out or any other relay operated.
c) Local/Remote selection should made a Local Position.
d) Auto/Manual should be in Auto Mode.
e) No lock out or fuse failure relay picked up on any of the two incomers.
f) Both the incomer should be in service and ON position (No under
voltage relay should be picked up condition).
g) Ensure that all the critical drives are available on the incomer, which
will remain in service.

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Procedure for closing the Bus-Coupler

h) Put Auto/Manual switch of B/C on Manual selection.

i) Ensure Auto/manual switch of incomer-1A is in Auto.
j) Put Trip selector switch of Bus coupler towards the Incomer-1A which
is to be taken out of service.
k) Put ON the Synch selector switch and SKE RELAY starts
synchronization between I/C-1A and I/C-1B voltages.
l) As soon as the two voltages are synchronized, relay SKE RELAY gives
a close permissive command.
m) Close Bus coupler from TNC switch.
n) The Closed condition of all the three Breakers is sensed by the relay
SKE RELAY which operates the output after set time delay. This
output will issue a trip command to the INCOMER-1A Breaker.

Post Change over Steps

o) Put OFF Sync Selector Switch at B/C.

p) Put Auto/ Manual Switch at Bus Coupler to Auto mode.
q) Put Trip Selector Switch at Incomer-1A.
r) Reset the timer relay.

11.41.2 INCOMER-1 BREAKER CLOSING & 415 V BUS COUPLAR OPENING.

Initial Checks for Restoration of Incomer-1A

a) Ensure Incomer-1A breaker, which has to be put ON is in service

position and spring charged condition.
b) Auto/ Manual Switch of Incomer breaker is in Auto mode.
c) The 6.6 KV upstream breaker should be in ON and service condition.
d) Ensure that the lockout relay of the 415 v downstream breaker of
incomer has not operated (no under voltage relay should be in picked
up).

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Procedure for closing Incomer-1A

e) Put Auto/manual switch of Bus coupler in Auto.

f) Ensure Auto/manual switch of Incomer-1 is in Manual.
g) Put Trip selector switch of Bus coupler towards the BUS COUPLER
which is to be taken out of service.
h) Put ON the Synch selector switch and SKE RELAY starts
synchronization between Incomer-1A and Bus voltages.
i) As soon as the two voltages are synchronized, relay SKE RELAY gives
a close permissive command.
j) Close Incomer-1A Breaker through TNC switch.
k) The Closed condition of all the three Breakers is sensed by the relay
SKE RELAY which operates the output after set time delay. This output
will issue a trip command to the BUS-COUPLER.

Post Changeover Steps

l) Put OFF Sync Selector Switch.

m) Make Auto/manual switch of Incomer-1 in AUTO.
n) Put Trip Selector Switch at B/C in Bus-coupler.
o) Reset the timer relay.

Note: Above Procedure is applicable for all PMCC, BMCC, ESPMCC,

CTMCC, CHPMCC, DMPMCC, FWMCC and TGMCC for LT feeders.

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12. 6.6KV Breaker (VCB) Operating Procedure

12.1 This SOP is applicable for all vacuum circuit breaker system.
12.2 Here we are using the VCB (Vacuum Circuit Breaker).
12.3 Ensure the all the wiring of breaker control and outgoing cables,
Bus Bars connections are made properly.
12.4 Read the instruction manual which is provided by OEM for smooth
operation and maintenance of breakers.
12.5 Ensure the breaker should be tested and commissioned properly by
electrical skilled persons, keep the test report for future use.
12.6 Ensure the availability of AC and DC control supply for breaker.
12.7 Ensure the breaker panel should be grounded properly.
12.8 Ensure the remote and local operation of breaker prior to the
loading.
12.9 Check the AUTO mode operation of breaker.
12.10 Ensure the breaker housing is in clean and good condition, no arc
flashing marks.
12.11 Ensure the breaker spring charging is happening manually and
automatically.
12.12 Ensure the all indications are showing on breaker panel, such as all
three phase supply, breaker position, spring charge, trip circuit
healthy, synchro check, auto trip alarm, DC control supply healthy,
Service position, Test Position etc.
12.13 Ensure the Breaker housing doors are in closed condition.
12.14 Ensure the all maintenance work is completed and work permit is
closed by electrical dept. prior to the taking in service.
12.15 Ensure you are standing on an insulating rubber mat while doing
visual inspection of breaker.
12.16 VCB Door Opening sequence
12.17 Ensure the VCB is OFF or Open condition.
12.18 Door is in closed position with the padlocking arrangement.
12.19 For Door padlocked to be removed, latch to be opened.
12.20 Door Handle shall be lifted upwards and Door shall be opened.
12.21 VCB Door Closing Sequence
12.22 Ensure the wheel bracket plates are at closed condition.

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12.23 Lift the VCB door handles, hold it in same position and swing the
door towards panel.
12.24 Once the door flushing with the panel, push the VCB door handles
downward and latch the padlock.
12.25 VCB Rack-IN & Rack-Out Operation Procedure- Closed
Door

12.26 Procedure for Closing the Breaker

12.27 Ensure the breaker in proper position inside the panel.
12.28 Ensure the trip circuit healthy indication appears on the panel.
12.29 Check the incoming voltage between the all three phases should be
6.6KV voltage showing in MiCom relay.
12.30 Ensue the spring is in charge condition, if not then charge manually
by rotating the racking handle slowly or it should be done
automatically with the help of mechanism. It takes the time for
spring charge less than 8-10sec.
12.31 Reset the all alarms appears in MiCom relay.
12.32 Reset the K86 master relay.
12.33 Close the breaker by help of TNC (Trip Neutral Close) switch turning
towards right side or by pressing the green button.

Note: - The procedure is applicable for all HT breaker.

13 Alternator Or Synchronous Generator Protection

Generator protections are given to protect the generator from

faulty condition. The following protections relays are provided in
STG,
13.1 Reverse Power Relay (32)
This is highly sensitive power relay, consisting of an instantaneous
power directional element which operates on the in phase component
of current plus a separate A.C. operated adjustable time delay
element. This is mainly provided to prevent generator from motoring
in case of prime mover failure.

13.2 Negative sequence time over current relay (46)

This relay is intended to protect generator against possible damage
from unbalanced phase current resulting from prolonged faults or

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unbalanced load conditions. Under such conditions stator current
includes (–ve) sequence components that sets up counter rotating
field in the machine. This causes double frequency current to flow in
the rotor iron and slot wedges, which results in local heating of the
core.

13.3 Generator Differential Protection relay (87G)

This is high speed differential protection to protect against phase to
phase and phase to ground fault in generator. There are two types of
relay i.e., Voltage Balance Relay, Current Balance Relay. This relay
functions on difference between the current entering one end of a
winding and that leaving the other end. This relay works on the principle
of KCL, during normal operation the circulating current in the relay point
is Zero. This relay gives the indication of internal faults of the generator.

13.4 Over All Differential Relay (87T)

This is percentage and harmonic restraint transformer differential
protection relay used to provide overall protection for transformer and
alternators, UAT as a unit. Percentage restraint provides accurate
discrimination between internal and external faults at high current,
whereas harmonic restraint provides discrimination between the
differential currents caused by an internal fault and that caused by
transformer magnetizing inrush.

13.5 Loss of Excitation relay (40)

On loss of excitation synchronous generator will tend to act as induction
generator- receiving excitation from the Grid. Loss of excitation can be
damaging to the machine. This protection sees impedance looking into
the generator and its value depending upon the machine characteristic,
the load flow to the loss of excitation and the type of excitation failure.
In this condition the generator draws magnetizing current from the
system, it leads to stator over loading and for long run stator core gets
overheated it may cause the failure of machine. Another name of this
protection is Los of field.

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13.6 Impedance Relay

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