Training Report 6th Sem. E.E. B.tech.

A GLOBAL BASE IN INDIA
MCC PTA India Corp. Private limited

Growing together beyond Chemistry
Report on Summer Training at MCC PTA India Corp. Private Limited in

Electrical Department from 1-06-2011 to 8-07-2011
Contents
Topics
PAGE NO
MCPI at a Glance ...................................................................................................................... 1
Electrical Departments Activity........................................................................................... 3

Industrial and Electrical Safety............................................................................................. 6
Schematic Diagram ............................................................................................................... 13
Induction Motor ...................................................................................................................... 17
Transformer ............................................................................................................................. 25
Switchgear ............................................................................................................................... 36
Diesel Generator ..................................................................................................................... 45
Energy Conservation ............................................................................................................. 46
Corrosion and Cathodic Protection ................................................................................... 49
5S & Mitsubishi ..................................................................................................................... 52
Crane ........................................................................................................................................ 55
Paging ....................................................................................................................................... 58
Conclusion ............................................................................................................................... 59
ACKNOWLEDGEMENT
It is great pleasure to me as, a future engineer, to get an opportunity to
communicate and interact with an industry during my training schedule at
Mitsubishi Chemical Corporation , Haldia.
First we would like to thank Dr. Prithwiraj Purkait(Head of the Department
of Electrical Engineering) and Mr. Jalal khan(Assistant Training & Placement
Officer)for helping me to arrange this training at MCPI , Haldia.
I sincerely thank Mr. Saptarshi Dutta(H.R) for allowing me at Mitsubishi
Chemical Corporation , Haldia as a summer trainee.
I am specially grateful to Mr. Swarup Roy (HOD,EE,MCPI) & the full
electrical department of MCPI for extending their kind cooperation to me and for
all their technical advice, valuable guidance and timely encouragement in making
this project work.
A special thanks to field members and all the operators for help and
guidance they provide. It was indeed a wonderful experience to visit one of the
most modernized industry in India.
Arnab Sen
CORPORATE PRINCIPLE
To contribute to the economy and society of India through its business activities,
establishing the interrelationship among people, society and nature.
KEY OBJECTIVES
To contribute to the development of Indian Polyester Industry with stable supplies of

the main raw material, PTA.
To contribute to the development of the industries of Haldia and West Bengal with the
help of the most modern technology and large-scale operation.
To be a strong PTA manufacturer in South Asia with the advanced competitive
technology of Mitsubishi Chemical Corporation as an important part of its global
PTA operation.
INVESTMENT HIGHLIGHTS
It is the largest Foreign Direct Investment (FDI) in the manufacturing sector in India.
Mitsubishi Chemical Corporation (MCC) is among the top 10 Chemical Companies of
the world. It has operations in 50 countries and leads about 282 affiliate companies.
Purified Terephthalic Acid (PTA), the raw material for various polyester products, is
one of the core businesses of MCC.
UTILITIES & OFF SITES

Area of Lands:
o Factory
o Housing Complex - 1
o Housing Complex - 2
: 324 acres
: 25 acres
: 6.22 acres
Power:
o (Captive) 14 MW [D.P.]
o 22 MW [H.P.]
(5 X 5 MW DEG sets)
(4 X 6 MW DEG sets)
Water:
o (Received from H.D.A.): 3.6 MGD [D.P]
o 8.5 MGD [H.P.]
MCPI AT A GLANCE
MCPI Phase I [DP]
PRODUCT
: PTA (Purified Terephthalic Acid)
INSTALLED CAPACITY
PRESENT CAPACITY
TECHNOLOGY
TOTAL INVESTMENT
TURNOVER
MAIN RAW MATERIAL
: 350,000 MT/Annum
: 470,000 MT/Annum
: MCC, Japan
: US$ 350 million / Rs. 1,475 Crores
: US$ 440 million / Rs. 1,956 Crores in 2010-2011
: Paraxylene, Acetic Acid (Solvent)
CONSTRUCTION PERIOD
COMMERCIAL OPERATION
: 27 Months, Sept 97 to Dec 99

: From April 2000
MCPI Phase II [HP]

PRODUCT
INSTALLED CAPACITY
PRESENT CAPACITY
TECHNOLOGY
TOTAL INVESTMENT
TURNOVER
: PTA (Purified Terephthalic Acid)

: 800,000 MT/Annum (1 Line)
: 520,000 per annum (1Line)
: MCC Cutting-edge Proprietary Technology
: US$ 370 Million/ Rs. 1,962 Crores
: US$ 351 million / Rs. 1,562 Crores in 2010-2011
MAIN RAW MATERIAL

CONSTRUCTION PERIOD
COMMERCIAL OPERATION
: Paraxylene, Acetic Acid (Solvent)

: 38 months, Feb2006 to Mar 2009
: From March 201
PLANT HIGHLIGHTS
The Plant has state-of-the-art technology developed in-house by MCC.
The Technology has proven reliability of process design, stability of operations and
economic performance in terms of consumption of utilities.
MCPI IS AN ISO 9001:2008, ISO 14001:2004, and OHSAS 18001:2007 Company.
It has set new benchmarks in all parameters of operation like health, safety,
environment, quality and efficiency in production.
Electrical departments activity

ELECTRICAL DEPARTMENTS ACTIVITIES
MAINTENANCE
ACTIVITIES
WRITTEN / VERBAL REQUEST

FOR NEW INSTALLATION / NEW
JOB / MODIFICATION JOB
ENGINEERING
AND
CALCULATIONS
RECORDED
BREAKDOWN
MAINTENANCE
CORRECTIVE
MAINTENANCE
ENGINEERING
RAISING PURCHASE
REQUEST and / or
REQUEST FOR
QUOTATION
REGULAR
PREVENTIVE &
PLANNED
MAINTENANCE
ANNUAL
SHUTDOWN
MAINTENANCE
List of main equipment under maintenance
STATUTORY
PROCUREMENT OF
SPARE PARTS AS PER
REQUIREMENT
Deg with control panel

Motor (LV & HV)
Motor control centre
Cranes
Transformers
Cathodic protection for pipeline
ESP
Fire engine and Fire alarm
VVVF
Air conditioner
Paging
Illumination System(plant,SHATAKU & H.O)
COMPLYING ANY
STATUTORY
REGULATIONS.
REFERRED TO
PROCUREMENT
MANUAL
Jobs of Electrical Department
Planning
Trouble and improvement activities
SDM planning
SDM modification job
Periodical Work based on Cycle
Daily Scheduled Jobs
Monthly Scheduled Jobs
Daily Scheduled Job
Motor Greasing daily
Motor Patrolling daily
Substation Patrolling daily
Transformer Patrolling daily
Monthly Scheduled Jobs
Cathodic Protection-by monthly (inside water/outside PX)
Battery Maintenance-by monthly(B/S / DEG / Fire water system)
Fire Engine Panel Maintenance-by monthly
EOT Crane Checking-monthly
Vibration Measurement of Critical equipments-monthly. Trend maintained in excel

file
Air Conditioner Maintenance-monthly (500 nos.)
Yearly Scheduled Jobs
Fire Alarm System-2 years
EOT Crane Overhaul-yearly
CM/BCM Oil Checking-half yearly
DEG Alternator Maintenance-yearly
Testing of Trans oil-yearly
Load Test of Lifting Tool-yearly
Earth Pit and Earth Resistance and Equipment and Motor Earthing-yearly
Tank Earth Continuity-half yearly
Calibration Check of Measuring Instruments-yearly
Shataku 1 & 2 Panel Maintenance-yearly
Motor
All HV motors and LV motors>15kw: as per OH schedule
All motors<15kw:as per condition monitored during daily patrolling
Cyclo (CM) & Bier Cyclo(BCM) motors
Motors Diagnostic Test (HV motors)-3 years
C-1711 main compressor
Periodical work based Middle & Long term range
HV switchgear, VCB & VCS
LV switchgear ,ACB and Motor Control Centre(MCC)
Transformer
Control and Protection Panels, Electrical Protection Relays
ESP
DC-UPS system and Battery Bank
Replacement of electric components, electrolytic capacitors, relays etc
DEG Electronic Governor
Air Conditioner Maintenance-monthly (500 nos.)
Tips on Industrial and Electrical Safety

Electricity is one of the biggest dangers in the workplace, especially if a person is an
electrician or works around electrical equipment. By keeping safety in mind, workers can
keep themselves safe from most common electrical hazards found in the workplace and at
home.
Electrical Hazards
Electricity is a hazard, regardless of the workplace. According to the OSHA Electrical
Safety manual, however, there are three big safety hazards when it comes to electricity in the
workplace. These hazards are: unsafe equipment or installation, an unsafe environment or
unsafe work practices. Flaws in equipment could be wires or "live" parts of a machine being
exposed to workers. A hazard in the work environment could be spilled water. Dangerous
work practices could be working without protective equipment being worn.
Grounding
Mentioned in the OSHA manual in part 1910.305, subpart S, Wiring Design, grounding is
one of the major tools for electrical safety. Grounding is when a low-resistance path is
purposefully created so electrical charges will flow out of the work area. This means that any
built-up electrical charges are initially pulled away from the work area, and that any charges
built up while work is going on will likewise be pulled away where they won't cause any
harm. Often grounding is built in as a permanent part of an electrical system.
Procedures
Tagging out electrical boxes and equipment is a major safety precaution that should be
followed. Tagging out refers to locking circuit breakers or other start-up panels closed and
attaching hazard tags to them so no one accidentally throws the wrong switch. Also according
to the OSHA manual, section 1910 sections 1910.331 through 1910.335 details other safety
procedures as well. These include: de-energizing equipment before maintenance, properly
maintaining any electrical tools, exercising proper caution when near live electrical lines and
wearing proper safety equipment for every job.
Fuses
Before removing any fuse from a circuit, be sure the switch for the circuit is open or
disconnected. When removing fuses, use an approved fuse puller and break contact on the hot
side of the circuit first. When replacing the fuses, install the fuse first into the load side of the
fuse clip, then into the line side.
GFCI
Ground fault circuit interrupter (GFCI) is an electrical device which protects personnel by
detecting potentially hazardous ground faults and quickly disconnecting power from the
circuit. A potentially dangerous ground fault is any amount of current above the level that
may deliver a dangerous shock. Any current over 8 mA is considered potentially dangerous
depending on the path the current takes, the amount of time exposed to the shock, and the
physical
condition
of
the
person
receiving
the
shock.
Therefore, GFCls are required in such places as dwellings, hotels, motels, construction
sites, marinas, receptacles near swimming pools and hot tubs, underwater lighting, fountains,
and other areas in which a person may experience a ground fault.
A GFCI compares the amount of current in the ungrounded (hot) conductor with the
amount of current in the neutral conductor. If the current in the neutral conductor becomes
less than the current in the hot conductor, a ground fault condition exists. The amount of
current that is missing is returned to the source by some path other than the intended path
(fault current). A fault current as low as 4 mA to 6 mA activates the GFCI and interrupts the
circuit. Once activated, the fault condition is cleared and the GFCI manually resets before
power may be restored to the circuit. See the Figure
GFCI protection may be installed at different locations within a circuit. Direct-wired GFCI
receptacles provide a ground fault protection at the point of installation. GFCI receptacles
may also be connected to provide GFCI protection at all other receptacles installed
downstream on the same circuit. GFCI CBs, when installed in a load centre or panel board,
provide GFCI protection and conventional circuit over current protection for all branchcircuit
components
connected
to
the
CB.
Plug-in GFCl provide ground fault protection for devices plugged into them. These plug-in
devices are often used by personnel working with power tools in an area that does not include
GFCI receptacles.
Electrical Shock
Strange as it may seem, most fatal electrical shocks happen to people who should know
better. Here are some electro-medical facts that should make you think twice before taking
chances.
It's not the voltage but the current that kills. People have been killed by 100 volts AC in the
home and with as little as 42 volts DC. The real measure of a shock's intensity lies in the
amount of current (in milli-amperes) forced through the body. Any electrical device used on a
house wiring circuit can, under certain conditions, transmit a fatal amount of current.
Currents between 100 and 200 milli-amperes (0.1 ampere and 0.2 ampere) are fatal.
Anything in the neighbourhood of 10 milli-amperes (0.01) is capable of producing painful to
severe shock. Take a look at Table AI-1.
Readings
Effects
1
Safe
Current
Values
mA
or
less Causes no sensation - not felt.
1 mA to 8 mA
Sensation of shock, not painful;

Individual can let go at will since
muscular control is not lost.
8 mA to 15 mA Painful shock; individual can let

go at will since muscular control
is
not
lost.
15 mA to 20 mA Painful shock; control of
adjacent muscles lost; victim can
not
let
go.
Unsafe
current
values
50 mA to 100 mA Ventricular fibrillation - a heart

condition that can result in death
is
possible.
100 mA to 200 mA Ventricular fibrillation occurs.
200 mA and over
Severe burns, severe muscular

contractions - so severe that
chest muscles clamp the heart
and stop it for the duration of the
shock. (This prevents ventricular
fibrillation).
As the current rises, the shock becomes more severe. Below 20 milli-amperes, breathing
becomes labored; it ceases completely even at values below 75 milli-amperes. As the current
approaches 100 milliamperes ventricular fibrillation occurs. This is an uncoordinated
twitching of the walls of the heart's ventricles. Since you don't know how much current went
through the body, it is necessary to perform artificial respiration to try to get the person
breathing again; or if the heart is not beating, cardio pulmonary resuscitation (CPR) is
necessary.
Electrical shock occurs when a person comes in contact with two conductors of a circuit or
when the body becomes part of the electrical circuit. In either case, a severe shock can cause
the heart and lungs to stop functioning. Also, severe burns may occur where current enters
and exits the body.
Prevention is the best medicine for electrical shock. Respect all voltages, have knowledge
of the principles of electricity, and follow safe work procedures. Do not take chances. All
electricians should be encouraged to take a basic course in CPR (cardiopulmonary
resuscitation) so they can aid a co-worker in emergency situations.
Always make sure portable electric tools are in safe operating condition. Make sure there is
a third wire on the plug for grounding in case of shorts. The fault current should flow through
the third wire to ground instead of through the operator's body to ground if electric power
tools are grounded and if an insulation breakdown occurs.
FIRST AID FOR ELECTRIC SHOCK:
Shock is a common occupational hazard associated with working with electricity. A person
who has stopped breathing is not necessarily dead but is in immediate danger.
However, the heart may continue to beat for some time after breathing has stopped, and the
blood may still be circulated to the body cells. Since the blood will, for a short time, contain a
small supply of oxygen, the body cells will not die immediately. For a very few minutes,
there
is
some
chance
that
the
person's
life
may
be
saved.
The process by which a person who has stopped breathing can be saved is called artificial
ventilation (respiration). The purpose of artificial respiration is to force air out of the lungs
and into the lungs, in rhythmic alternation, until natural breathing is re-established. Records
show that seven out of ten victims of electric shock were revived when artificial respiration
was started in less than three minutes. After three minutes, the chances of revival decrease
rapidly.
Artificial ventilation should be given only when the breathing has stopped. Do not give
artificial ventilation to any person who is breathing naturally. You should not assume that
an individual who is unconscious due to electrical shock has stopped breathing. To tell if
someone suffering from an electrical shock is breathing, place your hands on the person's
sides at the level of the lowest ribs. If the victim is breathing, you will usually be able to feel
movement.
Once it has been determined that breathing has stopped, the person nearest the victim
should start the artificial ventilation without delay and send others for assistance and medical
aid. The only logical, permissible delay is that required to free the victim from contact with
the electricity in the quickest, safest way. This step, while it must be taken quickly, must be
done with great care; otherwise, there may be two victims instead of one.
The injured person should be pulled free of contact with stationary equipment (such as a
bus bar) if the equipment cannot be quickly de-energized or if the survival of others relies on
the electricity and prevents immediate shutdown of the circuits. This can be done quickly and
easily by carefully applying the following procedures:
1. Protect yourself with dry insulating material.
2. Use a dry board, belt, clothing, or other available nonconductive material to free the
victim from electrical contact. Do NOT touch the victim until the source of electricity
has been removed.
Cardio Pulmonary Resuscitation (CPR)

Sometimes victims of electrical shock suffer cardiac arrest or heart stoppage as well as loss of
breathing. Artificial ventilation alone is not enough in cases where the heart has stopped. A
technique known as CPR has been developed to provide aid to a person who has stopped
breathing and suffered a cardiac arrest. Because you are working with electricity, the risk of
electrical shock is higher than in other occupations. You should, at the earliest opportunity,
take a course to learn the latest techniques used in CPR. The techniques are relatively easy to
learn and are taught in courses available through the American Red Cross.
Note: A heart that is in fibrillation cannot be restricted by closed chest cardiac massage. A
special device called a defibrillator is available in some medical facilities and ambulance
services.
Muscular contractions are so severe with 200 milli-amperes and over that the heart is
forcibly clamped during the shock. This clamping prevents the heart from going into
ventricular fibrillation, making the victim's chances for survival better.
Lockout/Tag out
Electrical power must be removed when electrical equipment is inspected, serviced, or
repaired. To ensure the safety of personnel working with the equipment, power is removed
and
the
equipment
must
be
locked
out
and
tagged
out.
A danger tag has the same importance and purpose as a lock and is used alone only when a
lock does not fit the disconnect device. The danger tag shall be attached at the disconnect
device with a tag tie or equivalent and shall have space for the worker's name, craft, and other
required information. A danger tag must withstand the elements and expected atmosphere for
as long as the tag remains in place. A lockout/tag out is used when:
Servicing electrical equipment that does not require power to be ON to perform the
service
Removing or bypassing a machine guard or other safety device
The possibility exists of being injured or caught in moving machinery
Clearing jammed equipment.
The danger exists of being injured if equipment power is turned ON.
Equipment must be locked out and tagged out before

preventive maintenance or servicing is performed.
A lockout/tag out shall not be removed by any person other than the person that installed it,
except in an emergency. In an emergency, the lockout/tag out may be removed only by
authorized personnel. The authorized personnel shall follow approved procedures. A list of
company rules and procedures are given to any person that may use a lockout/tag out. Always
remember:
Use a lockout and tag out when possible
Use a tag out when a lockout is impractical. A tag out is used alone only when a lock
does not fit the disconnect device
Use a multiple lockout when individual employee lockout of equipment is impractical
Notify all employees affected before using a lockout/tag out
Remove all power sources including primary and secondary
Measure for voltage using a voltmeter to ensure that power is OFF.
Clothing and Personal Protective Equipment:

Clothing should fit snugly to avoid danger of becoming entangled in moving machinery or
creating a tripping or stumbling hazard. See Figure 1-26.
Clothing should fit snugly to avoid danger of becoming entangled in moving machinery or
creating a tripping or stumbling hazard.
Recommended safe work clothes include:
Thick-soled work shoes for protection against sharp objects such as nails. Wear work
shoes with safety toes if the job requires. Make sure the soles are oil resistant if the
shoes are subject to oils and grease
Rubber boots for damp locations
A hat or cap. Wear an approved safety helmet (hard hat) if the job requires.
Do not wear jewellery. Gold and silver are excellent conductors of electricity.
FIRE SAFETY:
The chance of fire is greatly decreased by good housekeeping. Keep rags containing oil,
gasoline, alcohol, shellac, paint, varnish, or lacquer in a covered metal container. Keep debris
in a designated area away from the building. In MCPI at every office there are fire & smoke
detector. Sound an alarm if a fire occurs. Alert all workers on the job and then call the fire
department. After calling the fire department, make a reasonable effort to contain the fire.
Fire Extinguishers:
Always read instructions before using a fire extinguisher. Always use the correct fire
extinguisher for the class of fire. See Figure 1-27. Fire extinguishers are normally red. Fire
extinguishers may be located on a red background so they can be easily located.
Always use the correct fire

Extinguisher for the class of fire.
Be ready to direct fire fighters to the fire. Inform them of any special problems or
conditions that exist, such as downed electrical wires or leaks in gas lines.
Report any accumulations of rubbish or unsafe conditions that could be fire hazards. Also,
if a portable tool bin is used on the job, a good practice is to store a C02 extinguisher in it.
In-Plant Training:
A select group of personnel (if not all personnel) should be acquainted with all extinguisher
types and sizes available in a plant or work area. Training should include a tour of the facility
indicating special fire hazard operations.
In addition, it is helpful to periodically practice a dry run, discharging each type of
extinguisher. Such practice is essential in learning how to activate each type, knowing the
discharge ranges, realizing which types are affected by winds and drafts, familiarizing oneself
with discharge duration, and learning of any precautions to take as noted on the nameplate.
Extinguisher Maintenance Tips:
Inspect extinguishers at least once a month. It is common to find units that are missing,
damaged, or used. Consider contracting for such a service. Contract for annual maintenance
with a qualified service agency. Never attempt to make repairs to extinguishers. This is the
chief cause of dangerous shell ruptures.
Hazardous Locations:
The use of electrical equipment in areas where explosion hazards are present can lead to an
explosion and fire. This danger exists in the form of escaped flammable gases such as
naphtha, benzene, propane, and others. Coal, grain, and other dust suspended in air can also
cause an explosion. Article 500 of The Electrical Code National covers hazardous locations.
Any hazardous location requires the maximum in safety and adherence to local, state, and
federal guidelines and laws, as well as in-plant safety rules. Hazardous locations are indicated
by Class Division and Group Division.
To sum it all up...

Working with electricity can be dangerous. However, electricity can be safe if properly
respected.
So be careful out there!
Schematic diagram
A schematic diagram or layout represents the elements of a system using abstract, graphic
symbols rather than realistic pictures. A schematic usually omits all details that are not
relevant to the information the schematic is intended to convey, and may add unrealistic
elements that aid comprehension. In the schematic diagram, the symbolic elements are
arranged to be more easily interpreted by the viewer.
Electrical and electronic industry

In the electrical industry, a schematic diagram is often used to describe the design of
equipment. Schematic diagrams are often used for the maintenance and repair of electronic
and electromechanical systems. Original schematics were done by hand, using standardized
templates or pre-printed adhesive symbols, but today Electrical CAD software is often used.
In electric power systems design, a schematic drawing called a one-line diagram is
frequently used to represent substations, distribution systems or even whole electrical power
grids. These diagrams simplify and compress the details that would be repeated on each
phase of a three-phase system, showing only one element instead of three. Electrical
diagrams for switchgear often have common device functions designate by standard function
numbers.
Circuit Symbols
Circuit symbols are used in circuit diagrams which show how a circuit is connected
together. The actual layout of the components is usually quite different from the circuit
diagram. To build a circuit you need a different diagram showing the layout of the parts on
strip board or printed circuit board.
Wires and connections

Component
Circuit Symbol
Function of Component
Wire
To pass current very easily from one part of

a circuit to another.
Wires joined
A 'blob' should be drawn where wires are

connected (joined), but it is sometimes
omitted. Wires connected at 'crossroads'
should be staggered slightly to form two Tjunctions, as shown on the right.
Wires not joined
In complex diagrams it is often necessary to

draw wires crossing even though they are
not connected. I prefer the 'bridge' symbol
shown on the right because the simple
crossing on the left may be misread as a join
where you have forgotten to add a 'blob'!
Power Supplies
Component Circuit Symbol
Cell
Supplies
electrical
energy.
The larger terminal (on the left) is positive (+).
A single cell is often called a battery, but strictly a
battery is two or more cells joined together.
Battery
Supplies electrical energy. A battery is more

than
one
cell.
The larger terminal (on the left) is positive (+).
DC supply
Supplies
electrical
energy.
DC = Direct Current, always flowing in one
direction.
AC supply
Supplies
electrical
AC = Alternating Current,
changing direction.
Fuse
A safety device which will 'blow' (melt) if the

current flowing through it exceeds a specified
value.
Transformer
Two coils of wire linked by an iron core.

Transformers are used to step up (increase)
and step down (decrease) AC voltages. There
is no electrical connection between the coils.
energy.
continually
A connection to earth. For many electronic

circuits this is the 0V (zero volts) of the power
supply, but for mains electricity and some
radio circuits it really means the earth. It is
also known as ground.
Earth
(Ground)
Output Devices: Lamps, Heater, Motor, etc.

Component
Circuit Symbol
Lamp (lighting)
A transducer which converts electrical

energy to light. This symbol is used for a
lamp providing illumination, for example a
car headlamp or torch bulb.
Lamp (indicator)

energy to light. This symbol is used for a
lamp which is an indicator, for example a
warning light on a car dashboard.
Heater

energy to heat.
Motor

energy to kinetic energy (motion).
Bell

energy to sound.
Buzzer

energy to sound.
Inductor
(Coil, Solenoid)
A coil of wire which creates a magnetic

field when current passes through it. It may
have an iron core inside the coil. It can be
used as a transducer converting electrical
energy to mechanical energy by pulling on
something.
Switches
Component
Circuit Symbol
Push
Switch
(push-to-make)
A push switch allows current to flow only

when the button is pressed. This is the
switch used to operate a doorbell.
Push-to-Break
Switch
This type of push switch is normally

closed (on), it is open (off) only when the
button is pressed.
On-Off Switch
(SPST)
SPST = Single Pole, Single Throw.

An on-off switch allows current to flow
only when it is in the closed (on) position.
2-way Switch
(SPDT)
SPDT = Single Pole, Double Throw.

A 2-way changeover switch directs the
flow of current to one of two routes
according to its position. Some SPDT
switches have a central off position and
are described as 'on-off-on'.
Dual On-Off
Switch
(DPST)
DPST = Double Pole, Single Throw.

A dual on-off switch which is often used
to switch mains electricity because it can
isolate both the live and neutral
connections.
Reversing
Switch
(DPDT)
DPDT = Double Pole, Double Throw.

This switch can be wired up as a reversing
switch for a motor. Some DPDT switches
have a central off position.
An electrically operated switch, for
example a 9V battery circuit connected to
the coil can switch a 230V AC mains
circuit.
Relay
NO = Normally Open,
NC = Normally Closed.
COM = Common,
Resistors
Component
Resistor
Circuit Symbol
A resistor restricts the flow of current, for
example to limit the current passing
through an LED. A resistor is used with a
capacitor
in
a
timing
circuit.
Some publications still use the old resistor
symbol:
Variable Resistor
(Rheostat)
This type of variable resistor with 2

contacts (a rheostat) is usually used to
control
current.
Examples
include:
adjusting lamp brightness, adjusting motor
speed, and adjusting the rate of flow of
charge into a capacitor in a timing circuit.
Variable Resistor
(Potentiometer)
This type of variable resistor with 3

contacts (a potentiometer) is usually used to
control voltage. It can be used like this as a
transducer converting position (angle of the
control spindle) to an electrical signal.
This type of variable resistor (a preset) is

operated with a small screwdriver or similar
tool. It is designed to be set when the circuit
is made and then left without further
adjustment. Presets are cheaper than normal
variable resistors so they are often used in
projects to reduce the cost.
Variable Resistor
(Preset)
Capacitors
Component
Circuit Symbol
Capacitor
A capacitor stores electric charge. A

capacitor is used with a resistor in a
timing circuit. It can also be used as a
filter, to block DC signals but pass AC
signals.
Capacitor,
polarised
A capacitor stores electric charge. This

type must be connected the correct way
round. A capacitor is used with a resistor
in a timing circuit. It can also be used as a
filter, to block DC signals but pass AC
signals.
Variable Capacitor
A variable capacitor is used in a radio

tuner.
Trimmer
Capacitor
This type of variable capacitor (a

trimmer) is operated with a small
screwdriver or similar tool. It is designed
to be set when the circuit is made and
then left without further adjustment.
Diodes
Component
Circuit Symbol
Diode
A device which only allows current to flow

in one direction.
LED

energy to light.
Light Emitting Diode
Zener Diode
A special diode which is used to maintain a

fixed voltage across its terminals.
Photodiode
A light-sensitive diode.
Transistors
Component
Circuit Symbol Function of Component
Transistor NPN
A transistor amplifies current. It can be used with

other components to make an amplifier or switching
circuit.
Transistor PNP
A transistor amplifies current. It can be used with

other components to make an amplifier or switching
circuit.
Phototransistor
A light-sensitive transistor.
Audio and Radio Devices
Component
Circuit Symbol
Microphone
A transducer which converts sound to electrical

energy.
Earphone
A transducer which converts electrical energy to

sound.
Loudspeaker

sound.
Piezo Transducer

sound.
Amplifier
An amplifier circuit with one input. Really it is a

block diagram symbol because it represents a
circuit rather than just one component.
(general symbol)
Aerial
(Antenna)
A device which is designed to receive or transmit

radio signals. It is also known as an antenna.
Meters and Oscilloscope
A voltmeter is used to measure voltage.
Voltmeter
The proper name for voltage is 'potential difference',

but most people prefer to say voltage!
Ammeter
An ammeter is used to measure current.
Galvanometer
A galvanometer is a very sensitive meter

which is used to measure tiny currents, usually
1mA or less.
Ohmmeter
An ohmmeter is used to measure resistance.

Most multimeters have an ohmmeter setting.
Oscilloscope
An oscilloscope is used to display the shape of

electrical signals and it can be used to measure
their voltage and time period.
Sensors (input devices)
LDR
A transducer which converts brightness (light)

to resistance (an electrical property).
LDR = Light Dependent Resistor
Thermistor
A transducer which converts temperature

(heat) to resistance (an electrical property).
Logic Gates
Logic gates process signals which represent true (1, high, +Vs, on) or false (0, low, 0V, off).
For
more
information
please
see
the
Logic Gates
page.
There are two sets of symbols: traditional and IEC (International Electrotechnical
Commission).
Gate Traditional
Type Symbol
NOT
IEC Symbol
Function of Gate
A NOT gate can only have one input.
The 'o' on the output means 'not'. The
output of a NOT gate is the inverse
(opposite) of its input, so the output is
true when the input is false. A NOT
gate is also called an inverter.
AND
An AND gate can have two or more

inputs. The output of an AND gate is
true when all its inputs are true.
NAND
A NAND gate can have two or more

inputs. The 'o' on the output means 'not'
showing that it is a Not AND gate. The
output of a NAND gate is true unless
all its inputs are true.
OR
An OR gate can have two or more

inputs. The output of an OR gate is true
when at least one of its inputs is true.
NOR
A NOR gate can have two or more

showing that it is a Not OR gate. The
output of a NOR gate is true when none
of its inputs are true.
EXOR
An EX-OR gate can only have two

inputs. The output of an EX-OR gate is
true when its inputs are different (one
true, one false).
EXNOR
An EX-NOR gate can only have two

showing that it is a Not EX-OR gate.
The output of an EX-NOR gate is true
when its inputs are the same (both true
or both false).
5S & Mitsubishi
5S is the name of a workplace organization methodology that uses a list of five Japanese
words which are Seiri, Seiton, Seiso, Seiketsu and Shitsuke. Translated into English, they all
start with the letter "S". The list describes how to organize a work space for efficiency and
effectiveness by identifying and storing the items used, maintaining the area and items, and
sustaining the new order. The decision-making process usually comes from a dialogue about
standardization which builds a clear understanding among employees of how work should be
done.
And in Mitsubishi the 5s rule is well maintained. So here the working progress is very high
and all jobs are going on comfortably through a good discipline. Applying the 5s rule, MCPI
gets another 3s, Safety, Security and satisfaction. Employee Satisfaction and engagement of
Mitsubishi company in continuous improvement activities ensures the improvements will be
sustained and improved upon.
A stepping stone to continuous Improvement

SEIRI
Sorting Out
SEITON
Systematic Arrangement
SEISO
Spick and Span
SEIKETSU :
Serene Atmosphere
SHITSUKE :
Stick to Self Discipline
Phases of 5S
There are 5 primary phases of 5S: Sorting out, Systematic arrangement or setting in order,
Spick and span or Sweeping or shining or cleanliness, Serene atmosphere or Standardizing,
Stick to self discipline or self-discipline.
Sorting out (Seiri)
Eliminate all unnecessary tools, parts, and instructions. Go through all tools, materials, and
so forth in the plant and work area. Keep only essential items and eliminate what is not
required, prioritizing things as per requirements and keeping them in easily-accessible places.
Everything else is stored or discarded.
Systematic arrangement (Seiton)
There should be a place for everything and everything should be in its place. The place for
each item should be clearly labelled or demarcated. Items should be arranged in a manner that
promotes efficient work flow, with equipment used most often being the most easily
accessible. Workers should not have to bend repetitively to access materials. Each tool, part,
supply, or piece of equipment should be kept close to where it will be used in other words,
straightening the flow path. Seiton is one of the features that distinguish 5S from
"standardized cleanup". This phase can also be referred to as Simplifying
Spick and span (Seiso)
Clean the workspace and all equipment, and keep it clean, tidy and organized. At the end
of each shift, clean the work area and be sure everything is restored to its place. This makes it
easy to know what goes where and ensures that everything is where it belongs. Spills, leaks,
and other messes also then become a visual signal for equipment or process steps that need
attention. A key point is that maintaining cleanliness should be part of the daily work not an
occasional activity initiated when things get too messy.
Serene atmosphere (Seiketsu)
Work practices should be consistent and standardized. All work stations for a particular job
should be identical. All employees doing the same job should be able to work in any station
with the same tools that are in the same location in every station. Everyone should know
exactly what his or her responsibilities are for adhering to the first 3 S's.
Stick to self discipline (Shitsuke)
Maintain and review standards. Once the previous 4 S's have been established, they
become the new way to operate. Maintain focus on this new way and do not allow a gradual
decline back to the old ways. While thinking about the new way, also be thinking about yet
better ways. When an issue arises such as a suggested improvement, a new way of working, a
new tool or a new output requirement, review the first 4 S's and make changes as appropriate.
The Origins of 5S
5S developed, as with so many of todays best practice tools, in Japan. We first heard of it
as one of the techniques that enabled what we then termed Just in Time Manufacturing. The
Massachusetts Institute of Technologys 5-year study into the future of the automobile in the
late 1980s identified that the term was inappropriate since the Japanese success was built
upon far more than components arriving only at the time of requirement.
5S was developed by Hiroyuki Hirano within his overall approach to production systems.
However, Hirano provided a structure for improvement programmes. He pointed out a series
of clearly-identifiable steps, each building upon its predecessor. By differentiating between
Seiri and Seiton, Hirano made the distinction explicit. He taught that any effort to consider
layout and flow before the removal of the unnecessary items was likely to lead to a suboptimal solution. Equally the Seiso, or cleanliness, phase is a distinct element of the change
programme that can transform a process area. The broader kaizen, or continuous
improvement, approach is built, among other things, upon the companys valuation of all
members of the workforce. If employees dont feel valued within the overall company
culture, perhaps the change required falls outside the limits of a Housekeeping improvement
programme.
The Objectives of 5S
The most obvious benefit from items being organized in such a way (i.e. that they are
always readily available) is that of improved productivity.
The next aim is Quality. The degree of impact of dirt in a manufacturing environment,
obviously, varies with the nature of the product and its process but there are few, if any, areas
where dirt is welcome.
Operating Procedure for tool certification is much easier to achieve if the tool to be certified
is always in a clearly-marked location.
Another goal is improved Health & Safety. Clear pathways between workbenches and
storage racks can minimise accidents, as can properly-swept floors. As with Quality, a wellorganised, clean and tidy facility lends itself more readily to standard performance.
5S can also be a valuable sales tool when potential customers visit; a well-organised, clean
and tidy facility sends a message of a professional and well-organised supplier.
Crane
Main components of Cranes

1.L .T Drive
2.C.T Drive
3. Hoist Drive
4. Brakes
6. Wire rope
7. Gear box
8. Limit Switch
9. Pendent
Specification of PWH Crane
Model : NHEC3T
Capacity (SWL) : 3 Ton
Lift : 6 meter
Wire Rope : 12mm, 2 Falls
Hoisting Speed: 6.0Mtr/Min
Hoisting motor : 3.6Kw,4P
Trolley Speed : 18Mtr/Min
Power source : 3 Phase,415v,50Hz
Weight : 270 Kg
Make: Nippon hoist, Japan
Qty : 06 no.s
L.T. Drive
LT drive:- It is always used for running towards perpendicular direction of hoist

beam.
In our crane there is 2 nos LT motors in each crane. Both motor must be same spec
and same output ratings.
In MCPI all crane LT motor are Induction motor of different KW.
In case of Nippon Hoist crane LT motor s are geared induction motor but in Anupam
make cranes it is normal induction motor attached with a gear box and brake .
Gear box lubrication
Proper lubrication is important for prevention of gears and improvement in

performance of gear boxes.
Gear should be inside grease/oil at least 75% portion at idle condition.
Gear box drain valve, Oil inlet point should be covered properly.
CT DRIVE
In MCPI most of the crane having a CT motor, which used for axial running of hoist crane.
In case of Anupam Make crane CT motor are coupled with a gear box and brake. In case of
Nippon hoist CT motor are geared motor with disc type brake. Normally CT motor and LT
motor are similar spec.
Hoist Drive
It is used for hoisting or lowering the load .In case of Nippon hoist it is special type geared
motor.
Service life of a crane
Service life of a crane depend upon following :1. Load capacity

2. Duty factor
3. Start frequency
2M is better
Loadclass
LoadRatio 1Hrs 2Hrs 4Hrs 8Hrs 16Hrs24hrs
Light Load
K=50%
1M 1M 2M 2M 3M 4M
MediumLoad K=50%- 63% 1M 2M 2M 3M 4M 5M
Precaution
Never hoist the load which exceeds the rated load
If the hoist is frequently operated under overload, gears, bearings etc are damaged, wire
ropes are fatigued and the motor may be seized, thus reducing a service life of hoist. If
accidents occur, there is a possibility to cause a serious injure and trouble.
Dont collide the hoist frequently to the stopper

If the hoist is frequently collided to the stopper, the service life of hoist is reduced by shock.
There is a possibility of parts falling, hoists running away by simultaneous distribution of
contactor for cross travel. Also, if the stopper is damaged, hoist may fall, thus resulting in the
serious accident.
Dont unwind the wire rope by exceeding the rated head or more
When the wire rope of the crane is unwound, the rope of the length of two drum or more is
usually remained. However, if the rope is unwound over it, the rope end may be damaged.
Since the standard hoist is not equipped with the falling limit switch, if the wire rope is
reversely wound after fully unwinding the rope, the hoist cover etc, may be damaged.
Operate the crane according to each sign of a signalman if required
The operator must sufficiently understand the slinging method and sign method. Dont
operate the crane if the sign of the signalman is not clear or the sigh except the signalman is
performed.
Check around the crane before operating

Dont operate the crane, looking aside. To prevent direct and indirect accident by loading
carriage, check circumference before operating. Continuously ensure the safety of
circumference during operation.
Dont swing the load

Master the crane performance and operation to reduce the swing of load. Push the button of
East, West, South or North and then release the button when the hoist crane moves. When the
load is in just under the hoist, re-push the button to re-operate the hoist, thereby resulting in a
stable operation.
Dont operate at place just under the hoist

Dont carry the load over the head. It is recommend to walk alone the back or side of the
load to prevent a collision to the load.
Securely push the button switch

Check switch indications (operations, directions) before securely pushing the push button
switch. If buttons are incorrectly pushed, contacts are damaged.
Switchgear
The term switchgear, used in association with the electric power system, or grid,
refers to the combination of electrical disconnects, fuses and/or circuit breakers used to
isolate electrical equipment. Switchgear is used both to de-energize equipment to allow work
to be done and to clear faults downstream. This type of equipment is important because it is
directly linked to the reliability of the electricity supply.
The very earliest central power stations used simple open knife switches, mounted on
insulating panels of marble or asbestos. Power levels and voltages rapidly escalated, making
open manually-operated switches too dangerous to use for anything other than isolation of a
de-energized circuit. Oil-filled equipment allowed arc energy to be contained and safely
controlled. By the early 20th century, a switchgear line-up would be a metal-enclosed
structure with electrically-operated switching elements, using oil circuit breakers. Today, oilfilled equipment has largely been replaced by air-blast, vacuum, or SF6 equipment, allowing
large currents and power levels to be safely controlled by automatic equipment incorporating
digital controls, protection, metering and communications.
Types
A piece of switchgear may be a simple open-air isolator switch or it may be insulated
by some other substance. An effective although more costly form of switchgear is gas
insulated switchgear (GIS), where the conductors and contacts are insulated by pressurized
sulfur hexafluoride gas (SF6). Other common types are oil or vacuum insulated switchgear.
The combination of equipment within the switchgear enclosure allows them to interrupt
fault currents of thousands of amps. A circuit breaker (within a switchgear enclosure) is the
primary component that interrupts fault currents. The quenching of the arc when the circuit
breaker pulls apart the contacts open (disconnects the circuit) requires careful design. Circuit
breakers fall into these four types:
Oil circuit breakers rely upon vaporization of some of the oil to blast a jet of oil
through the arc.
Gas (SF6) circuit breakers sometimes stretch the arc using a magnetic field, and then
rely upon the dielectric strength of the SF6 to quench the stretched arc.
Vacuum circuit breakers have minimal arcing (as there is nothing to ionize other
than the contact material), so the arc quenches when it is stretched a very small
amount (<23 mm). Vacuum circuit breakers are frequently used in modern mediumvoltage switchgear to 35,000 volts.
Air circuit breakers may use compressed air (puff) to blow out the arc, or
alternatively, the contacts are rapidly swung into a small sealed chamber, the escaping
of the displaced air thus blowing out the arc.
Circuit breakers are usually able to terminate all current flow very quickly: typically
between 30 ms and 150 ms depending upon the age and construction of the device.
Several different classifications of switchgear can be made:
By the current rating.

By interrupting rating (maximum short circuit current that the device can safely
interrupt)
o Circuit breakers can open and close on fault currents
o Load-break/Load-make switches can switch normal system load currents
o Isolators may only be operated while the circuit is dead, or the load current is
very small.
By voltage class:
o Low voltage (less than 1,000 volts AC)
o Medium voltage (1,00035,000 volts AC)
o High voltage (more than 35,000 volts AC)
By insulating medium:
o Air
o Gas (SF6 or mixtures)
o Oil
o Vacuum
By construction type:
o Indoor (further classified by IP (Ingress Protection) class or NEMA enclosure
type)
o Outdoor
o Industrial
o Utility
o Marine
o Draw-out elements (removable without many tools)
o Fixed elements (bolted fasteners)
o Live-front
o Dead-front
o Open
o Metal-enclosed
o Metal-clad
o Metal enclose & Metal clad
o Arc-resistant
By IEC degree of internal separation
o No Separation
o Bus-bars separated from functional units
o Terminals for external conductors separated from bus bars
o Terminals for external conductors separated from functional units but not from
each other
o Functional units separated from each other
o Terminals for external conductors separated from each other
o Terminals for external conductors separate from their functional unit.
By interrupting device:
o Fuses
o Air Blast Circuit Breaker
o Minimum Oil Circuit Breaker
o Oil Circuit Breaker
o Vacuum Circuit Breaker
o Gas (SF6) Circuit breaker
By operating method:
o Manually-operated
o Motor-operated
o Solenoid/stored energy operated
By type of current:
o Alternating current
o Direct current
By application:
o Transmission system
o Distribution
By purpose:
o Isolating switches (disconnections)
o Load-break switches.
o Grounding (earthing) switches.
Functions
One of the basic functions of switchgear is protection, which is interruption of shortcircuit and overload fault currents while maintaining service to unaffected circuits.
Switchgear also provides isolation of circuits from power supplies.
Switchgear is also used to enhance system availability by allowing more than one
source to feed a load.
Safety
To help ensure safe operation sequences of switchgear, trapped key interlocking provides
predefined scenarios of operation. For example, if only one of two sources of supply are
permitted to be connected at a given time, the interlock scheme may require that the first
switch must be opened to release a key that will allow closing the second switch. Complex
schemes are possible.
Indoor switchgear can also be type tested for internal arc containment. This test is
important for user safety as modern switchgear is capable of switching large currents.
Switchgear is often inspected using thermal imaging to assess the state of the system
and predict failures before they occur.
Substations
Typically, switchgear in substations is located on both the high voltage and the low
voltage side of large power transformers. The switchgear located on the low voltage side of
the transformers in distribution type substations, now are typically located in what is called a
Power Distribution Centre (PDC). Inside this building are typically smaller, medium-voltage
(~15kV) circuit breakers feeding the distribution system. Also contained inside these Power
Control Centres are various relays, meters, and other communication equipment allowing for
intelligent control of the substation. For industrial applications, a transformer and
switchgear (Load Breaking Switch Fuse Unit) line-up may be combined in one housing,
called a unitized substation or USS.
Housing
Switchgear for low voltages may be entirely enclosed within a building. For
transmission levels of voltage (high voltages over 66 kV), often switchgear will be mounted
outdoors and insulated by air, though this requires a large amount of space. Gas insulated
switchgear used for transmission-level voltages saves space compared with air-insulated
equipment, although it has a higher equipment cost. Oil insulated switchgear presents an oil
spill hazard.
At small substations, switches may be manually operated, but at important switching
stations on the transmission network all devices have motor operators to allow for remote
control.
Circuit Breaker
Circuit breaker is an automatically operated electrical switch designed to protect
an electrical circuit from damage caused by overload or short circuit. Its basic function is to
detect a fault condition and, by interrupting continuity, to immediately discontinue electrical
flow. Unlike a fuse, which operates once and then has to be replaced, a circuit breaker can be
reset (either manually or automatically) to resume normal operation. Circuit circuit breaker is
an automatically operated electrical switch designed to protect an electrical circuit from
breakers are made in varying sizes, from small devices that protect an individual household
appliance up to large switch gear designed to protect high voltage circuits feeding an entire
city.
Operation
All circuit breakers have common features in their operation, although details vary
substantially depending on the voltage class, current rating and type of the circuit breaker.
The circuit breaker must detect a fault condition; in low-voltage circuit breakers this
is usually done within the breaker enclosure. Circuit breakers for large currents or high
voltages are usually arranged with pilot devices to sense a fault current and to operate the trip
opening mechanism. The trip solenoid that releases the latch is usually energized by a
separate battery, although some high-voltage circuit breakers are self-contained with current
transformers, protection relays, and an internal control power source.
Once a fault is detected, contacts within the circuit breaker must open to interrupt the
circuit; some mechanically-stored energy (using something such as springs or compressed
air) contained within the breaker is used to separate the contacts, although some of the energy
required may be obtained from the fault current itself. Small circuit breakers may be
manually operated; larger units have solenoids to trip the mechanism, and electric motors to
restore energy to the springs.
The circuit breaker contacts must carry the load current without excessive heating,
and must also withstand the heat of the arc produced when interrupting (opening) the circuit.
Contacts are made of copper or copper alloys, silver alloys, and other highly conductive
materials. Service life of the contacts is limited by the erosion of contact material due to
arcing while interrupting the current. Miniature and molded case circuit breakers are usually
discarded when the contacts have worn, but power circuit breakers and high-voltage circuit
breakers have replaceable contacts.
When a current is interrupted, an arc is generated. This arc must be contained, cooled,
and extinguished in a controlled way, so that the gap between the contacts can again
withstand the voltage in the circuit. Different circuit breakers use vacuum, air, insulating gas,
or oil as the medium in which the arc forms. Different techniques are used to extinguish the
arc including:
Lengthening / deflection of the arc

Intensive cooling (in jet chambers)
Division into partial arcs
Zero point quenching (Contacts open at the zero current time crossing of the AC
waveform, effectively breaking no load current at the time of opening. The zero crossing
occurs at twice the line frequency i.e. 100 times per second for 50Hz and 120 times per
second for 60Hz AC)
Connecting capacitors in parallel with contacts in DC circuits
Finally, once the fault condition has been cleared, the contacts must again be closed to
restore power to the interrupted circuit.
Types of circuit breaker

Many different classifications of circuit breakers can be made, based on their features
such as voltage class, construction type, interrupting type, and structural features.
Low Voltage Circuit Breaker

Low voltage (less than 1000 VAC) types are common in domestic, commercial and
industrial application, and include:
MCB (Miniature Circuit Breaker)rated current not more than 100 A. Trip
characteristics normally not adjustable. Thermal or thermal-magnetic operation. Breakers
illustrated above are in this category.
MCCB (Molded Case Circuit Breaker)rated current up to 2500 A. Thermal or

thermal-magnetic operation. Trip current may be adjustable in larger ratings.
Low voltage power circuit breakers can be mounted in multi-tiers in low-voltage

switchboards or switchgear cabinets.
Large low-voltage molded case and power circuit breakers may have electrical motor
operators, allowing them to be tripped (opened) and closed under remote control. These may
form part of an automatic transfer switch system for standby power.
Low-voltage circuit breakers are also made for direct-current (DC) applications, for
example DC supplied for subway lines. Special breakers are required for direct current
because the arc does not have a natural tendency to go out on each half cycle as for
alternating current. A direct current circuit breaker will have blow-out coils which generate a
magnetic field that rapidly stretches the arc when interrupting direct current.
Magnetic Circuit Breaker

Magnetic circuit breakers use a solenoid (electromagnet) whose
pulling force
increases with the current. Certain designs utilize electromagnetic forces in addition to those
of the solenoid. The circuit breaker contacts are held closed by a latch. As the current in the
solenoid increases beyond the rating of the circuit breaker, the solenoid's pull releases the
latch which then allows the contacts to open by spring action. Some types of magnetic
breakers incorporate a hydraulic time delay feature using a viscous fluid. The core is
restrained by a spring until the current exceeds the breaker rating. During an overload, the
speed of the solenoid motion is restricted by the fluid. The delay permits brief current surges
beyond normal running current for motor starting, energizing equipment, etc. Short circuit
currents provide sufficient solenoid force to release the latch regardless of core position thus
bypassing the delay feature. Ambient temperature affects the time delay but does not affect
the current rating of a magnetic breaker
Thermal Magnetic Circuit Breaker

Thermal magnetic circuit breakers, which are the type found in most distribution
boards, incorporate both techniques with the electromagnet responding instantaneously to
large surges in current (short circuits) and the bimetallic strip responding to less extreme but
longer-term over-current conditions. The thermal portion of the circuit breaker provides an
"inverse time" response feature which provides faster or slower response for larger or smaller
over currents respectively.
Medium-Voltage Circuit Breaker

Medium-voltage circuit breakers rated between 1 and 72 kV may be assembled into
metal-enclosed switchgear line ups for indoor use, or may be individual components installed
outdoors in a substation. Air-break circuit breakers replaced oil-filled units for indoor
applications, but are now themselves being replaced by vacuum circuit breakers (up to about
35 kV). Like the high voltage circuit breakers described below, these are also operated by
current sensing protective relays operated through current transformers. The characteristics of
MV breakers are given by international standards such as IEC 62271. Medium-voltage circuit
breakers nearly always use separate current sensors and protective relays, instead of relying
on built-in thermal or magnetic over current sensors.
Medium-voltage circuit breakers can be classified by the medium used to extinguish the arc:
Vacuum circuit breaker- With rated current up to 3000 A, these breakers interrupt the
current by creating and extinguishing the arc in a vacuum container. These are generally
applied for voltages up to about 35,000 V, which corresponds roughly to the mediumvoltage range of power systems. Vacuum circuit breakers tend to have longer life
expectancies between overhaul than do air circuit breakers.
Air circuit breaker- Rated current up to 10,000 A. Trip characteristics are often fully
adjustable including configurable trip thresholds and delays. Usually electronically
controlled, though some models are microprocessor controlled via an integral electronic
trip unit. Often used for main power distribution in large industrial plant, where the
breakers are arranged in draw-out enclosures for ease of maintenance.
SF6 circuit breaker- Extinguish the arc in a chamber filled with sulphur hexafluoride
gas.
Medium-voltage circuit breakers may be connected into the circuit by bolted connections to
bus bars or wires, especially in outdoor switchyards. Medium-voltage circuit breakers in
switchgear line-ups are often built with draw-out construction, allowing the breaker to be
removed without disturbing the power circuit connections, using a motor-operated or handcranked mechanism to separate the breaker from its enclosure.
High-Voltage Circuit Breaker
Electrical power transmission networks are protected and controlled by high-voltage

breakers. The definition of high voltage varies but in power transmission work is usually
thought to be 72.5 kV or higher. High-voltage breakers are nearly always solenoid-operated,
with current sensing protective relays operated through current transformers.
In substations the protective relay scheme can be complex, protecting equipment and buses
from various types of overload or ground/earth fault.
High-voltage breakers are broadly classified by the medium used to extinguish the arc.
Bulk oil
Minimum oil
Air blast
Vacuum
SF6
Due to environmental and cost concerns over insulating oil spills, most new breakers
use SF6 gas to quench the arc.
Circuit breakers can be classified as live tank, where the enclosure that contains the
breaking mechanism is at line potential, or dead tank with the enclosure at earth potential.
High-voltage AC circuit breakers are routinely available with ratings up to 765 kV. 1200KV
breakers are likely to come into market very soon.
High-voltage circuit breakers used on transmission systems may be arranged to allow
a single pole of a three-phase line to trip, instead of tripping all three poles; for some classes
of faults this improves the system stability and availability.
Other breakers
The following types are described in separate articles.
Residual-current device (RCD, formerly known as a residual current circuit breaker)

detects current imbalance, but does not provide over-current protection.
Residual current breaker with over-current protection (RCBO) combines the

functions of an RCD and an MCB in one package. In the United States and Canada,
panel-mounted devices that combine ground (earth) fault detection and over-current
protection are called Ground Fault Interrupter (GFI) breakers; a wall mounted outlet.
Earth leakage circuit breaker (ELCB) This detects earth current directly rather
than detecting imbalance. They are no longer seen in new installations for various
reasons.
Device or separately enclosed plug-in device providing ground fault detection and
interruption only (no overload protection) is called a Ground Fault Circuit Interrupter
(GFCI).
Autorecloser A type of circuit breaker which closes again after a delay. These are
used on overhead power distribution systems, to prevent short duration faults from
causing sustained outages.
Poly-switch (poly-fuse) A small device commonly described as an automatically
resetting fuse rather than a circuit breaker.
Vacuum Circuit Breaker

In this breaker, vacuum is being used as the arc quenching medium. Vacuum offers
highest insulating strength, it has far superior arc quenching properties than any other
medium. When contacts of a breaker are opened in vacuum, the interruption occurs at first
current zero with dielectric strength between the contacts building up at a rate thousands of
times that obtained with other circuit breakers.
Principle
When the contacts of the breaker are opened in vacuum (10 -7 to 10 -5 torr), an arc is
produced between the contacts by the ionization of metal vapours of contacts. The arc is
quickly extinguished because the metallic vapours, electrons, and ions produced during
arc condense quickly on the surfaces of the circuit breaker contacts, resulting in quick
recovery of dielectric strength. As soon as the arc is produced in vacuum, it is quickly
extinguished due to the fast rate of recovery of dielectric strength in vacuum.
Construction
It consists of fixed contact, moving contact and arc shield mounted inside a vacuum
chamber. The movable member is connected to the control mechanism by stainless steel
bellows .This enables the permanent sealing of the vacuum chamber so as to eliminate the
possibility of leak .A glass vessel or ceramic vessel is used as the outer insulating body.
The arc shield prevents the deterioration of the internal dielectric strength by preventing
metallic vapours falling on the inside surface of the outer insulating cover.
Working
When the breaker operates the moving contacts separates from the fixed contacts and
an arc is struck between the contacts. The production of arc is due to the ionization of metal
ions and depends very much upon the material of contacts. The arc is quickly extinguished
because the metallic vapours, electrons and ions produced during arc are diffused in short
time and seized by the surfaces of moving and fixed members and shields. Since vacuum has
very fast rate of recovery of dielectric strength, the arc extinction in a vacuum breaker occurs
with a short contact separation.
Vacuum Circuit Breaker
Advantages
They are compact, reliable and have longer life.

There are no fire hazards
There is no generation of gas during and after operation
They can interrupt any fault current. The outstanding feature of a VCB is that it can
break any heavy fault current perfectly just before the contacts reach the definite open
position.
They require little maintenance and are quiet in operation.
Can withstand lightning surges
Low arc energy
Low inertia and hence require smaller power for control mechanism.
Applications
For outdoor applications, the ranges are from 22 kV to 66 kV. It is suitable for
majority of applications in rural area.
Air Blast Circuit Breaker

Depending upon the direction of air blast in relation to the arc; air blast circuit
breakers are classified into:
Axial-Blast Air Circuit Breaker

Axial-blast type in which air-blast is directed along the arc part
The fixed and moving contacts are held in closed position by spring pressure under normal
conditions. The air reservoir is connected to the arcing chamber through an air valve. This
valve remains closed under normal conditions but opens automatically by tripping impulse
when a fault occurs on the system.
When a fault occurs the tripping impulse causes the opening of the air valve which connects
the circuit breaker reservoir to the arcing chamber. The high pressure air entering the arcing
chamber pushes away the moving contact against spring pressure. The moving contact is
separated and an arc is struck. At the same time, high pressure air blast flows along the arc
and takes away the ionised gases along with it. Consequently, the arc is extinguished and
current flow is interrupted.
It may be noted that in such circuit breakers, the contact separation required for interruption
is generally small about 1.75 cm. Such a small gap may constitute inadequate clearance for
the normal service voltage. Therefore, an isolating switch is incorporated as part of this type
of circuit breaker. This switch opens immediately after fault interruption to provide necessary
clearance for insulation.
Cross Blast Air Circuit Breaker

Cross-blast type in which air blast, is directed at right angles to the arc path. In this
type of circuit breaker, an air blast is directed at right angles to the arc. The cross-blast
lengthens and forces the arc into a suitable chute for arc extinction.
When the moving contact is withdrawn, am arc is struck between the fixed and moving
contacts. The high pressure cross-blast forces into a chute consisting of an arc splitters and
baffles. The splitters serve to increase the length of the arc and baffles give improved cooling.
The result is that arc is extinguished and flow of current is interrupted. Since the blast
pressure is same for all currents, the inefficiency at low currents is eliminated. The final gap
for interruption is great enough to give normal insulation clearance so that series isolating
switch is not necessary.
Radial-Blast Air Circuit Breaker
Radial-blast type in which the air blast is directed radially
Notes:
In MCPI, there are two units- DP & HP. In DP unit, air-blast circuit breaker is mostly used
and in HP unit, vacuum circuit breaker is mostly used.
Induction Motor
CONSTRUCTION
The 3-phase induction motor essential parts are:
a laminated stator core carrying a 3-phase winding,
a laminated rotor winding,
shaft-mounted slip-ring ,
a stiff shaft to preserve very short air-gap,
a frame to form the stator housing and carry the end covers,
bearings, and
Terminal box.
FRAME:
It is the outer body of the motor. Its functions are to support the stator core and
winding, to protect the inner parts of the machine sever as a ventilating housing. The frame
may be die-cast or fabricated. The machine up to 50kw rating may have frame die-cast in a
strong silicon-aluminium alloy, some time with the stator core cast in. The process of diecasting has the advantage that it facilitates the use of thicker cross-section of frame where
greater mechanical strength is required where as the advantage of fabrication is its
adaptability to new designs and modifications.
For large motors of rating 250kw to 10,000kw, the frames are generally fabricated in
the form of box-type enclosures having detachable top cover. Frames are provided with feet
by which they are fixed to the base plate.
The frame should be strong and rigid as air-gap length in an induction motor is very
small. If the frame is not rigid, the rotor will not remain concentric with stator giving rise to
unbalanced magnetic pull.
STATOR CORE:
The stator of an induction motor is to carry the alternating flux which produces
hysteresis and eddy current losses. In order to reduce eddy currents and hysteresis loss in the
in the stator core it is assembled of high grade, low electrical loss, silicon steel punching. The
thickness of punching varies from 0.35 mm to 0.65mm.In small motors, or if low core loss
is not so important slightly thicker laminations may be used. In small motor, the stator plates
from complete annular rings, but for large machines they are prepared of segmental
laminations to avoid wastage of steel. The punching are insulated from one another by
coating of varnish or oxide produced by heat treatment. The stampings are assembled under
hydraulic pressure and are keyed to the frame. Careful alignment is required to prevent the
rotor from rubbing against the stator, the air-gap between the stator and rotor being very
small. The radial ventilating ducts are provided along the length of the stator core , spaced
every 5 or 7cm.These are provided by the use of spacers placed between the practicable (0.3
to 0.35 mm in small machines and 1.0 to 1.5 mm in high power machines) so as to make airgap reluctance minimum. The slots are punched out on the inner periphery of the stator
laminations, to accommodate the stator winding. The motor especially of large power ratings,
have open type slots so that former wound coils can be used but usually the motors are
provided with semi-closed type slots to make air-gap reluctance minimum and to prevent
excessive tooth loos. In high speed motors open type slots are employed.
STATOR WINDING:
In a 3-phase induction motor the stator winding is usually 3-phase winding which is
usually supplied from 3-phase supply mains. The three phases of the winding can be
connected in either star or delta depending upon the methods of starting used.
The squirrel cage induction motors are usually started by star-delta starters and, therefore,
their stators are designed for delta connections and six terminals (two from each phase) are
brought out to be connected to the starter. The wound rotor motors are started by inserting
resistance in the rotor circuit and, therefore, the stator winding can be connected in either star
or delta as desired. It is wound for a definite number of poles as per requirement of speed.
Greater the number of poles, lesser the speed or vice-versa for a supply of given frequency.
In general, the same winding can be used on the stator of induction motor as were suitable
for synchronous generator or motors. The double layer winding is mostly used in medium
size motors because of its greater ease of manufacture, assembly, and repair. Moreover, stator
windings are almost always short-pitched because of reduced copper weight and winding
resistance as well as reduced leakage reactance and harmonic torque disturbances that result.
Small motors, operating at ordinary supply voltage (230 to 430 volts), with a small number of
slots having a large number of turns per phase may use single layer mush winding. For a
large motor or high voltage motors the stator windings may be formed by single layer
concentric coil. Double layer coils are placed in open slots so that former wound coils can be
used while mush winding is housed in semi-closed slots.
ROTOR:
The rotor comprises a cylindrical laminated iron core with slots, around the core,
carrying the rotor conductors. In general the same sheet steel laminations are employed for
the rotor core as for the stator, but owing to the lower frequencies of the rotor flux, thicker
laminations can be employed without excessive iron loss. The rotor laminations are punched
in one piece for small machines; in larger machines the laminations are segmented and
dovetailed to a fabricated spider. The laminations are stack together with the help of
hydraulic pressure. If there are ventilation ducts on the stator core, an equal number of such
ducts is provided on the rotor core also. Fan blades are usually employed on the ends of the
rotor core to force circulating air through the motor for cooling purpose.
The rotors employed in 3-phase induction motors, according to the type of winding
used, are of two typesSquirrel Cage Rotor
Slip Ring Rotor or Wound Rotor.
SQUIRREL CAGE ROTOR:

Almost 90 percent of induction motors are provided with squirrel cage rotor because
of its very simple robust and construction. In cage construction, copper, brass, or aluminium
bars are placed, as the rotor conductors, parallel or approximately parallel to the shaft (one
bar in each slot) and close to the rotor surface. At both ends of the rotor, the rotor conductors
are all short-circuited by the continuous end rings of similar material to that of the rotor
conductors. The rotor conductors and their end rings from a complete closed circuit in itself,
resembling a squirrel cage, thus explaining the name. The slots on the rotor are always not
parallel to the motor shaft but are usually skewed in order to obtain a uniform torque, reduce
the magnetic locking of the stator and rotor and reduce the magnetic humming noise while
running.
The slots on rotor are either of semi-closed type or totally closed type, because there
is little difficulty in inserting the rotor bars in such slots.
The advantage of semi-closed or totally closed type slots is that the effective crosssectional area of the air-gap is increased, therefore, magnetizing current is reduced.
Such slots also reduced the pulsations of flux in the individual teeth, therefore, tooth
loss is reduced.
The disadvantage of such slots is that these give higher slot inductance than the open
slots, which lowers the power factor and reduces the starting and breakdown torques
of the rotor.
Since the rotor winding is permanently short-circuited in cage construction, so there is
no possibility of adding any external resistance in the rotor circuit.
SLIP RING ROTOR:

As the name implies, such a rotor is wound with a insulated winding similar to that of
the stator except that the number of slots is smaller and fewer turns per phase of a heavier
conductor are used. Bar, strap, or wire is used for rotor winding, the last being used where
many turns are desired. A large number of rotor turns is increases the secondary voltage and
reduces the current that flows through the slip rings.
The rotor winding is always 3-phase winding. The rotor winding may be star or delta
connected but star-connection is usually preferred. The finish terminal are connected together
to from star-point and the three star terminals are connected to three phosphor-bronze (or
brass) slip rings mounted on but insulated from the rotor shaft. The brushes, which carry the
current from and to the rotor windings are held in box type holders mounted on insulated
steel rods, securely bolted to the end shield. Each brush is fed forward by a level held in
tension by an adjustable spring. The brushes are further externally connected to a 3-phase star
connected rheostat for the purpose of starting and speed control.
For high starting torque slip ring induction motors are used, after that running
condition shorted two sides and acts as a squirrel cage rotor.
SHAFTS:
The rotor shaft is supported by bearing housed in the end shield. The air-gap of an
induction motor is kept necessarily small, therefore, the rotor shaft must be made short and
stiff so that the rotor may not have any significant deflection. Even a minor deflection in the
shaft would develop large irregularities in the air gap which would lead to production of an
unbalanced magnetic pull. There is also a possibility of rotor and stator fouling with each
other.
BEARINGS:
A bearing is a device to allow constrained relative motion between two or more parts,
typically rotation or linear movement. Bearings may be classified broadly according to
the motions they allow and according to their principle of operation as well as by the
directions of applied loads they can handle.
There are at least six common bearings are:
Plain bearing: Also known by the specific styles: bushings, journal bearings, sleeve
bearings, rifle bearings.
Rolling-element bearings: Such as ball bearings and roller bearings.

Jewel bearings: In which the load is carried by rolling the axle slightly off-centre.
Fluid bearings: In which the load is carried by a gas or liquid.
Magnetic bearings: In which the load is carried by a magnetic field.
Flexure bearings: In which the motion is supported by a load element which bends.
Ball and roller bearings are generally employed as their use makes accurate centring
much simpler than with journal bearings. Also the overall length of the machine is reduced.
In small motors, a roller bearing may be employed at the driving end a ball bearing at the
other end. For large and heavy rotors journal bearings of self aligning spherical seated type
are useful.
OPERATION:
By contrast, the induction motor does not have any permanent magnets on the rotor;
instead, a current is induced in the rotor. To achieve this, stator windings are arranged around
the rotor so that when energised with a poly phase supply they create a rotating magnetic
field pattern which sweeps past the rotor. This changing magnetic field pattern induces
current in the rotor conductors. These currents interact with the rotating magnetic field
created by the stator and in effect cause a rotational motion on the rotor.
However, for these currents to be induced the speed of the physical rotor must be less
than the speed of the rotating magnetic field in the stator (the synchronous frequency ns) or
else the magnetic field will not be moving relative to the rotor conductors and no currents
will be induced. If by some chance this happens, the rotor typically slows slightly until a
current is re-induced and then the rotor continues as before. This difference between the
speed of the rotor and speed of the rotating magnetic field in the stator is called slip. It is unit
less and is the ratio between the relative speed of the magnetic field as seen by the rotor
(the slip speed) to the speed of the rotating stator field. Due to this, an induction motor is
sometimes referred to as an asynchronous machine. As well as generating rotary motion,
induction motors may be run as generators or modified to directly generate linear motion.
The synchronous speed of a motor is determined by the following formula:
where ns is the (synchronous) speed of the rotor (in rpm), f is the frequency of the AC
supply (in Hz) and p is the number of magnetic poles per phase.
TYPES OF AC INDUCTION MOTORS:

Generally, induction motors are categorized based on the number of stator
windings. They are:
Single-phase induction motor

Three-phase induction motor
Single-Phase Induction Motor

There are probably more single-phase AC induction motors in use today than the total of
all the other types put together. It is logical that the least expensive, low-cost maintenance type
motor should be used most often. The single-phase AC induction motor best fits this
description.
As the name suggests, this type of motor has only one stator winding (main winding)
and operates with a single-phase power supply. In all single-phase induction motors, the
rotor is the squirrel cage type. The single-phase induction motor is not self starting.
When the motor is connected to a single-phase power supply, the main winding carries an
alternating current. This current produces a pulsating magnetic field.
Due to induction, the rotor is energized. As the main magnetic field is pulsating, the
torque necessary for the motor rotation is not generated. This will cause the rotor to
vibrate, but not to rotate. Hence, the single-phase induction motor is required to have
a starting mechanism that can provide the starting kick for the motor to rotate.
The starting mechanism of the single-phase induction motor is mainly an additional
stator winding (start/ auxiliary winding). The start winding can have a series capacitor and/or
a centrifugal switch.
Once the motor reaches about 75% of its rated speed, a centrifugal switch disconnects
the start winding. From this point on, the single-phase motor can maintain sufficient torque to
operate on its own.
Except for special capacitor start/capacitor run types, all single-phase motors are
generally used for applications up to 3/4 hp only.
Depending on the various start techniques, single- phase AC induction motors ar further
classified as Split-phase induction motor
Capacitor start induction motor
Capacitor run induction motor
Capacitor start and run induction motor
Shaded pole induction motor
Three Phase Induction Motors:

Three-phase AC induction motors are widely used in industrial and commercial
applications. They are classified either as squirrel cage or wound-rotor motors.
These motors are self-starting and use no capacitor, start winding, centrifugal switch
or other starting devices.
They produce medium to high degrees of starting torque. The power capabilities and
efficiency in these motors range from medium to high compared to their single-phase
counterparts.
Popular applications include grinders, lathes, drill presses, pumps, compressors,
conveyors, also printing equipment, farm equipment, electronic cooling and other mechanical
duty applications.
Methods of Starting Three Phase Induction Motors:

As we know, once a supply is connected to a three phase induction motor a rotating
magnetic field will be set up in the stator, this will link and cut the rotor bars which in turn will
induce rotor currents and create a rotor field which will interact with the stator field and
produce rotation. Of course this means that the three phase induction motor is entirely capable
of self starting.
The need for a starter therefore is not, conversely enough, to provide starting but to
reduce heavy starting currents and provide overload and no-voltage protection.
There are a number of different types of starter:
Direct On-line Starter
Star-Delta Starter
Auto-Transformer
and
Rotor resistance
Direct-on-Line Starter (DOL):

The DOL starter switches the supply directly on to the contacts of the motor. As the
starting current of an induction motor can be 6-8 times the running current the DOL starter is
typically only used for motors with a rating of less than 5kw.
Advantages
o
o
o
o
Most economical starter.

Simple to establish
Operate and control simple circuitry.
Easy understand and trouble-shoot.
Disadvantages
o
o
o
o
Very high starting current (Typically 6 to 8 times the full load current of the motor).
Thermal stress on the motor, thereby reducing its life.
Voltage drop of the system, affecting other customers connected to the same lines.
Unnecessary high starting torque, even when not required by the load, thereby increased
mechanical stress on the mechanical systems such as rotor shaft, bearings, gearbox,
coupling, connected equipments leading to premature failure and plant downtimes.
Star Delta starter

This is the most common form of starter used for three phase induction motors. It
achieves an effective reduction of starting current by initially connecting the stator windings in
star configuration which effectively places any two phases in series across the supply. Starting
in star not only has the effect of reducing the motors start current but also the starting torque.
Once up to a particular running speed a double throw switch changes the winding
arrangements from star to delta whereupon full running torque is achieved.
Such an arrangement means that the ends of all stator windings must be brought to
terminations outside the casing of the motor.
Auto-Transformer Starting :
This method of starting reduces the start current by reducing the voltage at start up. It
can give lower start up currents than star-delta arrangements but with an associated loss of
torque. It is not as commonly utilised as other starting methods but does have the advantage
That only three connection conductors are required between starter and motor.
Rotor Resistance Starter:

If it is necessary to start a three phase induction motor on load then a wound rotor machine will
normally be selected. Such a machine allows an external resistance to be connected to the rotor
of the machine through slip rings and brushes.
At start-up the rotor resistance is set at maximum but is reduced as speed increases until
eventually it is reduced to zero and the machine runs as if it is a cage rotor machine.
Protection of Induction Motor:

Mainly three types of protection system are used to protect the induction
Motor, those are:
Over Current Protection
Short Circuit protection
Earth Fault Protection
and
First one over current protection are used to protect motor itself and other two
protection system are used to protect the system.
Induction Motor and MCPI

In MCPI two units are present those are:
DP Unit
HP Unit
Numbers of motor in DP unit is 592 and number of motors in HP unit is 650.

In DP unit maximum and minimum range of the motor are 8.7MW and 0.1MW
respectively.
In HP unit maximum and minimum range of the motor are 16MW and 1.2MW
respectively.
At starting condition 16MW motor required 13MW power and after that (running
condition) it will act as a generator.
Transformer
A transformer is a device that transfers electrical energy from one circuit to another through
inductively coupled conductorsthe transformer's coils. A varying current in the first or
primary winding creates a varying magnetic flux in the transformer's core and thus a varying
magnetic field through the secondary winding. This varying magnetic field induces a varying
electromotive force (EMF), or "voltage", in the secondary winding. This effect is called
mutual induction.
If a load is connected to the secondary, an electric current will flow in the secondary
winding and electrical energy will be transferred from the primary circuit through the
transformer to the load. In an ideal transformer, the induced voltage in the secondary winding
(Vs) is in proportion to the primary voltage (Vp), and is given by the ratio of the number of
turns in the secondary (Ns) to the number of turns in the primary (Np) as follows:
By appropriate selection of the ratio of turns, a transformer thus allows an alternating current
(AC) voltage to be "stepped up" by making Ns greater than Np, or "stepped down" by making
Ns less than Np.
History of transformer
Faraday's experiment with induction between coils of wire

The phenomenon of electromagnetic induction was discovered independently by Michael
Faraday and Joseph Henry in 1831. However, Faraday was the first to publish the results of
his experiments and thus receive credit for the discovery. The relationship between
electromotive force (EMF) or "voltage" and magnetic flux was formalized in an equation now
referred to as "Faraday's law of induction":.
where
is the magnitude of the EMF in volts and B is the magnetic flux through the
circuit (in Weber ).Faraday performed the first experiments on induction between coils of
wire, including winding a pair of coils around an iron ring, thus creating the first toroidal
closed-core transformer.
Transformers in MCPI
There are 10 big and 1 small transformers in MCPI. For big transformer the KVA rating is
2000KVA. The name plate of one of them is given below.
Basic principles
The transformer is based on two principles: first, that an electric current can produce a
magnetic field (electromagnetism), and, second that a changing magnetic field within a coil
of wire induces a voltage across the ends of the coil (electromagnetic induction). Changing
the current in the primary coil changes the magnetic flux that is developed. The changing
magnetic flux induces a voltage in the secondary coil.
An ideal transformer
An ideal transformer is shown in the adjacent figure. Current passing through the primary
coil creates a magnetic field. The primary and secondary coils are wrapped around a core of
very high magnetic permeability, such as iron, so that most of the magnetic flux passes
through both the primary and secondary coils.
Induction law
The voltage induced across the secondary coil may be calculated from Faraday's law of
induction, which states that:
Where Vs is the instantaneous voltage, Ns is the number of turns in the secondary coil and
is the magnetic flux through one turn of the coil. If the turns of the coil are oriented
perpendicular to the magnetic field lines, the flux is the product of the magnetic flux density
B and the area A through which it cuts. The area is constant, being equal to the cross-sectional
area of the transformer core, whereas the magnetic field varies with time according to the
excitation of the primary. Since the same magnetic flux passes through both the primary and
secondary coils in an ideal transformer, the instantaneous voltage across the primary winding
equals
Taking the ratio of the two equations for Vs and Vp gives the basic equation for stepping up or
stepping down the voltage
Np/Ns is known as the turns ratio, and is the primary functional characteristic of any
transformer. In the case of step-up transformers, this may sometimes be stated as the
reciprocal, Ns/Np. Turns ratio is commonly expressed as an irreducible fraction or ratio: for
example, a transformer with primary and secondary windings of, respectively, 100 and 150
turns is said to have a turns ratio of 2:3 rather than 0.667 or 100:150.
Ideal power equation
The ideal transformer as a circuit element

If the secondary coil is attached to a load that allows current to flow, electrical power is
transmitted from the primary circuit to the secondary circuit. Ideally, the transformer is
perfectly efficient; all the incoming energy is transformed from the primary circuit to the
magnetic field and into the secondary circuit. If this condition is met, the incoming electric
power must equal the outgoing power:
giving the ideal transformer equation
Transformers normally have high efficiency, so this formula is a reasonable approximation.

If the voltage is increased, then the current is decreased by the same factor. The impedance in
one circuit is transformed by the square of the turns ratio.[29] For example, if an impedance Zs
is attached across the terminals of the secondary coil, it appears to the primary circuit to have
an impedance of (Np/Ns)2Zs. This relationship is reciprocal, so that the impedance Zp of the
primary circuit appears to the secondary to be (Ns/Np)2Zp.
Parts of Transformer
Tank
Transformer tank contains the core of the transformer. It also contains transformer oil.
Breather
The satisfactory operation of transformer depends so largely on the condition of oil and
therefore devices and methods for keeping the oil clean and dry are prime important. Smaller
transformers are not totally field with oil and some space is left between oil level and tank
cover. This space is taken by the air. The tank is connected to the transformer through a vent
pipe. When oil expands air is expelled out while if it contracts air is drawn from the
atmosphere. This is called breathing of transformer. The air entering the transformer is passed
through an apparatus to extract moisture from it. A breather consists of a small container
connected to the vent pipe and containing a dehydrating material like silica gel crystals
impregnated with chloride. The material is blue when dry and whitish pink when damp. The
color can be observed through a glass window provided in front of the container.
Conservator
Due to some reasons oil is prevented from having contact with air as well as moisture.
Conservator is used for this purpose. The function of the conservator is to take up the
expansion and contraction of the oil without allowing it to come in contact with ambient air,
from which it might absorb moisture. The conservator is a tight cylindrical drum mounted on
or near the cover of the transformer and connected to it through a small pipe. The oil is set so
that the transformer tank is entirely full with oil and the conservator is half full. The interior
of the conservator above the oil level is connected to the atmosphere through a breather
having hydrating material.
Breather & Conservator
Buchholz Relay
It is a gas and oil actuated protected device and is used practically in all oil immersed
transformer with the exception of small distribution transformer. Buchholz Relay is used to
protect transformer against faults developed inside the transformer. The device relies on the
fact that an electrical fault inside the transformer tank is accompanied by generation of gas,
and if the fault current is high enough by a surge oil from the tank to the conservator.
The Buchholz relay is particularly useful is that it is capable of detecting fault condition of
very low magnitude such as inter-turns faults , incipient winding faults , and core faults due.
The relay is placed between transformer tank and the conservator. It consists of an oil filled
chamber. It consists of two floats, top float F1 and bottom float F2. Both float hinged so as to
be pressed by their buoyancy against to stop.
The operation can be explained as follows:
In case a fault occurs, gas bubbles are generated in the transformer tank on account of
increased heating produced by fault currents. The gas bubbles rise and go towards the
conservator through the pipe lines and these are trapped in the upper part of the relay
chamber. And this displaces the oil in the chamber and lowers the top float F1. The float
sinks ultimately causing closure of alarm circuit.
A small window in the wall of the relay chamber shows the amount of gas and its color. The
amount of gas indicates the severity of the fault and the color indicates the nature of the fault.
In case of mild faults in the transformer, the bottom floats F2 remains unaffected. In case of
severe faults, the gas production is violent and causes a surge which makes the bottom floats
to fall and close the trip circuit. This energizes the relay of a circuit breaker which opens
circuits the transformer thereby clearing the fault.
Buchholz Relay
Bushings
Transformers are connected to high voltage lines, and therefore, care must be taken to prevent
flashover from the high voltage connection to the earthed bank. Connections for cables are
made in cable boxes, but overhead connections must be brought through bushings
specifically designed for various voltage classes.
The bushing consist of a current carrying part in the form of a conducting rod, bus or cable, a
porcelain cylinder installed in a hole in the transformer cover and used for isolating the
current carrying part.
Cooling tubes
The higher rating transformers require increasingly improved of cooling. Hence cooling
tubes are used. Heat dissipating capability is increased by providing fins &
Corrugations are used. These not only provide additional cooling surface but also improve the
circulation of oil. It is clear that the oil in transformer is circulated on natural thermal head.
The oil takes away the heat from inside to outside. The oil is cooled in tubes by natural
circulation of air. Therefore the method is termed as ONAN (OIL NATURAL AIR
NATURAL).
The other method includes
(i)
(ii)
(iii)
Oil Natural Air Forced(ONAF)

Oil Natural water Forced(ONWF)
Forced circulation of oil(OF)
Bushings
Cooling tubes
Marshalling Box
Oil temperature indicator- The most obvious indicator of transformer temperature is
the temperature of hot oil. The oil temperature is measured by a dial type thermometer.
The bulb of thermometer is mounted in the oil and the dial is mounted outside the tank.
Winding temperature indicator- However, oil temperature is not a reliable measure
of winding temperature especially under sudden overload which cause the winding
temperature to rise more rapidly than the oil temperature. So it is desirable to use an
indicator which will show the actual temperature of hot spot in the windings.
And few MCBs and plug points are there in the box. All are shown in the picture. It is
one marshalling box of the transformer of MCPI.
Marshalling box
Magnetic Oil Gauge

It is used to indicate the oil level of the transformer.
TESTING SECTION
During the construction of a transformer each part is initially tested (core, L.V winding,
H.V winding etc.) & when the whole construction is construction is complete, then a no. of
tests are done necessarily before delivering it to the customers.
There are mainly several types of tests in transformer:
o Measurement of winding resistance
This test measures the resistance of the HV & LV winding. The values of resistance should
be balance for all three phases and should match the designed values.
Equipment used: Digital resistance meter.
o Measurement of insulation resistance
It measures the insulation resistance of HV & LV windings with respect to earth (body) and
between LV & HV winding. The resistance of the insulation is measured by Megger test.
Actually megger of the transformer should be kept high. Recommended Values are 2000
ohms for HV & 500 ohms for LV.
a) Separate source voltage withstand test (High Voltage tests on HV & LV)- This
test checks the insulation property between Primary to earth, Secondary to earth and
between Primary & Secondary.
o HV high voltage test: LV winding connected together and earthed. HV
winding connected together.eg- given 28 KV (for 11KV transformer) for 1
minute.
o LV high Voltage test: HV winding connected together and earthed. LV
winding connected together.eg- given 3 KV for 1 minute
b) Double Voltage Double Frequency test (DVDF test)- This test checks the inter turn
insulation. It is done to measure winding strength & insulation strength by using
motor-generator couples. A common shaft couples them.
Eg- For a 11KV/433V transformer, 866 Volts are applied at the 433V winding with
the help of a Generator for 1 minute. This induces 22KV on 11KV side. The
frequency of the 866V supply is also increased to 100HZ. Equipment used: MOTOR
GENERATOR SET.
c) Measurement of voltage ratio: This test measures the voltage ratio as per the
customers requirement.
V1/V2 = N1/N2
The voltage ratio is equal to the turns ratio in a transformer. Using this principle, the
turns ratio is measured with the help of a turns ratio meter. If it is correct, then the
voltage ratio is assumed to be correct. Equipment used: Turns Ratio meter.
d) Measurement of NO LOAD LOSS & current: The iron losses and no load current
are measured in this test. The L.V winding is charged at supply voltage & the H.V
winding is left open .The power consumed by the transformer at no load is the no load
loss in the transformer. Equipment used: Wattmeter or power analyzer.
e) Measurement of LOAD LOSS: This test measures the power consumed by the
transformer when the L.V winding is short circuited and the rated current is passed
through the H.V winding. Equipment used: Wattmeter or power analyzer.
f) Open circuit test: As the name suggests, the secondary winding( H.V) is kept open
circuited & nominal value of the input voltage is applied to the primary winding(L.V)
and the input current ,power are measured.
g) Short circuit test: the L.V side is shorted & the voltmeter, ammeter & wattmeter are
connected to the H.V side in series or parallel as required.
OPEN CIRCUIT TEST
SHORT CIRCUIT TEST
h) Temperature rise test: This is done to measure the full load efficiency of the
concerned transformer using the equipment.
i) Oil BDV test: This is done to measure the breakdown voltage (B.D.V) of the
transformer oil.
SPECIAL TEST
Noise level test: It is done to measure the noise within the transformer. If the core &
the windings are defective, then magnetic flux immerge from the core & goes to the
body of the tank. Thus leakage flux is created & noise is generated. This is done by
using noise detector.
Partial discharge test: Sometimes it is noted that even after switching the current,
some current still flows through the circuit. So immediately, if the flowing of the
current is not stopped, it will lead to leakage current & hence side discharge.
Dissolved gas analysis: If there is any gas dissolved in the transformer oil then in
high voltage transformer oil will be affected by ionization of the dissolved gas.
Corona test: Sometimes, especially in rainy season, too much humidity gathers in
air. It shorts the conductors on the bushings. So certain distance to be maintained in
between the bushings.
Transformer Failure & Protection

The importance of effective transformer and control transformer protection cannot be over
emphasized. After motors, transformers are typically the second most common application
where proper over current protection is required and utilized to provide the necessary protection
to facilities, electrical systems, equipment, and most importantly electrical workers and other
involved personnel.
Transformers of varied sizes and configurations are at the heart of all power systems. As a
critical and an expensive component of the power systems, transformers play an important
role in power delivery and the integrity of the power system network as a whole.
Transformers, however, have operating limits beyond which the transformer loss of life can
occur. If subjected to adverse conditions there can be a heavy damage to the system and
system equipment, besides intolerable interruption of service to the customers. Since the lead
time for repair and replacement of transformers is usually very long, limiting the damage to
faulted transformers is the foremost objective of transformer protection.
Economic impact of a transformer failure
The direct economic impact of repairing or replacing the transformer.

The indirect economic impact due to production loss.
Operating conditions like transformer overload, through faults, etc often result in
transformer failure, highlighting a need for transformer protection functions, such as over
excitation protection and temperature-based protection. Extended functioning of the
transformer under abnormal condition such as faults or overloads can compromise the life of
the transformer. Adequate protection should be provided for quicker isolation of the
transformer under such conditions. The type of protection used should reduce the
disconnection time for faults within the transformer and minimize the risk of catastrophic
breakdown to simplify eventual repair.
Transformer Failure
The risk of a transformer failure is two-dimensional: the frequency of failure, and the
severity of failure. Most often transformer failures are a result of "insulation failure". This
category includes inadequate or defective installation, insulation deterioration, and short
circuits, as opposed to exterior surges such as lightning and line faults.
Failures in transformers can be classified into
Winding failures resulting from short circuits (turn-turn faults, phase-phase faults,
phase-ground, open winding)
Core faults (core insulation failure, shorted laminations)
Terminal failures (open leads, loose connections, short circuits)
On-load tap changer failures (mechanical, electrical, short circuit, overheating)
Abnormal operating conditions (over fluxing, overloading, overvoltage)
External faults
Other causes of transformer failure may include

o Overloading - Transformers that experience a sustained loading that exceeds the
nameplate capacity often face failure due to overloading.
o Line Surge - Failure caused by switching surges, voltage spikes, line faults/flashovers,
and other T&D abnormalities suggests that more attention should be given to surge
protection, or the adequacy of coil clamping and short circuit strength.
o Loose Connections - Loose connections, improper mating of dissimilar metals,
improper torquing of bolted connections etc can also lead to failures in transformers.
o Oil Contamination - Oil contamination resulting in slugging, carbon tracking and
humidity in the oil can often result in transformer failure.
o Design/Manufacturing Errors This includes conditions such as: loose or
unsupported leads, loose blocking, poor brazing, inadequate core insulation, inferior
short circuit strength, and foreign objects left in the tank.
o Improper Maintenance/Operation - Inadequate or improper maintenance and

operation are a major cause of transformer failures. It includes disconnected or
improperly set controls, loss of coolant, accumulation of dirt & oil, and corrosion.
o External Factors Several external factors like floods, fire explosions, lightening
and moisture can be established as the causes of the failure as well.
Transformers Protection
Transformer failures and safety hazards can be avoided or minimized by ensuring that the
conductors and equipment are properly sized, protected and adequately grounded. Incorrect
installation of transformers can result in fires from improper protection, as well as electric
shock from inadequate grounding.
Once the transformer is placed, the tank must be permanently grounded with a
correctly sized and properly installed permanent ground.
Access should be restricted to the transformer liquid-filled compartment in conditions
of excessive humidity or rain.
o Dry air should be continuously pumped into the gas space if humidity exceeds
70%.
o Transformer should be given protection against rain such that no water gets
inside.
All equipment used in the handling of the fluid (hoses, pumps, etc.) should be clean
and dry. If the insulating liquid for inspection is drawn out, its level should not go
below the top of windings.
Sufficient gas pressure must be maintained to allow a positive pressure of 1 psi to 2
psi at all times (even at low ambient temperature) when liquid-filled transformers are
stored outside.
Final inspection of the transformer is essential before it is energized. All electrical
connections, bushings, draw lead connections should be checked.
Upon loading the transformer should be kept under observation during the first few
hours of operation. All temperatures and pressures should be checked in the
transformer tank during the first week of operation.
Surge arresters must be installed and connected to the transformer bushing / terminals
with the shortest possible leads to protect the equipment from line switching surges
and lightning.
Notes: The basement of every transformer of MCPI is equipped of stone. This is because oil
leakage from transformer may pollute the soil and can create a slippery ground near the
transformer which can occur an accident.
In MCPI two units are present those are: DP Unit and HP Unit. Numbers of transformer in
DP unit is 11 and number of transformers in HP unit is 12.
Corrosion
and
Cathodic Protection Theory
Corrosion
Nature has endowed each metallic substance with a certain natural energy level or
potential. When two metals having different energy levels or potentials are coupled together,
current will flow. The direction of positive current flow will be from the metal with the more
negative potential through the soil to that which is more positive. Corrosion will occur at the
point where positive current leaves the metal surface. A dry cell battery is one example of a
corrosion cell. DC railways and other machinery often generate direct current. When this
current flows through the soil indiscriminately, it is referred to as "stray" DC. The current
may contact and follow a buried metallic structure such as a pipeline, but wherever it leaves
that structure to return to it's origin, corrosion will occur.
Cathodic protection
Cathodic protection is an electrical method of preventing corrosion on metallic structures
which are in electrolytes such as soil or water. It has had widespread application on
underground pipelines, and ever increasing use as the most effective corrosion control
method for numerous other underground and underwater structures such as lead cables, water
storage tanks, lock gates and dams, steel pilings, underground storage tanks, well casings,
ship hulls and interiors, water treatment equipment, trash racks and screens. It is a scientific
method which combats corrosion by use of the same laws which cause the corrosion process.
Methods of Cathodic Protection

There are basically two methods of applying cathodic protection.
Impressed Current Cathodic Protection (ICCP).
Sacrificial Anode Cathodic Protection (SACP).
Impressed Current Cathodic Protection (ICCP)

Impressed Current Cathodic Protection method makes use of anodes which are energized
by an external DC power source. In this type of cathodic protection system, anodes are
installed in the electrolyte and are connected to the positive terminal of a DC power source
and the structure which is to be protected is connected to the negative terminal of that source.
Because the power source is almost always a rectifier unit, this type of system is often
referred to as a rectifier or impressed current type system.
Sacrificial Anode Cathodic Protection

The second method of protection makes use of galvanic anodes which have a higher energy
level or potential with respect to the structure to be protected. These anodes are made of
materials, such as magnesium or zinc, which are naturally anodic with respect to steel
structures and are connected directly to these structures.
In most cases, the rectifier type system is designed to deliver relatively large currents from
a limited number of anodes, and the galvanic anode type system is designed to deliver
relatively small currents from a large number of anodes. Each method of applying cathodic
protection has characteristics that make it more applicable to a particular problem than the
other. A comparison of those characteristics is as follows:
COMPARISON OF CP SYSTEM CHARACTERISTICS
Galvanic
NO External Power required
Fixed driving voltage
Fixed Current
Limited Current (10 to 50 Mili-amperes
Typical)
Usually used in lower resistivity electrolytes
Rectifier
External Power Required
Adjustable Voltage
Adjustable Current
Unlimited Current (10 to 100 Amperes
Typical)
Can be Used in almost Any Resistivity
Environment
Usually used with small or very well coated Can be Used on Any Size Structure
structures
Low $/Unit Cost
High $/Unit Cost
High $/Sq. Ft. of Metal Protected
Low $/Sq. Ft. of Metal Protected
Low Maintenance
Higher Maintenance
Does NOT cause Stray Current Corrosion
Stray DC Currents Can be Generated
Anode Materials
1. Galvanic Anodes.
Protective current generated by galvanic anodes depends upon the inherent potential
difference between the anodes and the structure to be protected. Thus, if the structure is made
of iron or steel, any metal that is more active in the electromotive force series can theoretically
be used as anode material. In practice, the materials generally used for galvanic anodes are zinc
and magnesium. Although aluminium is also a material which is more active than iron, it has
not yet proved to be an effective galvanic anode material for underground use because of the
polarization films which build up on the aluminium surface as it corrodes, thereby ceasing the
generation of protective current. In recent years, some alloys of aluminium have been used
successfully in seawater applications and work is progressing on alloys that may prove to be
effective in other applications.
2. Impressed Current Anodes.

When a rectifier type system is used, the current is derived from an outside source
and is not generated by the corrosion of a particular metal as is the case with galvanic anodes.
However, materials used as energized anodes do corrode. Thus, junk pipe and steel rails that
were at one time used extensively as anode materials in rectifier type systems. Therefore,
longer life anode materials were sought. The materials that are used almost universally today
are graphite, high silicon cast iron and precious metal oxide coated titanium. In underground
work, special coke breeze backfills are usually used for the purpose of providing a uniform
environment around the anode and for lowering the anode-to-earth resistance.
Benefits
Increased Accuracy of Voltage Measurements

Achieve the maximum life out of the pipe
Significant savings in man power
Can be controlled locally, remotely or pre-programmed
Problems
Production of hydrogen ions
A side effect of improperly applied cathodic protection is the production of hydrogen ions,
leading to its absorption in the protected metal and subsequent hydrogen brittleness of welds
and materials with high hardness. Under normal conditions, the ionic hydrogen will combine
at the metal surface to create hydrogen gas, which cannot penetrate the metal. Hydrogen ions,
however, are small enough to pass through the crystalline steel structure, and lead in some
cases to hydrogen brittleness.
Cathodic Shielding
Effectiveness of cathodic protection systems on steel pipelines can be impaired by the use
of solid film backed dielectric coatings such as polyethylene tapes, shrinkable pipeline
sleeves, and factory applied single or multiple solid film coatings. This phenomenon occurs
because of the high electrical resistivity of these film backings. Protective electric current
from the cathodic protection system is blocked or shielded from reaching the underlying
metal by the highly resistive film backing.
Conclusion
Cathodic protection is a highly adaptable and effective means of preventing corrosion on a
variety of underground or underwater structures. There are basically two types of systems:
namely, galvanic and impressed current. Each has characteristics which make it more
adaptable' under given circumstances. Cathodic protection designs can differ considerably
depending upon the coating, the configuration of the structure, the environment and the
presence of neighbouring structures. When a system is designed, installed and maintained
properly, cathodic protection is one of the most effective and economical methods of
preventing corrosion.
Paging
In MCPI-Haldia, paging is nothing but a connection system in entire industrial compound.

It is used for awareness, suitable calling process and mostly security. In industry there are
many wall-telephones, each of which have one receiver and two switches. During work when
someone needs another person to consult or working progress whatever, easily communicate
to that person, who is not present near the needy person by pressing one switch and calling
that person through receiver. When one speaks through the paging, the whole plant can hear
her voice. And after calling someone the needy person waits until the calling person come to
talk through any receiver of the plant by pressing another switch.
In MCPI, there are two plants, DP and HP. And the speakers of the paging are everywhere.
And most interesting matter is that in various offices there are few speakers instead of one of
various places (the name of the place is written on the speaker) to describe the approx
imagination of the needy person.
The main advantages are that
It is the best way to communicate among all staffs of the company.

It reduces a lot of time to reach the recovery team or calling persons to the needy
person. So the speed of work is growing up.
It reduces a lot of money to communicate among each other.
At abnormal condition or accident it is the best process to aware all staffs to secure
their life and the asset of the company.
But the main disadvantage is that for one time only one can communicate to other through
paging. If someone is speaking through paging, for that time the other needy person has to
wait to use the system until the previous two persons will stop the talk avoiding the
interference of the line.
However, paging is the very necessary thing in any industry to get these valuable benefits.
Energy Conservation
Introduction
Energy is power - the ability to do work. But, energy is not just the ability of a person
to move and work and play. Every time anything moves - the wind, water, cars, clocks,
animals, and more - energy is what makes it happen! All movement is energy.
Energy makes plants and animals grow. It takes energy to cook a meal or read a book!
We use energy every day.
Energy makes your remote control cars, radios, video games, and computers work.
Nothing can run well on an empty tank, not a car or a plane or even our bodies! We
need fuel so that we will have the energy to work and play. Our fuel is food. Food is
where we get our energy. The energy in food is called calories. We take in calories by
eating and drinking, and we use calories by moving. The more you move, the more
calories you burn. Your body even burns calories when you are asleep, but not very
many.
What Is Energy?
Energy is defined as the ability to do work.
Every living thing needs energy. Most of it comes from the sun. Plants are producers.
They capture the sun's energy. They use it to grow and reproduce. Any energy that is
not used by the plant is stored. Animals are consumers. They eat the plants to get
energy for their own life processes. We need energy in order to be able to do anything.
Forms of Energy
There are two types of energy:
Kinetic energy is the energy an object has because it is moving. The more mass the
object has and the greater the speed at which it is moving, the greater the kinetic
energy it has.
Potential energy is stored energy. It is the energy an object has because of its position
or shape. If the object is sent into motion, it would have kinetic energy. A rock
balanced on top of a mountain has a lot of potential energy.
Various forms of energy:

Potential Energy:
Chemical
Nuclear
Mechanical stored energy
Gravitational
Kinetic Energy:
Radiant
Thermal
Motion
Sound
Electrical
Primary and Secondary Energy:

Primary energy sources are those that are either found or stored in nature. Common
primary energy sources are coal, oil, natural gas, and biomass (such as wood).
Primary energy sources are mostly converted into secondary energy sources; for example
coal, oil or gas converted into steam and electricity. Primary energy can also be used directly.
Commercial and Non-commercial Energy:

The energy sources that are available in the market for a definite price are known as
commercial energy.
Examples are electricity, coal, lignite, oil, and natural gas
The energy sources that are not available in the commercial market for a price are
classified as non-commercial energy.
Examples are firewood, cattle dung and agricultural wastes, solar energy,
animal power, wind energy
Renewable & Non-renewable Energy :

These sources are constantly renewed or restored are called renewable energy source.
Examples are wind (wind power), water (hydropower), sun(solar),vegetation
(biomass), and internal heat of the earth (geothermal).
These are natural resources that cannot be replenished is called non-renewable energy
source.
Examples are (fossil fuels such as oil, gas, and coal).
Non-renewable Energy
Renewable Energy
Global Energy Reserves (End 2002)
Global coal reserves 9,84,453 million tones

1047.7 thousand million barrels of oil
155.78 trillion cubic meters of gas.
World oil reserves estimated to last 45 years
World gas reserves estimated to last 65 years and
Coal is likely to last a little over 200 years
Why is Energy Conversion important?
Because of the limited amount of nonrenewable energy sources on Earth, it is

important to conserve our current supply or to use renewable sources so that our
natural resources will be available for future generations.
Energy conservation is also important because consumption of nonrenewable sources

impacts the environment. Specifically, our use of fossil fuels contributes to air and
water pollution. For example, carbon dioxide is produced when oil, coal, and gas
combust in power stations, heating systems, and car engines.
Carbon dioxide in the atmosphere acts as a transparent blanket, that contributes to the
global warming of the earth, or "greenhouse effect."
It is possible that this warming trend could significantly alter our weather. Possible
impacts include a threat to human health, environmental impacts such as rising sea levels that
can damage coastal areas, and major changes in vegetation growth patterns that could cause
some plant and animal species to become extinct. Sulfur dioxide is also emitted into the air
when coal is burned. The sulfur dioxide reacts with water and oxygen in the clouds to form
precipitation known as "acid rain." Acid rain can kill fish and trees and damage limestone
buildings and statues.
Energy conservation helps endure resources for the future and also helps prevent pollution.
Explain that if we continue to consume nonrenewable sources at an increasing rate, these
sources will be depleted. Explain that not only are we depleting our nonrenewable sources,
but that use of fossil fuels has negative environmental impacts, such as global warming and
acid rain.
Conclusion
Mitsubishi Chemical Corporation is one of the most modern &
hi-tech industry in not only India but also all over South Asia. It has
been accredited for its commitment towards high quality products. The
company is noted for its honourable achievement in the field of safety &
environment.
It was an engineering experience for me to have completed my
summer training in the MCPI. I believe that this experience will
contribute immensely to my development as a successful engineer.

Training Report 6th Sem. E.E. B.tech.

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Training Report 6th Sem. E.E. B.tech.

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A GLOBAL BASE IN INDIA

MCC PTA India Corp. Private limited

Report on Summer Training at MCC PTA India Corp. Private Limited in

MCPI at a Glance ...................................................................................................................... 1

Electrical Departments Activity........................................................................................... 3

To contribute to the development of Indian Polyester Industry with stable supplies of

UTILITIES & OFF SITES

: PTA (Purified Terephthalic Acid)

: 27 Months, Sept 97 to Dec 99

MCPI Phase II [HP]

: PTA (Purified Terephthalic Acid)

MAIN RAW MATERIAL

: Paraxylene, Acetic Acid (Solvent)

The Plant has state-of-the-art technology developed in-house by MCC.

MCPI IS AN ISO 9001:2008, ISO 14001:2004, and OHSAS 18001:2007 Company.

Electrical departments activity

WRITTEN / VERBAL REQUEST

List of main equipment under maintenance

Deg with control panel

Jobs of Electrical Department

Trouble and improvement activities

SDM modification job

Periodical Work based on Cycle

Daily Scheduled Jobs

Monthly Scheduled Jobs

Daily Scheduled Job

Motor Greasing daily

Motor Patrolling daily

Substation Patrolling daily

Transformer Patrolling daily

Monthly Scheduled Jobs

Cathodic Protection-by monthly (inside water/outside PX)

Battery Maintenance-by monthly(B/S / DEG / Fire water system)

Fire Engine Panel Maintenance-by monthly

EOT Crane Checking-monthly

Vibration Measurement of Critical equipments-monthly. Trend maintained in excel

Air Conditioner Maintenance-monthly (500 nos.)

Yearly Scheduled Jobs

Fire Alarm System-2 years

EOT Crane Overhaul-yearly

CM/BCM Oil Checking-half yearly

DEG Alternator Maintenance-yearly

Testing of Trans oil-yearly

Load Test of Lifting Tool-yearly

Tank Earth Continuity-half yearly

Calibration Check of Measuring Instruments-yearly

Shataku 1 & 2 Panel Maintenance-yearly

All HV motors and LV motors>15kw: as per OH schedule

All motors<15kw:as per condition monitored during daily patrolling

Cyclo (CM) & Bier Cyclo(BCM) motors

Motors Diagnostic Test (HV motors)-3 years

C-1711 main compressor

Periodical work based Middle & Long term range

HV switchgear, VCB & VCS

LV switchgear ,ACB and Motor Control Centre(MCC)

Control and Protection Panels, Electrical Protection Relays

DC-UPS system and Battery Bank

Replacement of electric components, electrolytic capacitors, relays etc

DEG Electronic Governor

Air Conditioner Maintenance-monthly (500 nos.)

Tips on Industrial and Electrical Safety

less Causes no sensation - not felt.

Sensation of shock, not painful;

8 mA to 15 mA Painful shock; individual can let