DEPARTMENT OF ELECTRICAL AND INFORMATION ENGINEERING FACULTY OF ENGINEERING UNIVERSITY OF RUHUNA INDUSTRIAL TRAINING REPORT SUBMITTED IN PARTIAL FULFILMENT OF THE DEGREE OF BACHELOR OF SCIENCE IN ENGINEERING 3rd April 2017 CEYLON ELECTRICITY BOARD (From 19th December 2016 to 10th March 2017) BASNAYAKA W.B.M.C.M. (EG/2013/2151) PREFACE I had my training experience from 19th December 2016 to 10th March 2017 at Ceylon Electricity Board (CEB). Here in this report I present the experience, knowledge, skills I had during the training period. The report contains three chapters. The first chapter contains an introduction to Ceylon Electricity Board (CEB), company strategy and organizational structure. The second chapter contains the training experience, information on power system of Sri Lanka and equipment, project work and assignments that I involved during the training period. Next chapter contains the management structure of Ceylon Electricity Board (CEB). And the summery and conclusion were included in the last chapter. I had a very successful training period and the experience and knowledge I got is very valuable to my future career. Basnayaka W.B.M.C.M EG/2013/2151 Department of Electrical and Information Engineering, University of Ruhuna. i ACKNOWLEDGEMENT Knowledge is a great thing that repels the darkness of ignorance. Yet seeking the depths of knowledge without limits can be disastrous. However, one alone cannot simply gain knowledge without the gracious guidance of the teachers. There are lots of people who have helped me towards the successful completion of my Industrial Training. First of all, I would thank to University of Ruhuna and National Apprentice and Industrial Training Authority (NAITA) for arranging industrial training for undergraduates. Then I would like to thank Dr. J.M.R.S Appuhami the Director of the Engineering Education Center (EEC), Faculty of Engineering, University of Ruhuna, for arranging me this opportunity to have my training experience in Ceylon Electricity Board. I sincerely thank Eng. Chandani Premarathne Training Officer (Internal Training) and staff of Ceylon Electricity Board (CEB) for accommodating me as a trainee. I must greatly appreciate operation engineers in Lakvijaya and Kotmale power plants, Training assistant for giving me advices, sharing their knowledge and guiding me during the training period. I wish to express my gratitude again to all those people who helped me towards the success of my Industrial Training. Basnayaka W.B.M.C.M EG/2013/2151 Department of Electrical and Information Engineering, University of Ruhuna. ii CONTENTS 1 Introduction to the Ceylon Electricity Board ................................................................ 1 1.1 1.1.1 Vision .............................................................................................................. 1 1.1.2 Mission ............................................................................................................ 1 1.1.3 History of Ceylon Electricity Board ................................................................ 2 1.1 2 Overview of The Company..................................................................................... 1 Organization Structure ............................................................................................ 2 Training Experiences- Technical ................................................................................... 5 1.2 Generation Division ................................................................................................ 5 1.2.1 Present Status of Ceylon Electricity Board ..................................................... 5 1.2.2 Mahaweli Complex Reservoirs and Power Stations ....................................... 7 1.2.3 Introduction to Kotmale Power Station ........................................................... 7 1.2.4 The Main Physical Components of the Kotmale Project ................................ 9 1.2.5 Introduction to Lakvijaya Power Plant .......................................................... 19 1.2.6 Component of Lakvijaya power Plant ........................................................... 20 1.2.7 Operation Process of the Lakvijaya Power Plant ........................................ 26 2.1.1 Auxiliary System of the Plant........................................................................ 27 2.1.2 Coal Storage Management techniques .......................................................... 28 2.2 Transmission Division .......................................................................................... 29 2.2.1 Transmission Network in Sri Lanka .............................................................. 29 2.2.2 Grid sub station.............................................................................................. 31 2.2.3 Biyagama Sub Station ................................................................................... 31 2.2.4 Component of A Grid Sub Station ................................................................ 33 2.2.5 Electrical Power Transformer ........................................................................ 33 2.2.6 Circuit Breaker .............................................................................................. 35 2.2.7 Isolator and Earth Switches ........................................................................... 37 2.2.8 Current Transformers .................................................................................... 38 iii 2.2.9 Potential Transformers .................................................................................. 38 2.2.10 Bus Bar .......................................................................................................... 39 2.2.11 Grid Substation Overloading and blackout ................................................... 40 2.2.12 Introduction to System Control Center .......................................................... 40 2.2.13 Present Situation of Frequency Control in Sri Lanka .................................... 41 2.2.14 Frequency Controlling Method Use in Sri Lanka ......................................... 41 2.2.15 Droop Characteristics of a Generator ............................................................ 42 2.2.16 Basic Principles of Power System Operation ................................................ 43 2.2.17 Black Out Situation in Sri Lanka ................................................................... 44 2.2.18 Under-Frequency Load Shedding .................................................................. 45 2.2.19 Operational Planning and Dispatch ............................................................... 46 2.2.20 Utilization of Hydro Generation .................................................................... 46 2.2.21 Software and Methodologies of System Control Center ............................... 46 2.2.22 Introduction to Transmission and Generation Planning in Sri Lanka ........... 48 2.2.23 Electricity Demand Forecast Method and Past Demand ............................... 49 2.2.24 Long Term Transmission Plan ...................................................................... 50 2.2.25 Introduction to Heavy Maintenance of Low Voltage Transmission Line ..... 51 2.2.26 Design of Transmission Tower ..................................................................... 52 2.2.27 Types of Transmission Tower ....................................................................... 53 2.2.28 Transmission Line Maintenance .................................................................... 54 2.2.29 Major Tools Used for Live Line Maintenance .............................................. 55 2.3 Distribution Division ............................................................................................ 57 2.3.1 Introduction to Distribution Division ............................................................ 57 2.3.2 Transmission Lines of Distribution Network ................................................ 58 2.3.3 Present Situation of LV Lines ....................................................................... 58 2.3.4 Item Use in Overhead LV Construction ........................................................ 58 2.3.5 Issues and Concerns to be solved in CEB’s Distribution System ................. 60 iv 3 Training Experience –Management............................................................................. 62 3.1 Management Systems of CEB .............................................................................. 62 3.2 Asset management ................................................................................................ 62 3.3 Personal management ........................................................................................... 62 3.3.1 Welfare Unit .................................................................................................. 63 3.3.2 Security Section ............................................................................................. 63 3.3.3 Training Branch ............................................................................................. 63 3.3.4 5S System ...................................................................................................... 63 3.4 Safety Management .............................................................................................. 64 3.4.1 4 Safety Precautions ......................................................................................... 64 Summary and Conclusion............................................................................................ 65 4.1 Summary ............................................................................................................... 65 4.2 Conclusion ............................................................................................................ 65 Abbreviation ........................................................................................................................ 67 Reference ............................................................................................................................. 71 v LIST OF TABLES Table 2.1: Training Schedule................................................................................................. 5 Table 2.2:Power Station of Mahaweli Complex ................................................................... 7 Table 2.3 :Specification of the Dam ...................................................................................... 9 Table 2.4: Specification of Turbine ..................................................................................... 11 Table 2.5:Specification Of Generator .................................................................................. 15 Table 2.6:Specification Of Main Transformer .................................................................... 16 Table 2.7: Specification Of Turbine .................................................................................... 21 Table 2.8: Generator Parameters in Puttalam Coal Power Plant ......................................... 22 Table 2.9:Auxiliary Power Consumption Of Lakvijaya Plant ........................................... 28 Table 2.10: Specifications Of Transformers Of Biyagama ................................................. 34 Table 2.11 Load Shedding Scheme in Sri Lanka ................................................................ 45 Table 2.12:Voltage Criteria ................................................................................................. 48 vi LIST OF FIGURES Figure 1.1:Ceylon Electricity Board Logo ............................................................................ 1 Figure 1.2:Organization Structure Of CEB ........................................................................... 4 Figure 2.1 :Generation capacity Mix in MW -2014 .............................................................. 6 Figure 2.2 Arrangement Of Mahaweli Complex Reservoir .................................................. 7 Figure 2.3:Kotmale Reservoir ............................................................................................... 8 Figure 2.4: Radial Gate Of Kotmale Dam Spillway .............................................................. 9 Figure 2.5:Surge Chamber of Kotmale................................................................................ 10 Figure 2.6: Kotmale Under Ground Power Station ............................................................. 11 Figure 2.7:Arrangement of Turbine..................................................................................... 12 Figure 2.8: Turbine Runner Of Kotmale Power Plant ......................................................... 13 Figure 2.9:Guide Vanes Of The Power Plant ...................................................................... 14 Figure 2.10:Actuator of Governor ....................................................................................... 16 Figure 2.11:Kotamle Switch Yard ....................................................................................... 17 Figure 2.12: One Breaker And A Half Scheme Bus Arrangement ..................................... 18 Figure 2.13:Lakvijaya Power Plant ..................................................................................... 19 Figure 2.14:Generator Of Lakvijaya Power Plant ............................................................... 22 Figure 2.15: Unit Auxiliary Transformer ............................................................................ 23 Figure 2.16:Gas Insulator Substation In Lakvijaya Power Plant ........................................ 25 Figure 2.17:Operation Process Of Coal Power Plant .......................................................... 26 Figure 2.18:Coal Yard Of Lakvijaya Power Plant .............................................................. 29 Figure 2.19: Sri Lankan Transmission Network ................................................................. 30 Figure 2.20:Biyagama Grid Sub Station ............................................................................. 32 Figure 2.21: Main Transformer Of Biyagama Sub Station ................................................. 33 Figure 2.22:Minimum Oil Circuit Breaker Re- Installation ................................................ 36 Figure 2.23:Isolaters In 220Kv Switch Yard ....................................................................... 38 Figure 2.24: Current Transformers ...................................................................................... 38 Figure 2.25:Diagram Of 220kv Transformer Bay Section .................................................. 40 Figure 2.26: Speed Droop Characteristics Of Kotmale Hydro Power Plant ....................... 42 Figure 2.27:Daily Load Curve ............................................................................................. 49 Figure 2.28 :33kv Transmission Tower............................................................................... 51 Figure 2.29:Part Of Transmission Tower ............................................................................ 52 Figure 2.30:Transmission Tower Construction In Badulla Area ........................................ 53 vii Figure 2.31:Hot Line Maintenance In Transmission Line .................................................. 54 Figure 2.32:Hot Stick Use In Hot Line Maintenance .......................................................... 56 Figure 2.33 :Pin Insulator .................................................................................................... 60 viii Chapter One 1 Introduction to the Ceylon Electricity Board 1.1 Overview of The Company The Ceylon Electricity Board (CEB) is a government owned and controlled utility of Sri Lanka that takes care of the general energy facilities of the island. The Ministry of Power and Energy is the responsible ministry above the CEB. Ceylon Electricity Board (CEB), established by an CEB Act No. 17 of 1969, is under legal obligation to develop and maintain an efficient, coordinated and economical system of Electricity supply in accordance with any Licenses issued. Figure 1.1:Ceylon Electricity Board Logo 1.1.1 Vision “Enrich life through power” 1.1.2 Mission To develop and maintain an efficient, coordinated and economical system of electricity supply to the whole of Sri Lanka, while adhering to our core values Quality Service to the nation Efficiency and effectiveness Commitment Safety Professionalism Sustainability 1 1.1.3 History of Ceylon Electricity Board Sri Lanka's first public electricity supply was made available in Colombo in 1895 by Messrs Boustead Bros. The business was soon taken over by the United Planters Co., Who extended it and in 1899 built the Colombo electric tramways. In 1902, the Colombo Electric Tramways and Lighting Co. Ltd. was formed and provided electricity supply until 1927 when the Department of Government Electrical Undertakings (DGEU) was established to control the utility, which had by then been purchased by the Government. DGEU was succeeded in 1969 when the Ceylon Electricity Board (CEB), a statutory corporation, was established on the 1st of November 1969 under the Act of Parliament No.17 of 1969. While CEB is a public corporation the 1969 CEB Act does not endow it with fully autonomous powers and the government has reserved to itself a substantial role in important policy matters and in particular tariffs, capital investment, borrowing and the appointment of the Chairman and the General Manager. The conditions of service of all CEB staff are subject to the government regulation. In 1913, Devapura Jayasena Wimalasurendra (1874 –1953) gave his thoughts on the construction of a small hydro power station at Black pool, between NanuOya and NuwaraEliya, to supply electricity to the Nuwara Eliya town. In 1918, also he submitted a project report titled 'Economics of Hydro Power Utilization in Ceylon' to the Engineering Association to make his dream come true. Accordingly, the Laxapana hydro power scheme, the construction of which started in 1924 was thus resumed in 1938 and done to the finish. However, it was commissioned as the first hydro power plant of Sri Lankan history in December 1950. Between 1978 - 1985 under the Master Plan of Mahaweli Development Programme added seven hydro power stations to the national grid with a total installed capacity of 810 MW this can be considered as a great leap forward for electricity generation in Sri Lanka. 1.1 Organization Structure The Ceylon Electricity Board is a state-owned vertically integrated organization handling generation, transmission and distribution functions. CEB's organization structure was designed by consultants, Urwick International Ltd., in the early 1970's. There are seven divisions: the generation, transmission, distribution and operation, distribution development, commercial, headquarters, and finance manager divisions, under the board members such as the Chairman and General Manager. Though CEB has been established as an independent organ, executives are to be assigned by the Ministry of Power and Energy, and approval by the Government is required for investments and setting tariffs. 2 CEB is a corporate body governed by a seven-member Board; members serve a five-year term and may be reappointed. Board members are appointed by GSL, four with experience in either engineering, commerce, administration or accountancy, and the others representing local authorities, industry and the Ministry of Finance and may be removed at any time. The Chairman is appointed from amongst the Board members. The organization chart of CEB is shown in the Figure 1.2. 3 Figure 1.2:Organization Structure Of CEB 4 Chapter Two 2 Training Experiences- Technical I had my second industrial training experience from 19th December 2016 to 10th March 2017 at the Ceylon Electricity Board (CEB) and it is the largest electricity company in Sri Lanka. At the beginning of my industrial training programme I was reported to the office of the Deputy General Manager (Training), Piliyandala and I got the training schedule for threemonth training period. Schedule of In-plant training programme in different branches and units of CEB is shown in the table 2.1 below. Table 2.1: Training Schedule Division Generation Transmission Place Of Training Duration From To Lakvijaya Power Station 13.02.2017 09.02.2017 Kotmale Power Station 27.02.2017 10.03.2017 Transmission Operation and 30.01.2017 09.02.2017 System Control Center 16.01.2017 20.01.2017 Transmission And Generation 23.01.2017 27.01.2017 Project And Heavy Maintenance 02.01.2017 13.01.2017 Distribution Division (Southern 20.12.2017 30.12.2016 Maintenance Planning Distribution Province) 1.2 Generation Division 1.2.1 Present Status of Ceylon Electricity Board Since 1980s, Sri Lanka has been facing a continuously increasing electricity demand due to population growth, increase in electrification level, and socioeconomic development. By the end of 2014, 5.4 million consumers have been served by the Sri Lankan power sector and the total electricity demand of the Power Supply Performance country has grown to 12,357 GWh during 2013 compared to 587 GWh in 1969.Also, Electricity generation in Sri Lanka is primarily run by hydro power and thermal heat, with sources such as photovoltaics and wind power in early stages of deployment. 5 Hydroelectricity has played a very significant role in the national installed power capacity since it was introduced in the 1950s, with over 50% of the total grid capacity met by hydroelectricity in 2000–2010. Sri Lanka has two main hydro power complexes consisting of several power plants in each. These two main hydro power complexes are the Laxapana complex and the Mahaweli complex. Laxapana complex is based on the Kelani river while Mahaweli complex is based on Mahaweli river. In addition, there are two independent large scale hydro power stations, namely Samanalawewa and Kukule Ganga while small scale power plants such as Inginiyagala and Uda Walawa are also generating hydropower using their respective reservoir storages. For administrative purposes, these isolated hydropower plants are grouped together as a single complex identified by the CEB as the ‘Other Hydro’ Complex. Figure 2.1 :Generation capacity Mix in MW -2014 Details of the existing a hydro system are given in appendix 1 and the geographical locations of the Power Stations are shown in the appendix 1. As of 2015, 1,464 MW of the total thermal installed capacity was from state-owned fossil fuel power stations: 900 MW from Lakvijaya, 380 MW from the state-owned portion of Kelanitissa, 160 MW from Sapugaskanda, and 24 MW from Uthuru Janani. The remaining 641 MW of the installed thermal capacity are from six privately owned power stations Details of the existing a thermal system are given in appendix 1. 6 1.2.2 Mahaweli Complex Reservoirs and Power Stations The Mahaweli Hydro power complex is main hydro power complex in Sri Lanka. Figure 2.2 Arrangement Of Mahaweli Complex Reservoir It consists of seven major power stations which has an installed capacity of 810 MWs. Upper Kotmale, Kotmale, Victoria, Randenigala, Rantambe, Ukuwela, Bowatenna and Nilambe are major power stations coming under Mahaweli complex, each station has capacities as shown below table 2.2. Table 2.2:Power Station Of Mahaweli Complex Name of Power station Number of Units Capacity of a Total Capacity of Unit Power Plant Kotmale 3 67 201 Victoria 3 70 270 Randenigala 2 61 122 Randambe 2 24.5 49 Ukuwela 2 20 40 Bowatenne 1 40 40 Nilambe 2 1.66 2.32 Upper Kotmale 2 75 150 1.2.3 Introduction to Kotmale Power Station The kotmale dam is a large hydroelectric and irrigation dam in Sri Lanka. Also, it is one of five major head work projects being undertaken under the accelerated Mahaweli Ganga 7 Scheme. It is the most upstream of these projects and develops the hydro potential of a major right bank tributary of the Mahaweli Ganga, the Kotmale Oya. The Kotmale project was mainly for the development of hydro power and the regulated discharge from the reservoir to increase the flow diverted at the Polgolla barrage into the proposed Moragahakanda reservoir for augmenting the irrigation suppled in systems. The reservoir would reduce flood peaks and their frequency, thus alleviated the floods in the Gampola area below it. Figure 2.3:Kotmale Reservoir The water impounded by the reservoir would be conveyed through an underground water conductor system to an underground power station located at about 7.2 km. (4.5 miles) from the dam for generation of electric power. After power generation, this water will be discharged through the outfall into the Mahaweli Ganga at the Atabaghe Oya confluence. In addition to the generation of power, the regulated water will improve the pattern of inflows of the Mahweli Ganga at the existing Polgolla diversion dam. This will firm up the power benefits from Ukuwela power station and serve to increase the irrigation water supplies from the Bowatenne dam. Almost all of the water stored in this reservoir is used to supply water for irrigation demand along the Amban River basin. However, the more electrical energy is generated by operating the reservoir near the full supply level with the higher effective head and turbine efficiency. In this regard, this reservoir is normally operated at close to the full supply level except when the water is released for irrigation. 8 1.2.4 The Main Physical Components of the Kotmale Project I. Dam The catchment area of the river at the dam site is 544 square kms and the dam is a thick earth core rock fill structure with 87m high and 600m long. These is other specification of Kotamale Dam. Table 2.3 :Specification of the Dam Top water level (TWL) 703m – MSL Maximum flood level 704.3m –MSL Minimum operation level (MOL) 665m – MSL Gross storage up to TWL 174 x 106 m3 It has a chute spillway with a capacity of 5500m3/Sec consisting of 3 radial gates 14x15m.Daiagram of radial gate is shown figure 2.4. Figure 2.4: Radial Gate Of Kotmale Dam Spillway II. Intake Gates These are the gates built on the in outside of the dam. The water from the reservoir is released and controlled through these gates. These are called inlet gates because water enters the power generation unit through these gates. When the control gates are opened the water flows due to gravity through the penstock and towards the turbines. III. Tunnel and Penstock 9 Low pressure tunnel with diameter 6.2 m is totally 6954m long with a maximum capacity of 113.3m3 /sec & creates a 65.2m head. Penstock is a high pressure tunnel between the surge chamber and the power house. It is 120m long & it creates a 105.9m head. The structural design of the penstock is same as for any other tunnel expect it has to bear high pressure on the inside surface during sudden decease in the load and increase in the load. Also, penstocks are made of steel with circular 5.55-4.80m diameter and equipped with the head gates at the inlet which can be closed during the repair of the penstocks, a sufficient water head should be provided above the penstock entrance in the surge chamber to avoid the formation of vortices which may carry air in to the penstock and resulting in lower turbine blade efficiency. IV. Surge Chamber The main function of 143 m height surge chamber is to reduce the water hammering effect. When there is a sudden increase of pressure in the penstock which can be due sudden decrease in the load demand on the generator. When there is sudden decrease in the load, the turbine gates admitting water to the turbine closes suddenly owing to the action of the governor. This sudden rise in the pressure in the penstock will cause the positive water hammering effect. This may lead to burst of the penstock because of high pressures. Figure 2.5:Surge Chamber of Kotmale When there is sudden increase in the load, governor valves open and accepts more water to the turbine. This results in creation of vacuum in the penstock resulting into the negative water hammering effect. Therefore the penstock should have to withstand both positive water hammering effect created due to close of governor valve and negative water 10 hammering effect due to opening of governor valve. In order to protect the penstock from these water hammering effects, surge chamber is used in Kotmale power station. V. Power Station Kotmale power is underground power station with fully remote control system with automatic frequency control operation. The design and manufacture of the Francis turbine and generators for the Kotmale power station were done by KAMEWA Company and ASEA Company. Since the 3×67 MW vertical Francis turbine and 3×9000KVA vertical synchronous generator for this power station are the largest capacity machine in Sri Lanka expect for Victoria power station. Figure 2.6: Kotmale Under Ground Power Station VI. Turbine The turbine is a vertical-shaft, single-runner Francis type with steel spiral case and elbow type draft tube. Table 2.4: Specification of Turbine Number of Unit Three Type Vertical Francis turbine Speed of Rotation 375 rev/min Head Rated-201.5m Maximum-231m Rated output 67MW Rated discharge 35m3/s 11 Figure 2.7:Arrangement of Turbine Main Inlet Valve Main inlet valve is the primary control for entry water to turbine and is the principle protection for station. The main inlet valve is of the rotary type with double sealing to allow the service seal to be examined or replaced without emptying pipe line. Spiral Casing These machines have vertical shafts. The fluid enters from the penstock to a spiral casing which completely surrounds the runner. This casing is known as scroll casing or volute. The cross-sectional area of this casing decreases uniformly along the circumference to keep the fluid velocity constant in magnitude along its path towards the guide vane. Also, it is manufactured of steel welded plate. Turbine shaft The turbine shaft is a common shaft with generator shaft and is directly connected to rotor center of the through the trust support. The lower turbine shaft flange is connected to 12 runner. The shaft is hollow bored to diameter 150mm through its entire length and has an integrally cast color to from the side bearing surface. Runner Even through this machine is a large capacity with a high speed machine, a fabricating welded runner is partial casting having a better finishing profile of the runner blades than the whole carbon steel casting runner. Diameter of runner is 2.05 m and speed of runner is 375r/min. Figure 2.8: Turbine Runner Of Kotmale Power Plant Draft Tube The draft tube is a conduit which connects the runner exit to the tail race where the water is being finally discharged from the turbine. The primary function of the draft tube is to reduce the velocity of the discharged water to minimize the loss of kinetic energy at the outlet. This permits the turbine to be set above the tail water without any appreciable drop of available head. This turbine has Simple elbow type draft Tube and it consists of an extended elbow type tube. 13 Guided Vane Guided vans levers, links operating and sever motors are the principle parts of guide vans. The turbine gates comprise 24 guide vanes of steel. The vertical faces of adjacent vanes are connecting with each other when turbine is closed are accurately machine to prevent leakage. Figure 2.9:Guide Vanes Of The Power Plant The top of the upper stem of each guide vane is fitted with a cast steel lever and a gate lever which is connected to operating rings by two plate steel links and ping. The connection between stop lever and vane lever is by an adjustable friction joint. The friction joints protect the vital parts of the turbine from diagram it some obstruction should prevent closure of the gate. VII. Generator The generator is a vertical-shaft, semi- umbrella type three-phase synchronous brushless machine with AVR. Its rated continuous output is 90 MVA and has a lagging power factor of 0.85. The winding of the generator rotor and stator should have Class-F epoxy insulation. The stator windings are star connected and consists of identical single turn diamond lap coil with full class “F” insulation arranged in open slots with two coil sides per slot. Transposition of the standard forming a conductor is made outside the slots. The neutral ends are brought out to separate terminals. Stator core is built up of high-grade non ageing silicon steel punching, insulated on both sides with a heat resisting varnish. Generators are usually ventilated on the closed circuit system in which the same air is continually recirculated and passes through water cooling units. The water supply for both oil and air coolers can readily be drawn from the turbine casing, thorough reducing valves and strainers, so that it flows automatically when the main inlet valve opens. When water 14 head is high it is more economical to pump from the tail race/draft tube. Each turbine may then have its own pump, generally with one standby common to all units Table 2.5:Specification Of Generator Rated Power 90MVA Number of Units 3 Power factor 0.85 Rated speed 375 r/min Runaway speed 725 r/min Phase 3 Frequency 50Hz Excitation Voltage 220V Current 1250A Stator F Rotor F Insulation VIII. Governor system This is the speed/load control of turbine and governor is the main controller in which the governor adjusts the flow of water through the turbine to balance the input power with the load. With an isolated system; the governor controls the frequency. In interconnected system, the governor may be used to regulate the unit load and may contribute to the system frequency control. Electro-mechanical governor with speed and power control section and mechanical hydraulic actuator sections are now generally employed. Speed power control section and hydraulic actuator sections may be installed in separate locations. Governors are designed to regulate the speed and thereby the loading on the unit within a desired range by increasing or decreasing the amount of water supplied to the turbine runner. Turbines are fitted with gate limiters which are can be remotely controlled. The gate limiter is used for speed no load setting; desired control setting and over load of generators. The gate limiter adjustment usually extends down to zero and thus affords a means for remote stopping and starting at a safe and controlled rate. 15 Figure 2.10:Actuator of Governor IX. Main Transformer and Switchyard Equipment Three main transformer units are installed in the transformer cage next to the control room. The main features of the power transformer are as follows: Table 2.6:Specification Of Main Transformer Type Single phase power transformer with off circuit Tap changer Rated frequency 50Hz Rated power 30000KvA Rated Voltage Primary side 13.8Kv Secondary side 220Kv Primary side 1499A Secondary side 1575A Rated current Bank connection symbol YNd11 Type of cooling ONAN/ONAF Kotmale switch Yard is the main grid station in the transmission network of Sri Laka which was constructed under Mahawali transmission Project in 1984. Mainly, it is a 220K outdoor 16 substation (air insulated), consist four 220Kv double circuit lines come from Biyagama, Anuradapura, Victoria and Upper Kotmale substations. Figure 2.11:Kotamle Switch Yard There are three main 220/13.8kV three winding auto transformer with rating 90MVA each. 220 kV switchgear, in a one breaker and a half scheme bus arrangement, for six transformers bays.one breaker and a half is a compromise between double bus bar scheme and the double circuit breaker scheme. This scheme improves the reliability and flexibility because, even in case of loss of complete bus bar there is no disruption in the power supply of the feeders. 17 Figure 2.12: One Breaker And A Half Scheme Bus Arrangement X. Electrical Auxiliary Following electrical auxiliary system are provided and their control incorporated in the control system. Auxiliary Power AC System This includes auxiliary transformers and switchgear for the auxiliary.in Kotmale power house auxiliary power get though the earthling transformer. Also there are 400V in door substation for auxiliary. DC System and Batteries This includes DC batteries and switchgear for control, emergency lighting, generator field flashing etc. 18 1.2.5 Introduction to Lakvijaya Power Plant The plant is located approximately 100m inland from the shoreline near the villages of Narakkalli and Penaiyadi on the Kalpititya peninsula in the Puttalam district of the North Western Province. First 300 MW coal fired power plant of the Puttalam Coal Power Project which commissioned in 2011 is now in commercial operation. Peoples Republic of China has provided a concessionary loan for the implementation of the project. Figure 2.13:Lakvijaya Power Plant Transmission line of 115 km from Norochcholai to Veyangoda Grid Substation and associated infrastructure, coal unloading jetty with cranes and coal unloading barges and tugs, stationed at Norochcholai power plant were also included in addition to the 300 MW power plant included in the Phase I of the Project. Under second and third phases (2x300 MW) of 300 MW coal fired power plants and transmission line of 98 km from Norochcholai power plant site to Anuradhapura, Anuradhapura Grid Substation, New Chilaw Grid Substation. Constructions of the second 300 MW power plant was completed in February 2014 and third 300 MW unit were completed in August 2014. This power plant has generated 1,404 GWh Units in 2012, 1,469 GWh Units in 2013, 3,202 GWh Units in 2014 and 3,328 GWh Units by end of August 2015. 19 1.2.6 Component of Lakvijaya power Plant I. Boiler Boiler is the main part of the power plant. The purpose of the boiler is to boil water to produce steam. In actual, the boiler is made of several mechanical as well as electrical parts like boiler drum, de-aerator, economizer, water wall tubes, furnace, super-heaters etc. The 300MW unit boiler of Puttalam coal-fired power plant project is subcritical, one-stage reheat and natural circulation drum boiler, which adopts balance draft and tangential firing, fired bituminous coal. BMCR (boiler maximum continuous rating) condition is the design condition, the maximum Continuous steam output is 1025t/h; when unit electric load is 300MW the rated steam output is 964t/h. A pulverized coal-fired boiler is an industrial that generates thermal energy by burning pulverized coal (also known as powdered coal or coal dust since it is as fine as face powder in cosmetic makeup) that is blown into the firebox. The basic idea of a firing system using pulverized fuel is to use the whole volume of the furnace for the combustion of solid fuels. Coal is ground to the size of a fine grain, mixed with air and burned in the flue gas flow. Coal contains mineral matter which is converted to ash during combustion. The ash is removed as bottom ash and fly ash. The bottom ash is removed at the furnace bottom. II. Water Treatment Plant Sea Water is treated to remove the mineral contents as these minerals are harmful for boiler parts because presence of minerals may lead to corrosion. III. Coal Handling Plant The coal is the main fuel in a coal fired thermal power plant. First of all the coal is kept ready in CHP (Coal handling plant) to send it before the boiler because it may content some impurities as per their grade. IV. Ash Handling Plant Here the final ash coming out from ESP is collected. This ash can be used to make bricks, cement etc. V. Chimney The flue gas coming out from the plant side is thrown away by this giant pipe like design. chimney of Puththalam coal power plant is 200m height. 20 VI. Control Room The control room is equipped with a number of computers with smart visual simulating software to control the whole power plant machines by giving commands. VII. Turbine The turbine is a rotating mechanical metallic part to generate mechanical torque to drive the heavy turbo generator by using pressure of steam.300Mw boiler height about 70m.It is sub critical, single reheat, tandem compound, two casing double exhaust condensing steam turbine. Table 2.7: Specification Of Turbine VIII. Rated output 300MW Main steam pressure 16.7Mpa Reheat temperature 538°C Main steam temperature 538°C Regenerative stage 8 stage Generator This is a very important rotary electrical part where the plant output in the form of voltage and current are produced. The function of generator is to convert the mechanical energy of turbine to the electrical energy. Almost the generators are directly shaft coupled with the turbine. The type of turbo-generator is a 3-phase non-salient pole synchronous generator driven by a steam turbine. The rated rotating speed of the generator is 3000 r/min; frequency is 50 Hz. 21 Figure 2.14:Generator Of Lakvijaya Power Plant The rotation direction of the generator is clockwise when we observe it from driven end. The excitation is provided by static thyristor system. The generator adopts the cooling type of “W(water) and H(hydrogen)”. Stator coil adopts water internal cooling, rotor coil is hydrogen internal cooled, stator core and the end components is hydrogen surface cooled. Collector ring is cooled by air. Table 2.8: Generator Parameters In Puttalam Coal Power Plant Apparent power 353MVA IX. Active power 330MW Maximum continuous output (MCR) 332MW Rated power factor 0.85(lag) Rated stator voltage 20000V Rated stator current 10190A Exciting voltage (design date) 365V Exciting current (design date) 2642A Efficiency (design date) 98.9% Frequency 50 Hz Rotate speed 3000r/min Number of phases 3 Stator winding connection type YY Power Transformers in Puttalam Coal Power Plant 22 HV transformer The Generator Transformer (GT) type is three phase power transformer, technical specification is as follows: 50Hz, forced-oil forced-air cooled (ONAN/ONAF/ODAF), outdoor type transformer with two copper windings, with On Load Tap Changer. The rated capacity is 360 MVA, the HV sided rated voltage is 220kV/20 kV. The Unit auxiliary transformer (UAT) type is three phase transformer, technical specification is as follows: 50Hz, forced-air cooled (ONAN/ONAF), outdoor type transformer with split windings without on load tap changer, which rated at 31.5 MVA (LV winding). The rated voltage is 20kV/6.3 kV. Startup/standby transformer The Start/standby transformer (SST) type is a three phase transformer, technical specification is as follows: 50Hz, forced-air cooled (ONAN/ONAF), outdoor type transformer with split windings (with on load tap changer), which rated at 31.5 MVA (LV winding). The rated voltage is 220kV/6.3 kV. Figure 2.15: Unit Auxiliary Transformer X. Auxiliary System of Generator The auxiliary system is closely related to the generator operation. It affects normal operation and output of the generator directly. 23 The auxiliary system of generator is composed of the hydrogen and water cooling system, the temperature monitoring system, the excitation system, and the oil system and etc. The simple intro of the temperature monitoring system is as follow: Operation temperature of every part of the generator should be monitored during normal operation. The monitored positions are stated as follows: the stator winding, the stator core, the cold H2 area, the warm H2 area and the oil and etc. Temperature measuring units are buried at these positions and connected with the temperature monitor through wires. XI. Automatic Synchronizing Device The 300MW Generator Units is equipped with automatic synchronous detectors. Before connected to the power grid, excitation system of the generator should be put into operation and the voltages at two sides must meet with the requirements of synchronization. The phases, the frequency, and the phase sequences are all same with the system. XII. Composition and Function of Excitation System The generator is equipped with the excitation system of the type UNITROL manufactured by ABB Corporation. A static excitation system regulates the terminal voltage and the reactive power of the synchronous generator by direct control of the field current using thyristor converters. The entire system can be divided into four major function groups. Excitation transformer Excitation Modules with Control Electronics Thyristors' Converter units Field flashing and field suppression equipment In static excitation systems, the excitation power is taken from the generator terminals. The field current of the synchronous generator flows through the excitation transformer, the field circuit breaker -and the power converter (thyristor converter). The excitation transformer reduces the generator terminal voltage to the required input voltage for the thyristor converter, provides the galvanic isolation between the generator terminals and the field winding. The power converter (3 sets) converts the AC current into a controlled DC current If. At the beginning of the unit starting, the field flashing energy is derived from the residual generator terminal voltage, if the residual cannot meet with requirements; it will derived from the auxiliary power supply. As soon as 10 to 20 V at the input of the thyristor converter are reached, the thyristor converter and control electronics are ready for the normal operation and a soft-start sequence takes place. After synchronizing with the network, the excitation 24 system can operate in AVR mode regulating the generator terminal voltage and reactive power. XIII. Switchgear and Substation Mainly, it is a 220kv indoor substation consist four 220kv double circuit line come from Veyangoda and Anuradapura substation. Gas-insulated high-voltage switchgear (GIS) is a compact metal encapsulated switchgear consisting of high-voltage components such as circuit-breakers and disconnectors, which can be safely operated in confined spaces. Figure 2.16:Gas Insulator Substation In Lakvijaya Power Plant XIV. Electro Static Precipitator In order to save environment from harmonic micro particles as well as large dust particles, the dust in the form of fly ash are caught here and settled down. The ESP (Electro static precipitator) is an electrical device to produce high voltage corona effect to charge the dust particles. When passing through the high voltage electrostatic fields, dust particles in the gas will be charged by colliding with positive ions, negative ions and electrons or in the ion dispersion movement. The particles with electrons and ions will then move, under the influence of the electric force, toward and later accumulate on the electrodes of opposite polarity. By means of rapping, the layer of dust particles on the electrodes will be dislodged into the bottom hoppers. Practice shows that the higher the strength of electrostatic field, the more effective an ESP will be, and that it is preferable to have an ESP operating with negative corona. Therefore, our ESP is designed in the structure of high voltage negative corona. 25 1.2.7 Operation Process of the Lakvijaya Power Plant Figure 2.17:Operation Process Of Coal Power Plant Consider the operation process of the power plant simply which runs according to the Regenerative, Reheat Rankine Cycle. Pulverized coal from coal pulverizers is sent to the boiler and superheated steam is generated in the boiler by means of heat of fired coal. Superheated steam is initially sent to the High pressure turbine and turbine exit steam is sent again to the boiler for the purpose of reheating. Reheated steam is sent to the intermediate pressure turbine and that exit steam is directly sent to the law pressure turbine. All the three turbines are coaxially connected as a single shaft and the electricity generator is also connected to that shaft itself. The outlet of the LP turbine is directed to the condenser. Condensate from the condenser is pumped to the condensate polishing unit by using a condensate pump. Polished condensate from the polishers is sent to the LP heater no 8 and then to no 7, 6 and 5 respectively. Heated condensate from LP heaters is sent to the deaerator and condensate from de-aerator is pumped to high pressure heater no 03, and then to no 02 and 01 HP heaters using two boilers feed pumps. (After the Feed pumps the condensate is named as feed water.) In LP and HP heaters, condensate is indirectly heated using steam extracted from different levels of different turbines. De-aerator is a mixing type heat exchanger having both functions of heating of condensate and expelling dissolve oxygen from the condensate. Feed water from HP heater 01 is sent to the economizer in boiler and is heated using flue gas and then 26 it is sent to boiler drum. Then the condensate is circulated from the boiler drum to down comers and then to water wall tubes and then again to boiler drum. Qualified dry saturated steam is separated from the boiler drum and then flown to super-heater panels. Superheated steam from super heater panels is sent to the HP turbine and the steam cycle is completed. 2.1.1 Auxiliary System of the Plant The electric generator which has coaxially coupled to the steam turbine tandem produces the electric power and this power is defined as Gross Power output of the Power plant. For the various electric motor driven equipment and other electrical appliances, a significant fraction of that gross power output should be spent and that amount of that electricity is called as the house load or auxiliary power consumption or internal electricity demand of the power plant. In Lakvijaya Power station, about 30 MW out of 300MW of generator gross power output is consumed as the internal electricity demand. Then the net power output (difference between gross power output and internal electricity demand) will be nearly 270 MW. Auxiliary power consumption of different sections of the power plant can be identified as follows. All the sub system of the power plant can be classified into four main systems as Turbine Plant, Boiler Section, Coal Handling system and Balance of Plant system (BOP). Turbine section including Boiler Feed Water Pumping system (BFP), the Condensate Extraction Pumping system (CEP), Main Cooling Cater system (MCW), Close Cycle Cooling Water system (CCCW), Open Cycle Cooling Water system (OCCW) and other related sub systems having several high capacity pumps such as CEP, Booster pumps and main BFP, MCW pumps, OCCW pumps, CCCW pumps etc. Consumes about 14.9 MW from the 30MW of internal electricity demand. Out of that power, BFP consumes about 9.6 MW to pump the feed water from de-aerator to boiler drum from suction pressure of 0.9 mpa to discharge pressure of 22 mpa. Other than that, Main cooling water system consumes about 3.2 MW for two-mixed flow vertical type MCW pumps having a flow capacity of 18m3/s, for cooling the condenser. Coal handling system having several unloading cranes, stacker-reclaimers, conveyer belts, coal crushers and pulverizes etc. Consumes about 1.1MW from internal electricity demand. 27 Table 2.9:Auxiliary Power Consumption Of Lakvijaya Plant Equipment Power Consumption Percentage from internal (MW) electricity demand Cranes 0.80 2.67% Conveyor belts 1.05 3.50% Coal crushers 1.00 3.33% Pulverizers 1.35 4.50% Pumps 18.50 61.66% Fans 4.85 16.17% Compressors 1.10 3.67% BOP section including water treatment system, Chlorination plant, Hydrogen generation plant, Chillers for HVAC, Air compressors and fire & service water pumps etc consumes about 3.6 MW from the auxiliary power consumption. Out of that power, water treatment system including Sea water pre-treatment plant, Sea water desalination plant, Boiler make up water treatment plant and consumes about 1.8 MW for the number of different types of pumps and other appliance which are involved with this system. About 1.75MW of auxiliary power goes to air compressor system chillers having a large number of compressors and chill water pumps, compressors etc. Air and flue gas handling system of boiler, including various no of high capacity fans, pumps and other equipment such as, Forced Draft Fans (FDF), Induced Draft Fans (IDF), Primary Air Fans (PAF), Seal Air Fans, Air Pre-Heaters (APH), Absorber pumps, Booster fan and Aeration Fans for Flue Gas De-sulpurizer (FGD) etc consumes about 7.7 MW from the auxiliary power consumption. Other than that various electrical equipment in the power plant including lifts, lights, small pumps and fans, tools and equipment used for maintenance works, office equipment etc also poses a significant amount of power from the internal electricity demand. 2.1.2 Coal Storage Management techniques The existing conveyer system arrangement consists of mainly 8 numbers of belts. The capacities of stacking (Storing in compacted manner) and reclaiming coal (for the use in boiler) is indicated for each conveyer belt in the following diagram. Belt 09 construction and 28 Stacker Reclaimer 03 is yet in proposal stage. Earlier, prior to coal yard extension the coal yard is of total capacity was 989,531 MT. With the extension of the coal yard in future the coal storage capacity is increased up to 1.4 million MT. Figure 2.18:Coal Yard Of Lakvijaya Power Plant 2.2 Transmission Division 2.2.1 Transmission Network in Sri Lanka The electricity transmission network in Sri Lanka is solely owned and operated by Ceylon Electricity Board (CEB). CEB is responsible for the safe, secure and efficient operation of the electricity transmission in Sri Lanka. The transmission network is operated at 220kv and 132kv to transport electricity from generation points to distribution bulk supply points. Prior to 1980s, the Ceylon Electricity Board (CEB)’s transmission system was composed of 132Kv and 66Kv lines which had been developed in coordination with growth in demand and development of hydroelectric power project for delivering power to Colombo and other region. The Sri Lankan transmission system comprises 794 kilometers of 220kV overhead line circuits, 3102 kilometers of 132kVoverhead line circuits, 8 of 220kV Grid Substations and 55 of 132kV Grid Substations and is shown below. 29 Figure 2.19: Sri Lankan Transmission Network 220kV transmission system is mainly used to transmit power from Mahaweli complex hydro plants to main load center around Colombo through Kotugoda, Pannipitiya and Biyagama grid substation.132kV transmission network is used to interconnect most of grid substation and to transfer power from other power station. In 2011 the coal plants of Puttalam connected to the 220kV system by 100km long transmission line to new Anuradapura and a 70Km long 30 transmission line to Chilaw grid substation. The 220Kv transmission line of BiyagamaKotugoda, Kotugoda-Veyagoda, Veyangoda-New Chilaw, New Chilaw- Puttalam Coal, Puttalam Coal-New Anuradpura,New Anuradhapura-Kotmale and Kotmale-Biyagama create the 220Kv ring and act as backbone of the system. At present around 2400Mw is connect to the 220kv and around 1400MW connected to 132Kv network. Also, the transmission network consists of overhead transmission lines with ACSR conductors mounted on steel towers including a 13km length of 132kV underground cable network within the Colombo City supply. 2.2.2 Grid sub station A substation is a part of an electrical generation, transmission, and distribution system. Substations transform voltage from high to low, or the reverse, or perform any of several other important functions. Between the generating station and consumer, electric power may flow through several substations at different voltage levels. A substation may include transformers to change voltage levels between high transmission voltages and lower distribution voltages, or at the interconnection of two different transmission voltages. Substation has many components (e.g. circuit breakers, switches, fuses, instruments etc.) which must be housed properly to ensure continuous and reliable service. According to constructional features, the sub-stations are classified as: a Indoor sub-station Outdoor sub-station Pole-mounted sub-station 2.2.3 Biyagama Sub Station Biyagama substation is the main receiving station in the transmission network of Sri Laka which was constructed under Mahawali transmission Project in 1984. Mainly, it is a 220Kv/132Kv/33Kv outdoor substation consist four 220kV double circuit line come from Kotugoda,Kotmale,Kelanitissa and Pannipitiya substations and two 132Kv double circuit line come from switch yard of Sapugaskanda power station. There are two main 220/132kV three winding auto transformer with rating 250MVA each. Also it consists 33Kv switch yard which is connect to 132Kv bus bars through 132kv/33kv step down power transformer. 220 kV switchgear, in a double bus bar arrangement, for four transmission circuits (with space for six more), two transformers (with space for two more), and a bus coupler.132 kV switchgear, in double bus bar arrangement, for two transformers (with space for two more), one bus coupler, and four transmission circuits (with space for four more). The Biyagama 31 site has been selected as the closest possible one to Colombo allowing access for lines into all existing or planned major substations in and around the city. It is close to the Sapugaskande substation and free trade zone for heavy industry. Figure 2.20:Biyagama Grid Sub Station 220kV, 70.5km long, double circuit line from Kothmale power station to Biyagama switching station was energized in 1984 to dispatch hydro power generated at the Mahaweli complex power stations namely Kothmale, Victoria, Rantembe and Randenigala. The maximum power generated at Mahaweli complex is nearly 660MW. Due to the environmental factors maximum generation is possible only during raining (wet) season. ACSR type duplex Zebra (400sqmm) is used as a conductor of the Kotmale Biyagama line. This overhead line consists of two circuits mounted on steel lattice towers. The circuit is designed for a maximum 700 C conductor temperature. The thermal rating at night time and day time is 1450 A and 1960A respectively. Two series of distance protection schemes (Permissive under reach transfer tripping) consisting of two types of distance relays from two different manufactures were used to protect the line. Single phase auto reclosing facility and breaker failure protection is incorporated. Distance relays, CT windings and circuit breaker trip coils are duplicated to improve reliability of operation. Two power line carrier channels are used to transmit the trip signal between relays located at both ends. To provide maximum lightning protection two earth wires are mounted with zero shielding angles. Trip coils are duplicated to improve reliability of operation. Two power line carrier channels are used to transmit the trip signal between relays located at both ends. To provide maximum lightning protection two earth. 32 Biyagama to Kelanitissa 220 kV transmission line is 16 km long, double circuit, having two 300 sq. mm ACSR conductors per phase. Kelanitissa and Kolonnawa substations together supply the central part of the city of Colombo, where very rapid load growth is expected. Biyagama to Pannipitiya 220 kV transmission line is a double circuit line 17 km long, having one 400 sq. mm ACSR conductor per phase. It was built for 220 kV but operated initially at 132 kV. 2.2.4 Component of A Grid Sub Station Biyagama substation is an assembly of the following major electrical equipment: Electrical Power transformers Bus bars Instrument transformers Lightning arresters Conductors& Insulators Circuit breakers Isolators Relays 2.2.5 Electrical Power Transformer The power transformer is the most expensive equipment in a transmission grid substation and it does not require any exaggeration to understand the importance of operating and maintaining it properly for a longer service and for a reliable power supply. Figure 2.21: Main Transformer Of Biyagama Sub Station If we consider about transformer of Biyagama substation these power transformers were installed with the introduction of Mahaweli Hydroelectric project; hence the transformers are more than 30 years old now. Power transformers equipped with on-load tap changers (OLTCs) have been the main components of electrical networks. OLTCs enable voltage 33 regulation and/or phase shifting by varying the transformer ratio under load without interruption. Name and specifications of transformers are shown in below table. Table 2.10: Specifications Of Transformers Of Biyagama Name 250/3MVA transformer Outdoor use oil immersed air cooling non pressure sealed type. on-load tap-changing transformer HV 200/3-250/3 MVA Rated power I. MV 200/3-250/3 MVA LV 60/3MVA Rated frequency 50Hz Phase Single Name of sub station Biyagama Rated Voltage HV 220√3kV MV 132√3kV LV 33Kv Total weight 81000Kg Total oil amount 23050Liter Type of cooling ONAN/ONAF Standard IEC Number of Tap 13 Manufacture Takaoka Co.Ltd., Japan Temperature rise Win d 55°C Oil 50°C Maintenances and Checks of Transformer In the daily maintenance and check the operating condition of various units may be check in the walk –round check of the equipment in the plant yard. Transformer Temperature Transformer temperature has direct effect on the life of the insulation and it is so constructed as to prevent oil temperature from exceeding either 90°C for an open from or 95°C for sealed type when ambient temperature is 40°C. 34 The Amount of Oil The amount of insulation oil has great effect on the insulating and cooling functions. so, check as often as required to confirm the appropriate oil level. Also, quality of following components are checked in maintenance. i. ii. iii. iv. v. vi. Protective relays Oil feed pump On load tap changer Non –voltage tap changer Bushing Protective relay. 2.2.6 Circuit Breaker The circuit breakers are used to break the circuit if any fault occurs in any of the instrument. These circuit breaker breaks for a fault which can damage other instrument in the station. For any unwanted fault over the station we need to break the line current. This is only done automatically by the circuit breaker. These are load switches. It is able to make or break the normal load current as well as the fault currents. The basic construction of any circuit breaker requires the separation of contacts in an insulating fluid, which serves two functions. It extinguishes the arc drawn between contacts when the CB opens and it provides adequate insulation between the contacts and from each contact to earth. For successful operation of the circuit breaker, two functions are to be performed. These are Operating mechanism function and Arc quenching function. There are various operating mechanisms such as spring charge mechanism, Pneumatic mechanism and Hydraulic Mechanism. Minimum oil (called minimum oil circuit breakers-MOCB) and SF6 gas (called Sulphur Hexafluoride-SF6 gas CB) are used as arc quenching medium for CB in Biyagma substation. I. Minimum Oil Circuit Breaker Minimum oil circuit breaker consists of two oil filled chambers namely upper chamber and lower chamber which are separated from each other. There is extinction process is carried out in upper chamber. So, it is called an are extinction chamber or current interruption chamber of minimum oil circuit breakers(MOCB). This chamber house and are control device, an upper fixed contact and ring shaped lower fixed contact. There is control device is fitted to the upper fixed contact. The moving contact slide through the lower fixed contact such that a physical (or electrical) maintained between them. The electric assembly of upper 35 fixed contact, lower fixed contact and arc control devices enclosed in a glass fiber enclosure which is surrounding oil. The oil present in the lower chamber does not involve the arc extinction process and instead it is used only for insulation purpose. The operating rod which is permanently fixed to the moving contact is connected to the operating mechanism which provide vertical motion in order to make and break the circuit. Figure 2.22:Minimum Oil Circuit Breaker Re- Installation II. SF6 Circuit Breakers Sulphur hexafluoride (SF6) is an inert, heavy gas having good dielectric and arc extinguishing properties. The dielectric strength of the gas increases with pressure and is more than the dielectric strength of oil at 3 kg/cm2. The use of SF6 circuit breaker is mainly in the substations which are having high input KV, say above 220KV and more. The gas is put inside the circuit breaker by force i.e. under high pressure. When if the gas gets decreases there is a motor connected to the circuit breaker. The motor starts operating if the gas went lower than 20.8 bar. There is a meter connected to the breaker so that it can be manually seen if the gas goes low. The circuit breaker uses the SF6 gas to reduce the torque produce in it due to any fault in the line. The circuit breaker has a direct link with the instruments in the station, when any fault occurs alarm bell rings. 36 2.2.7 Isolator and Earth Switches Isolators are the no load switches and used to isolate the equipment. (Either line equipment, power transformer equipment or power transformer). With the isolators, we are able to see the isolation of the equipment with our naked eye. The line isolators are used to isolate the high voltage from flow through the line into the bus. This isolator prevents the instruments to get damaged. It also allows the only needed voltage and rest is earthed by itself. Isolator is a type of switching device. It has no control devices. Isolator is operated after the circuit breaker is opened. While closing the circuit, first close the isolator and after the circuit breaker is closed. Strictly speaking Isolators are operated under no current condition. In the following cases it is permissible to use isolator for making and breaking of the circuits. Air break isolators or disconnecting switches are not intended to break load though these are meant for transfer of load from one bus to another and also to isolate equipment for maintenance. These are available mainly in two types vertical break type and horizontal break type. The later type requires larger width. However, the space requirement can be reduced in the horizontal break isolators by having double break with a center rotating pillar. Pantograph and semi-pantograph disconnects involve vertical movements of contact arm and therefore require less separation between phases and thereby require less separation between phases and thereby help in reducing the sub-station area to a larger extent. The isolators could be operated mechanically or hydraulically or pneumatically or by electric motor. Earthling facility shall be provided wherever required. 37 Figure 2.23:Isolaters In 220Kv Switch Yard 2.2.8 Current Transformers Current transformer is a current measuring device used to measure the currents in high voltage lines directly by stepping down the currents to measurable values by means of electromagnetic circuit. Figure 2.24: Current Transformers 2.2.9 Potential Transformers An instrument transformer in which the secondary voltage, in normal conditions of use, is substantially proportional to the primary voltage and differs in phase from it by an angle which is approximately zero for an appropriate direction of the connections. Basic Functions of Voltage Transformers are: 38 To reduce the line voltage to a value which is suitable for standard measuring instruments relays etc. To isolate the measuring instruments, meters, relays etc. from high voltage side an installation. To sense abnormalities in voltage and give signals to protective relays to isolate the defective system. 2.2.10 Bus Bar Bus bars are the part of the substation where all the power is concentrated from the incoming feeders, and distributed to the outgoing feeders. That means that the reliability of Biyagama substation depends on the reliability of the bus bars present in the power system. An outage of any bus bar in Biyagama substation can have dramatic effect on Sri Lankan Power system. An outage of a bus bar leads to outage of the transmission lines connected to it. As a result, the power flow shifts to the surviving healthy lines that are now carrying more power than they are capable of. This leads to tripping of these lines, and cascading effect goes on until there is blackout or similar situation. I. Bus bar scheme of Biyagama substation Bus bar scheme of Biyagama substation is double bus bar scheme (2BB). the more complex scheme of a double bus bar system gives much more flexibility and reliability during operation of the substation. For this reason, this scheme is used for distribution and transformer substation nodes of the power supply system. It is possible to control the power flow by using the bus bars independently, and by switching a feeder from one bus bar to the other. Because the bus bar disconnections are not able to break the rated current of the feeder, there will be a short disruption in power flow. 39 Figure 2.25:Diagram Of 220 kV Transformer Bay Section 2.2.11 Grid Substation Overloading and blackout Overloading of grid substations is defined based on the loading levels of grid substation power transformers. Overloading of transformers must be avoided to avoid overheating, leading to equipment damages and reducing the life time. The total system failure on 13 March 2016 has initiated with the failure of tap changer of one of the 220/132/33kv transformers in Biyagama Grid substation which has activated the bus bar protection making the Grid dead. The subsequent collapse of Norochcholai coal power plants triggered the system failure. The complete system restoration was taken almost seven hours and hence the impact was immense. 2.2.12 Introduction to System Control Center The system control center is the central nerve system of the power system. It senses the pulse of the power system adjusts its condition and coordinates its movement. Normally, system control center collects real-time data of MW power outputs from power plants to conduct frequency control (FC) and economic dispatch (ED). Using system frequency as a surrogate measurement of power balance between generation and load in the country, frequency control was used to control generation in order to maintain frequency. A power generating system has the responsibility to ensure that adequate power is delivered to the load, both reliably and economically. The quality of power supply is affected due to continuous and random changes in load during the operation of the power system. Hence, the system control center is required to maintain a continuous balance between power generation and load demand. According to the Power system regulations and practice of Sri Lanka, it has been identified that: 40 Voltages at the live bus-bars of CEB network: 220 kV ±5% 132 kV ±10% System frequency (SF): Normal operating range: 50 Hz ±1% According to the current practice of CEB, Normal operating range: 50 Hz ±4% Short term variations: -6% to +5% up to 3s. 2.2.13 Present Situation of Frequency Control in Sri Lanka At present, 10 water turbines at 4 hydro power stations, Victoria (70MW×3, reservoir pond type), New Laxapana (50MW× 2, regulating pond type), Samanalawewa (60MW× 2, reservoir pond type) and Kotmale (67MW×3, reservoir pond type), are used for frequency control. Both Victoria and New Laxapana are used mainly for frequency control, and Samanalawewa and Kotmale are used subordinately. New Laxapana is used about 1500 hours per year, and Samanalawewa is used about 5 hours per month. 10 water turbines of 4 hydro power stations can be used for frequency control, but only one water turbine can be used at one time for frequency control except at Samanalawewa. Two or three water turbines cannot absorb load changes together at the same time. Only two units of Samanalawewa can absorb load changes together at the same time. Of course, some water turbines at different power stations cannot absorb load changes together at the same time. In Sri Lanka, governor free operation is used as a frequency control system. Under this control system, an amount of control offset (frequency deviation) is allowed, and control offset is manually cancelled by changing the output of water turbines. 2.2.14 Frequency Controlling Method Use in Sri Lanka Turbine power in accordance with the pre-determine power in accordance with Generating stations identified by the System Control Centre (SCC) of Ceylon Electricity Board (CEB) situated at Kotmale, Victoria, Laxapana and Samanalawewa which perform manual secondary frequency control. The SCC decides and selects one of these four generating stations to control the system frequency at a given time. The decision of the SCC is dependent on many aspects such as the available water storage capacity, downstream irrigation requirements and transmission line constraints. While the system is on steady state, when a sudden load is added to the power system, stored kinetic energy of turbine generators initially contributes in real time to help avoid the sudden imbalance between generation and 41 demand. As a result, turbine generator speeds drop. Following the change in turbine speeds, and hence the frequency, governors intervene and adjust the pre-determined set value, based on governor droop characteristics. 2.2.15 Droop Characteristics of a Generator In Sri Lanka, one of the four frequency controlling stations controls the system frequency at a time, while other stations are operated on a fixed output as determined by the SCC. The “master” frequency controlling station selected for this study is the 67MW unit of Kotmale. Speed droop characteristics of Kotmale hydro power plant are shown in Figure 2.26 Figure 2.26: Speed Droop Characteristics Of Kotmale Hydro Power Plant When on frequency control, the power plant generally operates closer to the midpoint of its Unit capacity range of 0 to 67MW. When the demand increases or decreases and when the frequency decreases or increases as a result, the operating point is moved first along the normal droop characteristic curve (marked 1) and settles down at a point above or below the set point corresponding to 50Hz. When the steady state operating point moves along the droop characteristic curve (without a change in the speed reference), the wicket gate position is adjusted by the governor controller via hydraulic actuators which adjust the active power delivered by the generator. 42 After Kotmale and all other generators connected to the system have changed their outputs to match the change in the demand, the frequency would settle down at a new steady state value along curve “1”, which is different to 50Hz. At that point, operators at the station on frequency control which is Kotmale in this case, adjust the “speed reference”, or shift the droop characteristic curve in Figure 2.26 to another parallel line (either 2 or 3), until the frequency is brought back to 50Hz. Once the frequency is brought back to 50Hz by Kotmale operator, all other stations that were on fixed load, would once again adjust their outputs to the points in the droop characteristic curve corresponding to the fixed outputs as requested by the SCC prior to the disturbance. 2.2.16 Basic Principles of Power System Operation Basic principles of system operation in the CEB power system are as follows: Reservoir pond type power stations, like Victoria, and Gas Turbine units are power sources for peak demand, but not for base demand. These power stations should be mainly operated at night peak and semi-peak, but not during the off peak portion of the night. Power stations which are obliged to run even during the off peak portion of the night, like New Laxapana, should be mainly used for frequency control during the mid-night period, midnight to 6 a.m., instead of reservoir pond type power stations, like Victoria. At the end of the rainy season, all of the water levels at reservoir ponds should reach their highest levels and water levels should be kept as high as possible (High Water Level Operation). When large scale units, such as the 300MW units, stop due to sudden outage or scheduled maintenance, gas turbines should be operated as little as possible. Reservoir pond type power plants should be mainly operated instead of the large scale unit. After the large scale unit is operated in parallel, water levels at each reservoir pond should be restored to the scheduled level. When an amount of water is given, it is most efficient to share the discharge equally among the water turbines running parallel. Hence, when frequency control operation is required, it is desirable to absorb load changes equally among water turbines running in parallel. (High Efficiency Operation due to Governor Joint Operation) Since, in the Kelani Complex, all three regulating ponds, Laxapana, Canyon and Norton regulating ponds, have only a small capacity, it is very hard to change output freely and suddenly. Sudden and big load changes, such as large scale units dropping out or load forecast error, should be absorbed by power stations with their reservoir pond type power stations with less restrictive conditions, like Victoria and Samanalawewa. In addition, 43 Polpitiya has oscillation problems. In this case, output per unit running at Polpitiya should be fixed at 35MW or more, and total output at Polpitiya should be decided by the number of units in service. Total output at Polpitiya should be either 0MW, about 35MW or about 70MW. (High Efficiency Operation due to Starting and Stopping) Next Day Operation Plans should be decided on the condition that: Polpitiya is operated at a fixed load, about 35MW per unit and Next day, all power stations with small regulating ponds in the Kelani Complex are operated on a schedule decided the previous day. Load forecast error and outage at other plants should be absorbed mainly by Victoria and Samanalawewa with less restrictive conditions. The number of startup and shut off events may increase at most once or twice per day more than now, and hardly effect machine life. Water turbines at the power stations with reservoir ponds or regulating ponds should not be operated at light load except for unavoidable reasons, such as frequency control and irrigation demand. By using the regulating capacity of the regulating ponds or reservoir ponds fully, starting and stopping of water turbines should be done moderately and always operated near maximum efficiency output. Since excessive saving of investment and maintenance expenditure causes fuel expenditure increase, reasonable and moderate judgement is indispensable. 2.2.17 Black Out Situation in Sri Lanka Power system of Sri Lanka has a daily maximum power consumption of around 2, 100 MW. This always falls as the night peak of the ‘Load Curve’ of Sri Lanka. A 65% of the total generation is from thermal and the majority of the balance is from Hydro Power Plants (PP). Currently, around 200 MW of the total generation is from embedded generation, which comprises with Hydro and wind power. 900 MW ‘Lakwijaya’ PP (which is the PP with highest capacity in Sri Lanka and has been connected to the grid in 2011), contributes the system with approximately as, 22% of the total installed capacity, while 26% of the average generation. Since it operates on coal, cost of a unit of electricity is considerably low compared to that of all other thermal plants. Therefore, it performs a very important role in economic aspects too. Hence, if it happened to isolate “Lakwijaya” from the national grid due to a faulty situation, there would be a considerable impact on the PS stability that may lead to a system brown-out or black out situation. On the other hand, with the increased penetration of intermittent renewable energy, PS encounters increased uncertainty and variability causing generation and load imbalances. 44 2.2.18 Under-Frequency Load Shedding During a Load and Generation imbalance situation, since the amount of over load is not known at the instant of disturbance, the load is shed in blocks until the frequency stabilizes. Different methodologies are available for implementing Load Shedding schemes the three main categories of Load Shedding methodologies are traditional, semi-adaptive and adaptive. Traditional Load shedding scheme is mostly implemented because of its fewer requirements of sophisticated relays. It sheds a certain amount of load when the system frequency falls below a threshold. If this load drop is sufficient, the frequency will stabilize or increase. This process continues until the frequency sensitive relays get operated. The value of the threshold and the relative amount of load to be shed are decided off line based on experience and simulation. Although this approach is effective in preventing inadvertent Load Shedding in response to small disturbances with relatively longer time delay and lower frequency threshold, it is not able to distinguish between normal oscillations and large disturbances of the power system. Thus, this approach is prone to shed lesser loads at large disturbances. The semi adaptive Load Shedding scheme uses the frequency decline rate as a measure of the generation shortage. In this scheme, the rate of change of frequency thresholds and the size of load blocks to be shed at different thresholds are decided off-line on the basis of simulation and experience. Adaptive Load Shedding scheme is the one that can prevent black-outs through controlled disintegration of a power system into a number of islands together with generation tripping and or Load Shedding. Table 2.11 gives the Load Shedding scheme that is being implemented in Sri Lanka. Table 2.11 :Load Shedding Scheme In Sri Lanka Frequency Time Delay And Magnitude Of Load Shedding f ≥48.75 Hz State f < 48.75 Hz f < 48.5 Hz f < 48.25 Hz No load shed Step 1: 6.5% of load 100 ms time delay Step 2: 6.5% of load 500 ms time delay Step 3: 12% of load 500 ms time delay f < 48 Hz Step 4: 9%+3.5%* =12.5% of load 500 ms time delay f < 47.5 Hz Step 5: 3%+4.5%* =7.5% of load Instantaneous f < 49.0 Hz and -0.85<df/dt 13%+3.5%+4.5%=21% of load, 100 ms time delay 45 2.2.19 Operational Planning and Dispatch The use of individual generators is driven by operational planning and dispatch decisions. The objective of these decisions should be to minimize the total costs of electricity supply while complying with the practical constraints imposed by different technologies and by the electricity transmission system. In this section, I review the current operational planning and dispatch of system control center. 2.2.20 Utilization of Hydro Generation Hydro output is driven by hydrological conditions. The best measure of operating efficiency of hydro power plants is, therefore, the extent to which water storage is managed effectively to ensure adequate resources are available to meet peak demand and displace costly thermal generation. Reservoirs in Sri Lanka fill during the South West monsoon from May to September. The optimal water management policy, as regards electricity generation, is, therefore, to reduce reservoir levels to their lowest point by the start of May before allowing them to refill up to September. The stored water can then be used during the period to the start of the North East monsoon, in December to February, which again replenishes reservoirs. External constraints on the management of water storage and releases must be considered. In planning water storage and release from the Mahaweli complex, priority is given to meeting irrigation requirements under ‘dry’ year conditions. Once the resulting water release requirements have been calculated, the expected generation from hydro power plants is determined. If, after allowing for projected thermal generation, there remains a shortfall relative to expected demand then planned output from hydro plants is increased and water release programmes adjusted accordingly. The final programme of projected releases and generation is provided to CEB for its operational planning. 2.2.21 Software and Methodologies of System Control Center Operational data is very important for system operations. However, SCC is not equipped fully with a Supervisory Control and Data Acquisition/Energy Management System (SCADA/EMS), which can be used to collect data automatically. A SCADA system was installed in 1990 and upgraded in 2008 but does not have full coverage of the electricity system. Instead most operational data is still collected manually. 46 I. Software SCC uses the following software packages: Long-term and medium-term generation operation planning: SDDP Day-ahead and three day-ahead generation operation planning: NCP Power system study: PSS/E These are all standard software packages used extensively by other system operators internationally. However, there are some limitations. In particular: SDDP and NCP are designed as longer-term operational planning tools. To reduce computational time, SDDP does not use hourly modeling meaning it cannot readily represent the constraints on hour-by-hour dispatch. The two models are also unable to represent individual power plants in detail. This reduces their accuracy and increases the level of forecasting errors. SCC has explained that the SDDP and NCP software was recently procured to comply with the requirements of the Methodology for Merit Order Dispatch issued by PUCSL. This software is used to prepare longer-term operational plans for the purposes of reservoir management, maintenance scheduling, and fuel procurement. II. Planning At present, SCC’s planning horizons are as follows: year-ahead, six month-ahead, monthahead and day-ahead. The year-ahead plan is repeated every month, and has a planning horizon of 12 months into the future, the first month result is month-ahead operation planning. The daily plan is taken rolling for the next three days III. Real-Time Dispatch Real-time dispatch uses the most recent day-ahead plan. Deviations from this only occur where a generator fails or actual load deviates very substantially from forecast levels. In these instances, SCC revises the plan by rerunning the calculation in NCP. In emergency situations, load is shed according to a pre-determined plan IV. Methodologies At each step of the planning process, SCC prepares forecasts of system load, water inflows to hydro power plants (and, therefore, hydro generation) and renewable energy output. It then imposes physical constraints on the operation of thermal power plants (eg, start and stop timings) and on the transmission system and inputs the variable or energy costs of generators and requirements to hold-back a part of capacity to provide spinning reserve. 47 Planning software is then used to calculate the resulting optimal operational plan under a number of scenarios. The issues identified in the methodologies applied relate to load forecasting, the forecasting of water inflows, the setting of spinning reserve levels and the selection of scenarios for modeling. V. Power Transmission Line Control Procedure In general transmission system analysis comprise load flow studies, reliability studies and stability studies. To identify controlling criteria violation and required mitigating measure these studies are required. Load flow studies are required to determine the power system performance in steady state. Voltage criteria The voltage criterion defines the permitted voltage deviation at any live bus bar of the network under normal operating condition as given table 2.12 Table 2.12:Voltage Criteria Bus bar voltage Allowable voltage variation 220Kv ±5% 132Kv ±10% 2.2.22 Introduction to Transmission and Generation Planning in Sri Lanka The Ceylon Electricity Board (CEB) is under a statutory duty to develop and maintain an efficient, coordinated and economical system of Electricity Supply for the whole of Sri Lanka. Therefore, CEB is required to generate or acquire sufficient amount of electricity to satisfy the demand. In order to fulfill the requirement, CEB annually plans its development activities in the document as Long Term Generation Expansion Plan covering the growing electric power demand. The analysis was done based on the study processes and results of Long Term Generation Expansion Plan (LTGEP), which was prepared by the Generation Planning Section, Transmission and Generation Planning Branch, Ceylon Electricity Board. The following scenarios were chosen to analyze in the study to compare the adherence of the above energy policy elements: Scenario 1: Baseline Scenario – Scenario which fulfill the forecast future electricity demand under least cost principle while absorbing optimum Non-Conventional Renewable Energy (NCRE) to the system by year 2020 48 Scenario 2: Reference Scenario– Scenario considering no future NCRE developments Scenario 3: Energy Mix Scenario – Scenario considering fuel diversification in to LNG and Nuclear Scenario 4: Demand Side Management (DSM) Scenario – Scenario considering Demand Side Management forecast by Sustainable Energy Authority (SEA) Scenario 5: Scenario with Natural Gas - Considering Recoverable Natural Gas potential in Mannar Basin by 2020 2.2.23 Electricity Demand Forecast Method and Past Demand I. Past Demand Figure 2.27 shows the country’s daily load curve recorded on the day of annual peak for previous eight years. From the Figure 2.27, it is seen that the shape of the load curve has not changed much during the last eight years. The system peak demand occurred only for a short period from about 19.00 to 22.00 hours daily. The recorded maximum system peak is 2,164MW in year 2013, while in year 2014 the peak is 2,152MW. Figure 2.27:Daily Load Curve Electricity sales are forecasted using econometrical analysis. The model for the analysis is carefully composed based on the national policy of each category. Power generation at sending end is projected based on the electricity sales forecast, considering the 49 transmission/distribution losses, renewable energy forecasting, and the effect of energy conservation measures /DSM prediction. II. Methodology Econometric approach which combines economic theory and statistical techniques is used to estimate the relationship between electricity demand and GDP, electricity prices, population, energy intensity, household electrified, and number of rural electrification schemes completed. The electricity demand is chosen as the explained variable and other remaining variables are chosen as explanatory variables. Using historical data from 1977 to 2013 pertaining to the above seven variables, this relationship is derived by employing the special technique e. However, prior to fitting the model, time series properties of data and the order of integration need to be investigated for stationary. The electricity demand considered in this study is the total consumption of electricity (in GWh) in Sri Lanka. This represents the total amount of electricity consumed by all electricity consumers which include domestic, commercial and industrial customers. This regression analysis will be performed against different sectors like, domestic, industrial and others as there are different consuming habits within these categories.as an example following analysis method use for forecast domestic sector demand. In regression analysis, it was found that two variables for domestic sector: Gross Domestic Product Per Capita and Previous Year Domestic Consumer Accounts were significant independent variables for the domestic sector demand growth. Ddom (t) i = 84.602 + 6.017 GDPPC (t) i + 0.661 CAdom (t − 1) Where, Ddom (t) - Electricity demand in domestic consumer category (GWh) GDPPC (t) - Gross Domestic Product Per Capita (’000s LKR) CAdom (t-1) - Domestic Consumer Accounts in previous year (in ’000s) 2.2.24 Long Term Transmission Plan Based on these 10-year regional demand forecasts, and the annually updated generation expansion plan, the CEB’s Transmission Planning Branch prepares a 10-year transmission expansion plan. This plan is updated every year. This plan is prepared at a national level and is a comprehensive plan, using tools such as Power System Simulation Software (PSS/e), and provides information with regard to security analysis, stability, fault levels and reliability of the system. The plan also provides information on the weak points in the system and 50 proposes new projects to accommodate the new generation additions as well as to improve the quality and reliability of supply to customers. The main issues considered for transmission development are: i. Transmission lines and inter-bus transformer overloading under normal and single outage (n-1) operating conditions ii. Overloading of transmission equipment under normal and single outage (n-1) operating conditions iii. Corrective measures for voltage criteria violations under normal and single outage (n-1) operating conditions iv. Corrective measures for transient stability criteria violations 2.2.25 Introduction to Heavy Maintenance of Low Voltage Transmission Line The main supporting unit of overhead transmission line is transmission tower. Transmission towers have to carry the heavy transmission conductor at a sufficient safe height from ground. In addition to that all towers have to sustain all kinds of natural calamities. Figure 2.28 :33kv Transmission Tower So transmission tower designing is an important engineering job where all three basic engineering concepts, civil, mechanical and electrical engineering concepts are equally applicable. A power transmission tower consists of the following parts, Peak of transmission tower Cross arm of transmission tower Boom of transmission tower 51 Cage of transmission tower Transmission Tower Body Leg of transmission tower Stub/Anchor Bolt and Base plate assembly of transmission tower. The main parts among these are shown in the figure. I. Peak of Transmission Tower The portion above the top cross arm is called peak of transmission tower. Generally, earth shield wire connected to the tip of this peak. II. Cross Arm of Transmission Tower Cross arms of transmission tower hold the transmission conductor. The dimension of cross arm depends on the level of transmission voltage, configuration and minimum forming angle for stress distribution. III. Cage of Transmission Tower The portion between tower body and peak is known as cage of transmission tower. This portion of the tower holds the cross arms. IV. Transmission Tower Body The portion from bottom cross arms up to the ground level is called transmission tower body. This portion of the tower plays a vital role for maintaining required ground clearance of the bottom conductor of the transmission line. Figure 2.29:Part Of Transmission Tower 2.2.26 Design of Transmission Tower During design of transmission tower the following points to be considered in mind, 52 The minimum ground clearance of the lowest conductor point above the ground level. The length of the insulator string. The minimum clearance to be maintained between conductors and between conductor and tower. The location of ground wire with respect to outer most conductors. The mid span clearance required from considerations of the dynamic behavior of conductor and lightening protection of the line. Figure 2.30:Transmission Tower Construction In Badulla Area 2.2.27 Types of Transmission Tower According to different considerations, there are different types of transmission towers. The transmission line goes as per available corridors. Due to unavailability of shortest distance straight corridor transmission line has to deviate from its straight way when obstruction comes. In total length of a long transmission line there may be several deviation points. According to the angle of deviation there are four types of transmission tower. I. A – type tower – angle of deviation 0o to 2o. II. B – type tower – angle of deviation 2o to 15o. III. C – type tower – angle of deviation 15o to 30o. IV. D – type tower – angle of deviation 30o to 60o. As per the force applied by the conductor on the cross arms, the transmission towers can be categorized in another way. Tangent suspension tower and it is generally A - type tower. 53 Angle tower or tension tower or sometime it is called section tower. All B, C and D types of transmission towers come under this category. Based on numbers of circuits carried by a transmission tower, it can be classified as; I. Single circuit tower II. Double circuit tower III. Multi circuit tower. 2.2.28 Transmission Line Maintenance By using live line techniques to maintain transmission line infrastructure, circuits and transmission lines are able to remain in service while maintenance tasks are carried out. This is a major advantage to transmission asset owners because less redundancy is needed in the transmission network. Electricity consumers who are supplied by spur lines (single circuit supplies typically in rural areas) also benefit from live line work. They do not suffer the inconvenience of a cut in their electricity supply every time maintenance is carried out on their supply lines. Given the high cost of transmission lines and the impact that transmission lines have on the environment, there is a major advantage in being able to avoid duplication of assets purely for maintenance purposes. Figure 2.31:Hot Line Maintenance In Transmission Line 54 Live Line Maintenance can be Resorted for • Changing of insulators • Replacement of damaged section of conductor • Testing of insulators (on-line insulator tester) • Changing of cross arm • Changing of poles • Transferring conductor to higher pole 2.2.29 Major Tools Used for Live Line Maintenance Wire tongs: Normally used on pin type or suspension type construction for maneuvering and holding live conductors clear of the working area or for transferring to conductors to knee positions. Wire tongs saddle: are used to secure wire tongs to a structure. Tie stick: used for manipulation of the wires. Strain link sticks: used principally for supporting heavy conductor loads either for assisting wire tongs or for supporting entire load when changing insulators on running corners and dead end structures. Roller link sticks: used principally to hold conductors aside when relocating poles in mid span. Suspension link sticks: principally designed for lifting the conductor to relieve the strain from suspension insulators on high voltage lines. Strain carrier: used principally for relieving the strain on conductors when changing insulators on dead end structure. Auxiliary arms: used principally for holding conductors while damaged conductors or cross arms are being changed on pole structure. Double string dead end insulator tool: normally used to remove the strain from the one side of the double insulator strings. Gin poles: Used for lifting heavy conductors, hoisting transformers switches and other heavy items around energized conductors and other objects. Cum-a-along-clamp: normally used to grip the conductor when tension is applied to the clamps by rope blocks, link sticks etc. Safety equipment like conductor guards, cross arm guards, insulator covers, hand gloves etc. 55 Techniques used are Hot line maintenance is usually done by using one of the following methods: I. Hot Stick Method Using Insulated Sticks In this method the linemen are at the ground potential and is isolated from the energized conductor. This method is generally adopted for transmission lines up to 220 KV. The sticks enable the linemen to carry out the work without infringing minimum clearance distances from live equipment. Tools, such as hooks or socket wrenches can be mounted at the end of the pole. More sophisticated poles can accept pneumatically or hydraulically driven power tools which allow, for example bolts to be unscrewed remotely. A rotary wire brush allows a terminal to be scoured clean before a connection is made. However, a worker's dexterity is naturally reduced when operating tools at the end of a pole that is several meters long. Figure 2.32:Hot Stick Use In Hot Line Maintenance II. Bare Hand Technique In this method linemen works either from the insulated bucket / truck or ladder and is bonded to the energized conductor and isolated from the ground. This method is generally employed for transmission lines above 220 kV. However, this method is not use by CEB –DD3. III. Major Safety Precautions to be Observed During Live Line Working. A golden rule for hot line operation is "nothing is too safe when a life is at stake". Records prove that hot line work on high voltage lines is actually safer than maintenance work on "Cold" lines which could possibly become energized while the line is being worked. Linemen working with hot sticks are always conscious of the 56 danger involved, and being aware of this danger they work more cautiously and keep a safe distance While working it should be kept in mind that the person working invariably keeps a certain distance from the earth point. In addition to this he should also keep a certain safe distance from the other phases of the lines. Use freely safety equipment like cross-arm guards, hand gloves, etc. Never use a tool which is not tested and which is not familiar, never use a damp tool. Do not exceed the manufacturer’s ratings in the use of hot line tools. Linemen must know the approximate weight of a conductor span and the line tensions which they are dealing with. When in doubt use a longer tool or two identical tools. Check each tool regularly for indicating that the tool may have been overstressed. When not in use, tools should be kept in the tool container and not on the ground. IV. Cold line maintenance In the cold line method, the maintenance is carried out by availing outage on the line. The works of replacement of defective insulator string. tightening loss nuts and bolts, cold line insulator washing and defects noticed in through line patrolling are rectified, however since there is interruption in the line, there is huge revenue loss and customer dissatisfactions which are the main disadvantage in cold line maintenance. 2.3 Distribution Division 2.3.1 Introduction to Distribution Division Ceylon Electricity Board (CEB) is the licensee which is responsible for generating, transmitting, distribution and sale of electrical energy in majority the geography of Sri Lanka. While being the sole licensee for transmission it is also the licensee for bulk of the power generation in the country. Further, through four licenses for distribution and sale of electricity, it covers the entire geography of the country including the perimeter sea up to the border. The Distribution System of the Ceylon Electricity Board (CEB) is divided in to four distribution divisions. Each Distribution Division is managed by an Additional General Manager. A Distribution Division comprises of several Distribution Provinces and Distribution Areas, but the boundaries of these Distribution Provinces may not necessarily coincide with the boundaries of administrative provinces of Sri Lanka. A Distribution Province is managed by a Deputy General Manager while an Area is managed by either a 57 Chief Electrical Engineer or an Electrical Engineer, generally referred to as the Area Electrical Engineer. The Distribution Division 4 covers a part of the Western Province (Western Province South I), the entire Southern Province and a few parts of the Sabaragamuwa and Uva Provinces. Western Province South I covers the Areas of Ratmalana, Kalutara and Dehiwala and Southern Province covers the Areas of Ambalangoda, Galle, Hambantota, Matara, Tangalle, Weligama and Baddegama. The Distribution network of Division 4 extends from Dehiwala to Kataragama. 2.3.2 Transmission Lines of Distribution Network Power Transmission Lines The most common methods for transfer of electric power are Overhead AC and Underground AC. An overhead power line is a structure used in electric power transmission and distribution to transmit electrical energy along some distances. It consists of one or more conductors (commonly multiples of three) suspended by towers or poles. Since most of the insulation is provided by air, overhead power lines are generally the lowest-cost method of power transmission for large quantities of electric energy. Towers for support of the lines are made of wood, steel (either lattice structures or tubular poles), and concreate poles. The bare wire conductors on the line are generally made of aluminum A major goal of overhead power line design is to maintain adequate clearance between energized conductors and the ground so as to prevent dangerous contact with the line, and to provide reliable support for the conductors. 2.3.3 Present Situation of LV Lines In Sri Lanka, three-phase four wire system is adopted for LV lines, but many single-phase two wire systems still remain in rural areas. The conversion from single-phase to three-phase is being carried out one by one at this moment, thus it may take substantial time to convert a single-phase line to three-phase line. The losses on LV lines can be reduced to 1/6 times. CEB’s distribution system uses two kinds of ACSR conductors. One is ACSR Lynx (37/2.79 mm) used for 33 kV trunk lines named the backbone lines and the other is ACSR Raccoon (7/4.09 mm) used for 33/11 kV branch lines, named the pole lines. 2.3.4 Item Use in Overhead LV Construction I. Concrete poles 8.3m or 9m LV reinforced concrete poles shall be under for all new overhead construction lines higher size of poles may be used in combined run as appropriate 58 Poles position are classified as: Terminal-where the line is terminated with LV shackle insulators on the pole Tension –where the line is terminated with LV shackle insulators on both side of the pole. Intermediate-where the line is unbroken and supported on LV shackle insulators. Self-supported poles may be used in urban and densely populated areas where stays and struts cannot be erected. II. Stay assembly Stay assembly consists of the Stay Rod with Ratchet Nut, Stay Tightener and Stay Plates III. Conductors Two type of bar conductors are used in low voltage overhead lines these are Fly conductors (7/3.40mm) ACC and Wash conductors (7/4.39mm) ACC. The aluminum connector and termination are made out of high strength and high conductivity Aluminum. They are tubular or H type construction. Four wire Aerial bundled conductor system comprises three separately insulated aluminum conductors with XLPE (cross link poly Ethylene) aluminum alloy neutral conductor wire. IV. Insulators The insulator is made of good commercial grade wet process porcelain.it is Brown or White Glazed and the entire glazed surface is relatively free from imperfection. Three type of insulators are used in the construction of LV and MV lines they are; Pin, Post and Tension insulators. Pin insulators pin insulators are made of brown glazed porcelain. There pin insulators incorporate a hot dipped galvanized steel spindle, nuts spring washers two flat washers. 59 Figure 2.33 :Pin Insulator Line insulators These solid core line post insulators are made of brown glazed porcelain. these insulators are incorporate the necessary hardware such as steel spindle, nut, spring washer and 2 Nos. of flat washers, suitable of fix on channel iron cross arm. Tension insulators Tension insulators are disc type and made out of either porcelain or glass. The hardware part of the disc insulator is cap and pin type assembly with a 16mm ball and socket coupling. 2.3.5 Issues and Concerns to be solved in CEB’s Distribution System Voltage drop Voltage drop is observed at many locations on CEB’s distribution system. The root causes of voltage drop are the distribution of electric power on long distribution lines and overloading. The following three countermeasures are considered to rectify voltage drop. Provide additional distribution lines and/or size up the conductors; Construct new GS to shorten the distribution lines Salt contamination along the seaside Since salt contamination is observed on overhead lines along the seaside, the CEB 60 applied 33 kV insulators for 11 kV distribution lines to increase the creepage distance of insulators. As a drastic measure to solve salt contamination, cables should be adopted to distribution lines instead of overhead conductors. 61 Chapter Three 3 3.1 Training Experience –Management Management Systems of CEB While the Chairman is responsible through the Board for policy matters and close liaison with government, the General Manager is CEB's Chief Executive Officer. He is responsible for the overall direction and control of CEB's day-to-day business. The present General Manager was recently promoted to the post and is an experienced and long-serving engineer. He or she is presently assisted by ten Additional General Manager, several Deputy General Managers and a Finance Manager. With the exception of the Finance Manager, who is fully qualified in matters of finance, all top management posts are filled by engineers. The Commercial and Personnel Managers, Chief Internal Auditor, and the Legal Officer all report directly to the General Manager. 3.2 Asset management Since asset Management is a part of infrastructure development, this division plays a vital role in enabling the economic growth, social advancement & environmental development of the CEB. Assets Management division has branches to handle following work; 3.3 • Assets Management & Corporate • Training • Project Management (Vidulakpaya) • Workshop &Ancillary Services • Civil works & Buildings • Security Services Personal management The CEB during the year under review continued to provide a conducive working environment for all its employees and encouraged them autonomy, creativity and responsibility in them work. The following functions continued to be carried out by the Personnel Branch of the CEB while other Human Resources (HR) functions were carried out by the HR units of the respective Divisions. • Recruitment of employees to the permanent cadre. • Promotions and disciplinary matters of employees • Formulations of HR policies 62 • HR administration of all employees of Branches. The total number of employees in CEB as at the end of 2013 was 16,326 and 412 personnel were recruited during the year 2013, while 795 Employees left employment due to retirement, resignation, etc. The consumer to employee ratio increased from 298 in 2012 to 319 at the end of 2013. 3.3.1 Welfare Unit A network of Circuit Bungalows is maintained by CEB, at important locations such as Hatton & Bandarawela in the cool climes and in religious/archaeological cities such as Anuradhapura, Minneriya, Kandy, Kataragama and Jaffna. This facility is one of the major benefits available to the employees which they can make use of when on holiday. Continuous improvements are being made to the facilities provided at these bungalows with a view to providing the best service to the occupants. 3.3.2 Security Section The Security Section is responsible for ensuring safety of all vulnerable locations and CEB premises including power stations, reservoirs and the office of the Ministry of Power & Energy. Four Security Units are deployed for the security of the main Divisions of CEB namely Generation, Transmission, Distribution and Projects. 3.3.3 Training Branch Over the years Training Branch has taken steps to build up a competent work force through education, training, skills development of the employees so that they become capable of carrying out their work effectively in line with a modern integrated industry. CEB Training Centre, Piliyandala is famous training center for power sector employers. 3.3.4 5S System CEB uses 5S system very effectively to do their all the works very efficiently. The whole CEB premises are arranged according to the 5S system. 5S is workplace management where the work area and workplace are organized to minimize the loss of time and the use of movement. 5S is much more than “a place for everything and everything in its place”. 5S comprises five principles to make people highly efficient and effective in doing their work. Sort -Keep near you only what you regularly use Straighten -Find exactly what you need to use in less than 30 seconds Shine -Have your workplace and equipment ready for immediate use 63 Standardize -Everyone does each job in the same way and is challenged to improve it 3.4 Sustain -Everyone does their part to foster a safe, efficient and effective workplace Safety Management In any organization's safety of the workers or personals is the first thing which concerns in operation. And the safety of the equipment is concerned as the second. I could learn about safety instructional of site operation and maintenance work. All engineers, electrical superintendents, workers and helpers follow site safety instruction at the site and power plants. Transmission tower climber uses special safety tool kit for their safety. 3.4.1 Safety Precautions All circuit breakers, isolators, reclosers, load break switches, sectionalizers and Distribution substations were kept under lock and key. Only the authorized persons who are provided with a master key have access to them. Following are the most important safety precautions that need to be taken, when working on apparatus, equipment connected to a medium and higher voltage system, considered as dead: (a) Isolation of the system, plant, apparatus on which work is to be carried out from the remainder of the system and also from all infeeds such as embedded generators, selfgenerating plants and equipment, using visible isolation devices that have to be kept locked in the isolated position (b) Discharging and earthing the system/plant/apparatus on which work is to be carried out, by way of providing a connection with an approved earthing device, where practicable keeping the same locked and immobilized. It is not always possible to make LV equipment/apparatus dead and hence work on such apparatus were carried out as if they are live, unless such equipment is proved dead. Where applicable, suitable precautions were taken by screening or other means to avoid danger from inadvertent contact with live conductors. Work on live apparatus were only be undertaken by competent persons. 64 Chapter Four 4 4.1 Summary and Conclusion Summary During 12 weeks of my training programme in Ceylon Electricity Board, I was able to get a thorough knowledge about new technical things and also to how to behave at the industry and how to survive at the industry. Throughout this report, it is described that the things what I train during my training period of 12 weeks. Also, I gained a lot of technical experience about power engineering sector. I was able to identify what are the equipment of the power system of Sri Lanka and technics at the generation and transmission divisions and also visited Lakvijaya and Kotmale power plants which are hubs of Sri Lankan power sector. Also, I studied about generation and transmission planning methodology. In the system control center, I was familiar with that frequency controlling method, basic principles of power system operation and software such as PSS and SDDP which are used for operational planning and dispatch of s power system. I also got a chance to familiar with the regional and operations management processes with the staff of Ceylon Electricity Board. During this period, I got the chance to participate several training Session those are conducted specially for Trainees by the Engineers who are working at the CEB. 4.2 Conclusion Ceylon Electricity Board is one of the finest training places for any of the undergraduates who are interested in power sector and related technologies. It provided me a very good opportunity to obtain a good theoretical, technical and management knowledge on power system. The aim of the industrial training, which I underwent during the last period, was to gain practical knowledge and professional experience with the required theoretical background. It was a great experience to be a trainee at Ceylon Electricity Board the foremost government institute in Sri Lanka with modern technology and well-qualified staff. Apart from technical knowledge, the soft skills that we were exposed to will be invaluable for our future lives. Working with staff of different statuses, collectively working as a team, handling customers, documentation and reporting, punctuality, adjusting to the office culture are some of the skills we developed during these three months. Especially the engineers and the technical Officers are very helpful and friendly and we could reach them for any clarification regarding the training without hesitation. Nobody went 65 away when we had a problem. They always try to take us whenever they are going to operate equipment or fault correction or check the site. All of them gave me good support to success my industrial training. Also, I must appreciate National Apprentice and Industrial Training Authority (NAITA) and Engineering Education Center (EEC), Faculty of Engineering, University of Ruhuna for their help to make my industrial training success. Finally, I can say that I completed my Industrial training period successfully, I got lots of experience and guidance for my future career. 66 Abbreviation AAC - All Aluminum Conductors ABC - Arial Bundle Conductor ABS - Air Brake Switch ACSR - Aluminum Conductor Steel Reinforce ADB - Asian Development Bank AGM - Additional General Manager AIS - Air Insulated System AM -Asset Management AVR - Auto Voltage Regulator BFP -Boiler Feed Pump BFPT -Boiler Feed Pump Turbine BMCR -Boiler Maximum Continuous Rating BST -Bulk Supply Tariff CB - Circuit Breaker CE - Chief Engineer CEB - Ceylon Electrical Board CHP -Coal Handling Plant COND- Condenser CPC -Ceylon Petroleum Corporation CPP -Coal Power Plant CT - Current Transformer CVT - Capacitor Voltage Transformer DC - Direct Current DDLO - Drop Down Lift Off DGEU-Department of Government Electrical Undertakings DGM - Deputy General Manager DL -Distribution Line DRTR -De-aerator DSM - Demand Side Management DT - Distribution Transformer EBPT- Extraction Back Pressure Turbine ED-Economic Dispatch 67 EE - Electrical Engineer EIA - Environmental Impact Assessment EMS-Energy Management System ES - Electrical Superintendent ESP - Electrostatic Precipitator EXIM - Export and Import Bank of China FDF- Forced Draft Fan FGD -Flue Gas De-Sulfurizer FOR - Forced Outage Rate GDP - Gross Domestic Product GIS - Gas Insulated Substation GIS-Gas Insulated Switchgear GM - General Manager GoSL -Government of Sri Lanka GS - Grid Substation GT - Gas Turbine GT-Generator Transformer GWh- Giga Watt hour HP- High pressure HPH -High Pressure Heater HPP - Hydropower Plant HPT- High Pressure Turbine HQ -CEB Corporate Headquarters HR -Heat Rate HRSG - Heat Recovery Steam Generator HT - High Tension IDF -Induced Draft Fan IEC - International Electrotechnical Commission IPP - Independent Power Producer IPT -Intermediate Pressure Turbine JICA - Japan International Cooperation Agency kVA -Kilo Volt Ampere LA- Local Authority LBS - Load Break Switch 68 LDC - Load Duration Curve LECO - Lanka Electricity Company LF - Load Factor LP - Low Pressure LPH - Low Pressure Heater LPT -Low Pressure Turbine LT - Low Tension LTGEP - Long Term Generation Expansion Plan LV-Low Voltage LVPS -Lakvijaya Power Station MCR- Maximum continuous output MCW- Main Cooling Water MOCB-Minimum Oil Circuit Breakers MVA - Megavolt Ampere MW - Megawatt NAITA- National Apprentice and Industrial Training Authority NCRE -Non-Conventional and Renewable Energy NLPS - New Laxapana O&M - Operation and Maintenance OCCW -Open Cycle Cooling Water OLPS - Old Laxapana Power Station OLTC-On Load Tap Changers ONAF - Oil Natural Air Force ONAN - Oil Natural Air Natural PAF -Primary Air Fan PF - Plant Factor PLCC- Power Line Carrier Communication PPA - Power Purchase Agreement PSS/E - Power System Simulation PT-Potential Transformers PUCSL-Public Utilities Commission of Sri Lanka RC - Reinforce Concrete SCADA-System Capture and Data Acquisition SCC - System Control Centre 69 SDDP - Stochastic Dual Dynamic Programming SEA-Sustainable Energy Authority VT - Voltage Transformer WCP-West Coast Power 70 Reference Ceylon Electricity Board, (2014). “Long Term Generation & Expansion Plan,20112025,” Transmission and Generation Planning Branch, Transmission Division, Ceylon Electricity Board, Sri Lanka. 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