INTERNSHIP PRESENTATION

ON
“ Maintenances and installation”

Presented By Industrial Supervisor Internship Coordinator

Mr. Saurabh.S. Bhosale Asst. V.C.Kulkarni Prof. N. V. Khandekar

INTRODUCTION
This EIA report has been prepared for Phase-II project by Shri Vitthal Sahakari Sakhar
Karkhana Ltd. (SVSSKL). SVSSKL proposed sugar modernization from 5000 TCD to 7500 TCD by
crushing capacity addition of 2500 TCD & bagasse based cogeneration power expansion from 10 MW to
29.8 MW by capacity addition 19.8 MW at Shri Vithal Sahakari Sakhar Karkhana Ltd. Gut No. 299,
300,301,302, 150 (A) Venunagar, Post – Gursale – 413 304 Tal. Pandharpur, Dist. Solapur Maharashtra .

Shri Vithal Sahakari Sakhar Karkhana Ltd. (SVSSKL) has been registered under registration no.
SUR/PRG/(A)-4 dated April 6, 1974. It is an agro based co-operative sugar factory focused on manufacture
of sugar, co-gen power generation and ethanol production.

The capacity of this sugar factory has grown over the years, from 1250 TCD in 1974 to 5000 TCD today.
They have already established and running a fully integrated sugar industry consisting of 5000 TCD sugar
plant, 30 KLD distillery and 10 MW co-gen power plant. The performance of the sugar factory is excellent
The area under sugarcane command area is about 21726 Ha. The expected net cane availability since 2012-
13 crushing season will be over 16.00 lakh MT. The excess sugarcane is being remain uncrushed & hence
SVSSKL management has decided to increase the crushing rate to take care of the additional sugarcane
cultivated in the area of operation.

.
20 MW TURBINE GENREATOR
A 10 MW steam turbine is a medium-sized turbine used in various industrial applications for power generation.
Here is an overview of its key features and applications
Key Features:
Power Output:
Nominal power output of 20 MW (megawatts).
Operating Principle:
Converts thermal energy from steam into mechanical energy, which is then converted into electrical
energy by a generator.
Efficiency:
High thermal efficiency, often exceeding 40-45%, depending on the specific design and operating
conditions.
Steam Conditions:
Typically operates with steam pressures ranging from 30 to 60 bar and temperatures from 495 to 600 degrees
Celsius.

Construction:
Made from high-grade materials to withstand high temperatures and pressures.
Includes rotors, blades, casing, and other components designed for durability and efficiency.
Control Systems:
Equipped with advanced control systems for precise operation, including speed and load control, safety
mechanisms, and monitoring systems.
20 MW TURBINE GENREATOR
 GENERATOR
For a 20 MW (megawatt) generator, there are several key aspects to consider, including the type of generator,
fuel type, efficiency, dimensions, and maintenance requirements. Below are the general details for such a
generator:

1. Types of Generators
- Diesel Generators: Commonly used for their reliability and efficiency. suitable for both prime and standby
power applications.
- Natural Gas Generators: More environmentally friendly than diesel, suitable for continuous or prime power
applications.
- Turbine Generators: Suitable for large-scale power generation, often using natural gas or steam.

2. Fuel Type
- Diesel: Commonly used for high power applications and standby power.
- Natural Gas: Preferred for continuous operation due to lower emissions.
- Biogas: Renewable option with lower emissions.
- Heavy Fuel Oil (HFO): Used in some large-scale industrial applications.

3. Efficiency
- Diesel generators: Typically 30-45% thermal efficiency.
- Gas turbines: Typically 35-40% thermal efficiency for simple cycle, up to 60% for combined cycle.
- Combined Heat and Power (CHP) systems: Can exceed 80% efficiency when capturing and using waste heat.
SYNCHRONISING PROCESS
SYNCHRONISING PANAL
AC MOTOR VFD MODULE
This module is provided separately and is compatible only with PH Advance models. A variable
frequency drive (VFD) (also termed adjustable frequency drive, variable-speed drive, AC drive, micro
drive or inverter drive) is a type of adjustable-speed drive used in electro-mechanical drive systems to
control AC motor speed and torque by varying motor input frequency and voltage. This kit operates on
230Vsupply.

A VFD or variable frequency drive is an electronic device used to control an AC induction motor or
synchronous motor. A VFD controls the torque, speed, and direction of the motor, smoothly starting
and accelerating the motor to the desired speed at a controlled acceleration rate. VFDs allow you to
use a single motor for a variety of processes and conditions that may require different speeds. Variable
Frequency Drives (VFDs) are crucial in sugar factories for enhancing the efficiency, control, and
reliability of various motor-driven processes. Here are the key uses of VFDs in a sugar factory:

1. Cane Handling and Processing

2. Centrifugals
3. Pump
4. Evaporators and Crystallizers
5. Cooling Towers
6. Safety and Control
PANAL MAINTENANCES

Maintaining an Automatic Voltage Regulator (AVR) panel is essential to ensure its reliable
operation and longevity. Here’s a comprehensive guide on AVR panel maintenance:

• Regular Inspection and Cleaning

• Electrical Checks
• Functional Testing
• Component Maintenance
• Firmware and Software Updates (for Digital AVRs)
• Record Keeping
• Training and Safety
• Spare Parts and Tools
TRANSFORMER
 A three-phase electrical system in used to generate and transmit electric power over long
distances for use by offices and industry. Three-phase voltages (and currents) are raised or lowered by
means of three phase transformers as the three phase transformer can have its windings connected in
various ways.

Thus far we have looked at the construction and operation of the single-phase, two winding
voltage transformer which can be used increase or decrease its secondary voltage with respect to the
primary supply voltage. But voltage transformers can also be constructed for connection to not only
one single phase, but for two-phases, three-phases, six-phases and even elaborate combinations up to
24-phases for some DC rectification transformers.

If we take three single-phase transformers and connect their primary windings to each other
and their secondary windings to each other in a fixed configuration, we can use the transformers on a
three-phase supply.
Three-phase, also written as 3-phase or 3φ supplies are used for electrical power generation,
transmission, and distribution, as well as for all industrial uses. Three-phase supplies have many
electrical advantages over single-phase power and when considering three-phase transformers we
have to deal with three alternating voltages and currents differing in phase-time by 120 degrees as
shown below.
PROTECTION
Protection devices for electrical circuits undertake two main utilities such as consistency and
protection. In this, Protection is assured via detaching power supply, and it is the overcurrent protection.
To point out, various protection devices act as a protection agent and prevent us from many electrical
damages. Generally, these devices remove fire hazards and electrocution.
Protection devices useful for the protection of circuits. Usually, this protection is from extreme
voltage or current. To mention, circuit protections are the electrical device that prevents the devices
from the flow of unnecessary currents as well as the short currents.

Here are the some of the protection devices of the circuit.

1. Fuse
2. Circuit Breaker
3. PolySwitch
4. RCCB
5. Metal Oxide Varistor
6. Inrush Current Limiter
7. Gas Discharge Tube
8. Lighting Arrester
GAS CIRCUIT BREAKER
To protect your electrical assets, L&T Electrical & Automation (E&A) offers a complete
range of Gas Circuit Breakers (GCBs) up to 3150A. The C-Power range of GCBs is designed and
manufactured to protect electrical systems and machines from overcurrent and short-circuit.
In power systems, circuit breakers are used to switch electrical equipment and networks
under normal and fault conditions. The primary function of a circuit breaker is to interrupt the flow of
current (load or short circuit) by opening its contacts and thereby isolating the switched parts of the
system.
Sulfur hexafluoride circuit breakers may be used as self-contained apparatus in outdoor air-
insulated substations or may be incorporated into gas-insulated switchgear which allows compact
installations at high voltages.
Instead of oil, air, or a vacuum, a sulfur hexafluoride circuit breaker uses (SF 6) gas to cool
and quench the arc on opening a circuit. Advantages over other media include lower operating noise
and no emission of hot gases, and relatively low maintenance.
INSULATION
Motor winding insulation max temperature ratings carry NEMA designations.
These ratings are defined as:

The allowable temperature rises (at full load) for a 1.0 S.F. motor are:
MOTOR STARTER
A motor starter is an electrical device that is used to start & stop a motor safely. Like a relay,
the motor starter switches the power ON/OFF, but unlike a relay, it also provides thermal overcurrent
protection.

The main function of a motor starter is:

1. To safely start or stop a motor.
2. To reverse the direction of a motor.
3. To protect the motor from low voltage & overcurrent.

A motor starter consists of 2 main components:

4. Contactor: The main function of the contactor is to make or break the current to an electric motor.
5. Overload Relay: Overheating and drawing too much current can cause damage to the motor.
Overload relays prevent this from happening and protect the motor from any potential danger.
Types of Starter Used:

1. Star Delta Starter:

2. Variable Frequency Drive(VED)

3. Soft Star Delta Starter:
AC MOTOR MAINTENANCES

AES has a complete machine shop facility, and we employ a dedicated team of repair
specialists who understand everything there is to know about maintaining, repairing, rewinding and
rebuilding AC motors, DC motors, and servo motors of all shapes and sizes. Here are just a few
maintenance and repair services we provide for electric motors:

1. Bearing Replacement
2. Motor Rewinding
3. Dynamic Balancing
4. Motor-Specific Cleaning & Painting
DC MOTOR MAINTENANCES
Brushes are vital to the efficiency and uptime of your DC and brushed AC motors
because they are the electrical connection between the power source and the commutator. To
effectively and efficiently transmit the electricity, brushes must have full, flat contact with the
commutator at all times. Maintenance of brushes and commutators can help ensure a long
lifetime of your DC motors.

1. When examining your brushes

2. DC Motor Brush Problem: Threading
3. DC Motor Brush Problem: Grooving
4. DC Motor Brush Problem: Copper Drag
5. DC Motor Brush Problem: Flashover
MEGGER TEST
We can test your circuits for the existing connections and melted fault areas that may have
occurred during a fire event. These results are then analysed and specific circuits can be isolated and
replaced to insure that there are no further problems on your affected circuits. If you have had a fire
talk to your Adjuster and see if megger testing is required. It is normally covered by Insurance since
the last thing they want to do is pay another claim a month after you are able to reclaim your
domicile.

Carelabs has the equipment on hand and the expertise to perform your Megger Test and get
those results logged and filed with your insurance carrier as well as the Local Building Department. We
are here to help you make sure your existing wiring is safe, and of course, to install new wiring as
needed as well. We are here for all of your electrical needs.

This can be separated into mainly two categories:

•Electronic Type (Battery Operated)

•Manual Type (Hand Operated)
THANK
YOU