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International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
2226 Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
Abstract — Bagasse cogeneration describes the use of fibrous
sugarcane waste, bagasse to cogenerate heat and electricity at
high efficiency in sugar mills. Proposed work is a case study on
sugarcane industry and economics is worked out for advanced
cogeneration power system. In generally, different kinds of
co-generation plants are available based on products in industry
and bagasse is derived from several types of the cogeneration
plant. By replacing low-efficiency mill turbines with hydraulic
drives and DC motors, cogeneration power increases in sugar
mill to operate at high efficiency (65-70%). This replacement
can aid increase of power to a grid, resulting in additional
revenue for sugar plant. The research evaluates the technical
feasibility and economic viability of reconfiguring the sugar
industries towards cogeneration and also quantifies the
emissions from Bagasse cogeneration. The total electric power
that can be produced and fed to the national grid, the economic
issues and the issues of emissions.
Key Words — Bagasse, Boiler, Feed Water Heater,
Condenser, Turbine, Chimney, ID Fan, S.A Fan, F.D Fan.
I. INTRODUCTION
Fig.1 shows the line diagram of steam/thermal power
plant [1]. The fuel for a thermal power plant is coal/Bagasse.
The coal is pulverized in coal pulverization plant for required
sizes to feed in the boiler unit of steam/thermal power plant
[2]. The water in boiler gets heated once the coal/bagasse is
fired in the furnace. Gradually the water gets converted into
steam after heating it up to 4800C. The steam flows through
the superheater such that the moisture content in the steam
gets evaporated and turn into super saturated steam [3]. The
hot flue gas from the boiler is fed to superheater which
increases the temperature of the superheater and removes the
moisture content. The flue gas flowing through super heater
flows through economizer and air pre-heater. The main
function of the economizer is that it will increase the
temperature of the feed water by utilizing the heat from the
hot flue gases [4].
The feed water is again sent to the boiler for
conversion of steam [5]. The air pre-heater increases the
temperature of the air supplied for coal burning by deriving
heat from flue gases [6]. By preheating the air there will be an
increase in thermal efficiency and increase in steam capacity
per square meter of boiler surface. The super saturated steam
from superheater is fed to the impulse reaction turbine by
means of the main valve [7]. The valve placed in between
superheater and the turbine is for limiting the excess flow
level of steam to the turbine. The turbine converts steam
energy into mechanical energy [8].
The turbine is coupled with the Turbo Alternator with
the help of couplings. The Turbo Alternator converts
mechanical energy into electrical energy [9]. The generated
electrical energy is stepped up by using power transformer
and feed to bus bar with various protection systems.
Fig. 1 Line Diagram of Steam Power Plant
The 132KV power generated is sent to the nearest
substation. The exhaust steam from steam turbine is again
converted into water in the condenser and it is sent to the
cooling tower with the water from the river/pond, where the
water is cooled and sent to circulating water pump [10]. Again
the water is sent through condensate extraction pump to LP
water heater and then to HP feedwater heater. Then the water
Study of a Cogeneration Plant in Sugar
Mill by using Bagasse as a Fuel
1C.Dinakaran, Assistant Professor, Dept. of EEE, Sri Venkateswara College of Engg. & Tech., Chittoor 2S.Purushotham, Assistant Engineer, S.N.J Sugars and Products Limited, Nelavoy Village, Chittoor 3S.M.Harikrishna, Trainee Engineer, S.N.J Sugars and Products Limited, Nelavoy Village, Chittoor
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
2227 Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
is sent to economizer and from there it is circulated to boiler
[11]. This process repeats simultaneously. The ash in the
furnace is sent to ash handling plant where it is mixed in water
in order to stop the spreading of the ash in the air and it is sent
to ash storage plant. The electrostatic precipitator collects the
dust from the furnace and sends the exhaust gases through a
chimney.
II. COGENERATION PLANT ACCESSORIES
EQUIPMENT
A. Boiler
Fig. 2 Babcock and Wilcox Boiler
The Babcock and Wilcox boiler is a water tube,
internally fired and natural water circulation boiler. The steam
and water drum which is placed about 8Meter in length and
2Meter in diameter. It is inclined at an angle of 10° to 15°
from the normal position to promote water circulation. Fig.2
shows the Babcock and Wilcox boiler, Coal is fed to the grate
through the fire door and is burnt. The hot flue gases rise
upward and pass across the left side portion of the water tubes.
The baffles are used to deflect the hot gases in the zigzag
manner and for an upward and downward direction of the flue
gases movement over the water tubes along with superheater.
The part of the water tubes which is just above the furnace is
heated to a higher temperature so that the water density is
decreased. Due to a decrease in density, the water rises into
the drum through the uptake header. In this position, the water
and steam are separated in the drum. In fact, the steam is
having lighter weight compared to water. So it is collected in
the upper parts of the drum. The circulation of water is
obtained by convective currents and it is known as natural
circulation. The steam is taken from the drum through a tube
to the superheater for superheating the steam. A damper is
fitted to regulate the flue gas outlet and the boiler is fitted with
necessary mountings.
B. Super Heater
The steam produced in the boiler is wet and is passed
through a superheater where it is dried and superheated (i.e..,
the steam temperature increased above that of boiling point of
water) by the flue gases on their way to the chimney.
Superheating provides two principal benefits. Firstly, the
overall efficiency is increased and secondly, too much
condensation in the last stages of a turbine (which would
cause blade corrosion) is avoided. The superheated steam
from the superheater is fed to steam turbine through the main
valve. The Superheater is used to increase the temperature of
saturated steam without raising its pressure and it is placed on
the hot flue gases path in the furnace.
C. Impulse – Reaction Turbine
Fig. 3 Impulse – Reaction Turbine
Fig.3 shows the impulse -reaction turbine. This type
of turbine is a combination of impulse and reaction turbine.
The total pressure drop of the steam from the boiler to
condense pressure is divided into a number of stages as done
in pressure compounding and velocity obtained in each stage
is also compounded. For a given pressure drop, this type of
turbines is designed in compact sizes. The dry and
superheated steam from the superheater is fed to the steam
turbine through the main valve. The heat energy of steam
when passing over the blades of a turbine is converted into
mechanical energy. After giving heat energy to the turbine,
the steam is exhausted to the condenser which condenses the
exhausted steam by means of cold water circulation.
D. Alternator
Fig. 4 Turbo Alternator
Fig.4 shows the turbo alternator. The steam turbine is
coupled to an alternator. The alternator converts mechanical
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
2228 Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
energy of turbine into electrical energy. The electrical output
from the alternator is delivered to the bus bars through
transformer, circuit breakers and isolators.
E. Exciter
Fig. 5 Exciter
Exciters are nothing but the D.C. generators. Its
main function is to supply DC power to the field system /
rotor. These are mounted on the same shaft of the Alternator.
The capacity of the exciter is about 0.5% to 3% of the
alternator capacity. The exciter was a small DC generator
coupled to the same shaft as the rotor. Therefore, when the
rotor rotates this exciter produces the power for the
electromagnet. Control of the exciter output is done by
varying the field current of the exciter. This output from the
exciter then controls the magnetic field of the rotor to produce
a constant voltage output by the generator. This DC current
feeds to the rotor through slip rings as shown in Fig.5.
F. Power Transformer
Fig. 6 Power Transformer
A transformer is a static device which transfers the
electrical power or energy from one alternating current circuit
to another with the desired change in voltage or current and
without any change in the frequency. A power transformer is
used in a substation to step-up (or) step-down the voltage.
Fig.6 shows the substation transformer which is installed
upon the length of rails fixed a concrete slabs having
foundation 1 to 1.5 m deep.
G. Lightning Arrester
Fig. 7 Lightning Arrester
The Fig.7 shows the substation lightning arrestors.
Lightning arrestors are the instrument that is used in the
incoming feeders so that to prevent the high voltage entering
the main station. This high voltage is very dangerous to the
instruments used in the substation. Even the instruments are
very costly, so to prevent any damage lightening arrestors are
used. The lightening arrestors do not let the lightning fall on
the station. If some lightening occurs the arrestors pull the
lightning and ground it to the earth. In any
substation/generating station the main important is of
protection which is firstly done by these lightning arrestors.
The lightening arrestors are grounded to the earth so that it
can pull the lightning to the ground. The lightening arrestor
works with an angle of 30° to 45° making a cone.
H. Potential Transformer
Fig. 8 Potential Transformer
The Fig.8 shows the substation potential
transformer. There are two potential transformers used in the
bus connected both sides of the bus. The potential transformer
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
2229 Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
uses a bus isolator to protect itself. The main use of this
transformer is to measure the voltage through the bus. This is
done so as to get the detail information of the voltage passing
through the bus to the instrument. There are two main
functions in it
a. Measurement
b. Protection
I. Current Transformer
Fig. 9 Current Transformer
Fig.9 shows current transformer. Current transformers
are basically used to take the readings of the currents entering
the substation. This transformer steps down the current from
800Amps to 1Amp. The current transformer works on the
principle of variable flux. This is done because we have no
instrument for measuring of such a large current. The main
use of this transformer is
a. Distance Protection
b. Backup Protection
c. Measurement
J. Isolator
Fig. 10 Isolator
Fig.10 shows isolator, the use of this isolator is to
protect the transformer and the other instrument in the line.
The isolator isolates the extra voltage to the ground and thus
any extra voltage cannot enter the line. Thus an isolator is
used after the bus also for protection.
K. Bus bar
Fig. 11 Bus Bar
A bus-bar term is used for a bar (or) conductor carrying
an electric current to which many connections may be made as
shown in Fig.11.
L. Relay
Fig. 12 Relay Panel
Fig.12 shows a relay panel. A relay is a device which
detects the fault and initiates information to the circuit breaker
to isolate the detective element from the rest of the system.
M. SF6 Circuit Breaker
Fig.13 shows a sulphur hexafluoride circuit breaker.
The sulphur hexafluoride gas (SF6) is an electronegative gas
and has a strong tendency to absorb free electrons. The
contacts of the breaker are opened in a high-pressure flow of
sulphur hexafluoride (SF6) gas and an arc are struck between
them. The gas captures the conducting free electrons in the arc
to form relatively immobile negative ions. This loss of
conducting electrons in the arc quickly builds up enough
insulation strength to extinguish the arc. The sulphur
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
2230 Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
hexafluoride (SF6) circuit breakers have been found to be very
effective for high power and high voltage service.
Fig. 13 Sulphur Hexafluoride Circuit Breaker
III. PROTECTIVE SYSTEMS
A. Alternator Protection
The protections that are used in a thermal power plant
for a generator or alternator are as follows,
Differential protection
Reverse power protection
Over frequency protection
Stand by earth fault
Loss of excitation protection without u/v
Loss of excitation protection with u/v
MET protection PT fuse fail generator negative PH
sequence-1
Generator negative PH sequence-2
Under Frequency protection-1
Under Frequency protection-2
Voltage restraint o/c relay
Generator over voltage protection-1
Generator over voltage protection-2
Generator under voltage protection
Overload protection
AVR PT fuses fail
Emergency trip
GRP self-test fail
GRP power supply fail
Over fuse protection
Class-A trip
Direction sensitive E/F trip
MIT overload relay
B. 132KV Switch Yard Protections
VT fuse fails relay
Standby earth fault
Over current relay R
Over current relay y
Over current relay B
Neutral displacement relay
Overvoltage relay
Under voltage relay
Buchholz trip relay
Winding temperature trip relay
Oil temperature trip relay
Oil surge trip relay
PRD alarm
MOG alarm
Buchholz alarm relay
Winding temperature alarm
Oil temperature alarm
LV master trip relay
HV master trip relay
Trip relay coils supervision relay
11KV Tie CB coil supervision relay
132KV CB trip coil-1 supervision relay
132KV CB trip coil-2
PRD trip relay
IV. STANDARDS TO GENERATE POWER IN SUGAR
MILL BY USING BAGASSE/COAL
As per the industrial records, some of the standard
values are mentioned below,
If one tonne of bagasse is burnt 2.2 tonne of steam is
produced.
If one tonne of coal is burnt 4 tonne of steam is
produced as per the calorific value of coal.
To generate 1MW of power 4 tonne of steam is
required.
To generate 20MW of power 80 tonne of steam is
required.
The boiler used for steam production is Thermal
Babcock and Wilcox Boiler with an operating
capacity of 80 TPH, the pressure of 67 ATA, the
temperature of 487±50C.
If one tonne of a cane is crushed 300Kg of bagasse is
produced.
In a day to generate 20MW of power 50 tonne of
de-mineralized water is used.
To generate 1MW of power 6.55 tonne of water is
required.
To generate 20MW of power 131 tonne of water is
required.
The moisture content in the bagasse must be from 490
to 550C.
V. VARIOUS PARAMETERS OF STEAM TURBINE
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
2231 Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
S.NO TURBINE PARAMETERS UNITS 6:00 AM 7:00AM
1. TURBINE LOAD MW 11.1 11.2
2. TURBINE SPEED RPM 7122 7167
3. INLET STEAM PRESSURE KG/CM2 63 62
4. INLET STEAM TEMPERATURE °C 477 476
5. INLET STEAM FLOW TPH 71 72
6. AFTER FIRST STAGE STEAM PRESSURE KG/CM2 32 33
7. HP EXTRACTION STEAM PRESSURE KG/CM2 7.0 6.9
8. HP EXTRACTION STEAM TEMPERATURE °C 235 230
9. HP EXTRACTION STEAM FLOW TPH 8.4 8.6
10. LP EXTRACTION STEAM PRESSURE KG/CM2 1.02 1.01
11. LP EXTRACTION STEAM TEMPERATURE °C 125 124
12. LP EXTRACTION STEAM FLOW TPH 60 63
13. AUXILIARY STEAM PRESSURE KG/CM2 9.9 9.9
14. AUXILIARY STEAM TEMPERATURE °C 431 432
15. SEALING STEAM PRESSURE KG/CM2 0.05 0.05
16. SEALING STEAM TEMPERATURE °C 245 245
17. EXHAUST STEAM PRESSURE KG/CM2 -0.93 -0.93
18. EXHAUST STEAM TEMPERATURE °C 43 43
19. CONDENSATE FLOW TPH 4 6
20. HP VALVE DEMAND % 69 70
21. HP VALVE POSITION MM 27 27
22. LP VALVE DEMAND % 30 29
23. LP VALVE POSITION MM 7/5 7/5
24. CONTROL OIL PRESSURE KG/CM2 9.5 9.6
25. LUBE OIL PRESSURE KG/CM2 1.9 1.9
26. DIFFERENTIAL PRESSURE ACROSS FILTERS KG/CM2 0.45 0.45
27. OIL COOLER OIL INLET TEMPERATURE °C 58 58
28. OIL COOLER OIL OUTLET TEMPERATURE °C 42 42
29. CONDENSER CW INLET PRESSURE KG/CM2 0.80 0.80
30. CONDENSER CW OUTLET PRESSURE KG/CM2 0.65 0.65
31. CONDENSER COOLING INLET TEMPERATURE °C 32 32
32. CONDENSER COOLING OUTLET TEMPERATURE °C 35 35
33. OIL COOLER COOLING WATER INLET TEMPERATURE °C 32 32
34. OIL COOLER WATER OUTLET TEMPERATURE °C 35 35
35. MAIN OIL TANK LEVEL MM N N
36. OIL OVERHEAD TANK OVERFLOW YES/NO Y Y
37. LUBE OIL SUPPLY PRESSURE AT TURBINE THRUST BEARING KG/CM2 0.45 0.45
38. LUBE OIL RETURN TEMPERATURE AT TURBINE THRUST
BEARING
°C 54 54
39. LUBE OIL RETURN TEMPERATURE AT TURBINE FRONT
BEARING
°C 55 55
40. LUBE OIL SUPPLY PRESSURE AT TURBINE FRONT BEARING KG/CM2 0.95 0.95
41. LUBE OIL SUPPLY PRESS. AT TURBINE REAR BEARING KG/CM2 0.69 0.69
42. LUBE OIL SUPPLY PRESSURE AT GEAR BOX KG/CM2 1.18 1.18
43. LUBE OIL SUPPLY PRESSURE AT GENERATOR FRONT KG/CM2 0.69 0.69
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
2232 Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
BEARING
44. LUBE OIL SUPPLY PRESSURE AT GENERATOR REAR
BEARING
KG/CM2 0.63 0.63
45. LUBE OIL RETURN TEMPERATURE AT TURBINE REAR
BEARING
°C 60 60
46. LUBE OIL RETURN TEMPERATURE AT GEN GEAR BOX °C 51 51
47. LUBE OIL RETURN TEMPERATURE AT GENERATOR FRONT
BEARING
°C 50 50
48. LUBE OIL RETURN TEMPERATURE AT GENERATOR REAR
BEARING
°C 46 46
49. TURBINE THRUST BEARING TEMPERATURE (ACTIVE) (A) °C 54 54
50. TURBINE THRUST BEARING TEMPERATURE (ACTIVE) (D) °C 54 54
51. TURBINE FRONT BEARING TEMPERATURE (F) °C 87 87
52. TURBINE REAR BEARING TEMPERATURE (I) °C 69 69
53. GEAR PINION FRONT BEARING TEMPERATURE (K) °C 80 80
54. GEAR PINION REAR BEARING TEMPERATURE (J) °C 87 87
55. GEAR PINION WHEEL FRONT BEARING TEMPERATURE (M) °C 67 67
56. GEAR PINION WHEEL REAR BEARING TEMPERATURE (W) °C 63 64
57. GENERATOR FRONT BEARING TEMPERATURE (P) °C 60 60
58. GENERATOR REAR BEARING TEMPERATURE (Q) °C 57 57
59. HOT WELL TEMPERATURE °C 43 43
60. HOT WELL LEVEL % 33 32
61. CONDENSER VACUUM KG/CM2 -0.93 -0.93
62. CEP SUCTION PRESSURE KG/CM2 -0.82 -0.82
63. CEP DISCHARGE PRESSURE KG/CM2 7.6 7.6
64. CONDENSATE TEMPERATURE BEFORE EJECTOR °C 42 42
65. CONDENSATE TEMPERATURE AFTER EJECTOR °C 58 58
66. CONDENSATE BEFORE GLAND STEAM CONDENSER °C 55 55
67. CONDENSATE TEMPERATURE AFTER GLAND STEAM
CONDENSER
°C - -
68. GENERATOR AIR COOLER WATER INLET TEMPERATURE °C 32 32
69. GENERATOR AIR COOLER WATER OUTLET TEMPERATURE °C 34 34
70. AXIAL DISPLACEMENT MM 0.22/0.26 0.25/0.26
71. TURBINE FRONT SHAFT VIBRATION MICRONS 65/75 66/73
72. TURBINE REAR SHAFT VIBRATION MICRONS 27/35 28/35
73. GEAR PINION SHAFT VIBRATION (HSS) MICRONS 22/33 28/31
74. GEAR WHEEL SHAFT VIBRATION (LSS) MICRONS 18/19 16/18
75. GENERATOR FRONT SHAFT VIBRATION MICRONS 33/25 37/26
76. GENERATOR REAR SHAFT VIBRATION MICRONS 24/33 21/35
77. HP SECONDARY OIL PRESSURE KG/CM2 3.0 3.0
78. LP SECONDARY OIL PRESSURE KG/CM2 2.6 2.6
VI. CONCLUSION
Bagasse otherwise a refuse, if used as cogeneration
fuel is proved to have been technically feasible, economically
viable for the competitive industrial environment of sugar
industries, environmentally friendly because of greenhouse
neutral emissions and acceptable regarding social matters. By
using this type of plants we save natural resources like coal,
water because the byproduct of sugar cane i.e., bagasse is
used as raw material for combustion. By erecting the plant as
per the design it results in the reduction of atmospheric
pollution and increases the power generation and the
efficiency of the plant increases. By these designs, the step by
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
2233 Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
step process of power generation will be in a progressive level
such that interruption in power generation will not happen
and fault identification and rectification will be easy for any
working individual.
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International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
2234 Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
APPENDIX
TYPES OF EQUIPMENT USED IN COGENERATION PLANT
AVR PANEL:
SL.NO : S30381
MAKE : BHEL
NOMINAL OUTPUT : 7.12 A, 78.4 V
CEILING OUTPUT : 11.27 A, 150 V
LOAD : EXCITER HELP
COOLING : AN
MAXIMUM AMBIENT : 50°C
AUXILIARY DC SUPPLY : 1100
AUXILIARY AC SUPPLY : 415 V, 3 PHASE, 50HZ
NEUTRAL GROUNDING RESISTORS:
MAKE : NATIONAL SWITCH GEARS, CHENNAI-98
SYSTEM VOLTAGE : 125 KV, AC, 50HZ
FAULT CURRENT : 100 A
DURATION : 30 SECOND
TOTAL RESISTANCE : 63.5 OHMS
ELEMENT MAT./TYPE : COIL WOUND / PUNCHED
AMBIENT TEMPERATURE : 50°C
TEMPERATURE RISE : 25°C
SL.NO./YEAR OF MFG. : NGR/T/38/2000
REFERENCE DRG. : NGP-3-1868
ESP ELECTRONIC CONTROLLER-1:
MODEL : ADOR CORONA
MAKE : ADOR POWERTRON LTD., PUNE
SL.NO. : 0796-01-03-2001
RATED INPUT VOLTAGE : 415 V, AC, 50 HZ
RATED INPUT CURRENT : 120 A
RATED OUTPUT VOLTAGE : 95 KV (PEAK) DC
RATED OUTPUT CURRENT : 500 MA DC
ESP ELECTRONIC CONTROLLER-2:
MODEL : ADOR CORONA
MAKE : ADOR POWERTRON LTD., PUNE
SL.NO. : 0795-01-03-2001
RATED INPUT VOLTAGE : 415 V, AC, 50 HZ
RATED INPUT CURRENT : 120 A
RATED OUTPUT VOLTAGE : 95 KV (PEAK) DC
RATED OUTPUT CURRENT : 500 MA DC
FLOAT CUM BOOST BATTERY CHARGER-1:
TYPE : 110TP150
INPUT : 415 V, AC,50 HZ
OUTPUT : 110 V,150 A, AC
SL.NO. : 2037-1195
MANUFACTURING : JUNE 2001
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
2235 Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
FLOAT CUM BOOST BATTERY CHARGER-2:
TYPE : 110TP150
INPUT : 415 V, AC,50 HZ
OUTPUT : 110 V,150 A, AC
SL.NO. : 2038-1195
MANUFACTURING : JUNE 2001
INCOMER FROM STG FEEDER: (VCB)
VOLTAGE : 11 KV
FREQUENCY : 50 HZ
CIRCUIT CURRENT : 2000 A
BUS BAR CURRENT : 2000 A
TYPE : VM12
SL.NO. : BP9055146
MAKE : BHEL, BHOPAL
SPEC. : IS3427 / IEC 298
TO GENERATOR TRANSFORMER FEEDER: (VCB)
VOLTAGE : 11 KV
FREQUENCY : 50 HZ
CIRCUIT CURRENT : 2000 A
BUS BAR CURRENT : 2000 A
TYPE : VM12
SL.NO. : BP9055145
MAKE : BHEL, BHOPAL
SPEC. : IS3427 / IEC 298
TURBO GENERATOR:
MAKE : BHEL, HYDERABAD
DRIVE : ST
KVA : 25500
KW : 20400
POWER FACTOR LAG : 0.8
FREQUENCY : 50
RPM : 1500
PHASE : 3 AC
CONNECTION : STAR
STATOR VOLTS : 11000
STATOR AMPS : 1338
ROTOR VOLTS : 93
ROTOR AMPS : 838
AMBIENT AIR : 39°C
COOLING : CACW
DUTY : CONT.
ALTITUDE : <1000M
TOTAL WEIGHT : -
OVER SPEED : 10%
GAS PRESSURE : NA
WINDING INSULATION : CLASS F
STANDARD : IEC - 34, IS : 4722
TYPE : TA11 1240 12P - 15
PROTECTION : IP- 54
SL.NO. : 1408
YEAR : 2001
BRUSHLESS EXCITER:
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
2236 Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
MAKE : BHEL
TYPE : EAR 80/9 -15/16 - 217
INSULATION CLASS : F
SL.NO. : 10558
YEAR : 2001
STANDARD NO. : IS : 4722
KW : 94
CONT. VOLTS : 102
CONT. AMPS : 922
RPM : 1500
EXCITATION W : 544
EXCITATION V : 77.41
EXCITATION A : 7.03
PERMANENT MAGNET GENERATOR:
MAKE : BHEL
TYPE : EAP11/ 16-15/6
KVA : 1.5
VOLTAGE : 220
AMPS : 3.94
FREQUENCY : 75 HZ, 3 PHASE
RPM : 1500
UPS PANEL-1:
CAPACITY : 15 KVA
INPUT : 415 V, 50 HZ
OUTPUT : 230 V
MAKE : HI - REC
SL.NO. : 01082296
ISOLATOR WITH EARTH SWITCH DEVELOPER ENDMAIN SWITCH:
MAKE : VERSATECK, HYDERABAD
VOLTS : 132 KV
AMPS. : 1250 AMPS
SL.NO. : 673
EARTH SWITCH:
MAKE : VERSATECK, HYDERABAD
VOLTS : 132 KV
AMPS : 1250 AMPS
SL.NO. : 671
R-PHASE CURRENT TRANSFORMER- DEVELOPER END:
CURRENT RATIO : 250 - 125/ 1-1-1 AMPS
FREQUENCY : 50 HZ
HSV : 145 KV
INSULATION CLASS : 275 KV RMS / 650 KV (PEAK)
SHORT TIME CURRENT : 31.5 KA FOR 1 SEC
QUANTITY OF OIL : 105 Ltrs.(APPROXIMATELY)
TOTAL WEIGHT : 290 Kg
TOTAL GREEPAGE DISTANCE : 3625mm (MINIMUM )
STANDARD : IS: 2705 (1992)
MAKE : ITC
SL.NO. : 9058-07
CORE SEC. PRL RATIO BURDE CLASS RCT/N VK IX MA
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
2237 Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
CONN. CONN. AMPS N OHMS VOLTS VK /2
1 1S1-1S2
1S1-1S3
P1-P2
P1-P2
125/1
250/1
-
-
PS
PS
<=2.5
<=5
120(RC
T+2)
30 MA
2 2S1-2S2
2S1-2S3
P1-P2
P1-P2
125/1
250/1
20VA
20VA
5P20
5P20
-
-
-
-
-
-
3 3S1-3S2
3S1-3S3
P1-P2
P1-P2
125/1
250/1
20VA
20VA
0.2
0.2
-
-
-
-
-
-
SF6 CIRCUIT BREAKER DEVELOPER END:
MAKE : ALSTOM
SL.NO. : 031110
RATED VOLTS : 145 KV
NORMAL CURRENT : 3150 A
FREQUENCY : 50 HZ
LIGHTING IMPULSE WITHSTAND VOLTAGE : 650 KV (PEAK)
FIRST POLE CLEAR FACTOR : 1.5
SHORT TIME WITHSTAND CURRENT : 31.5 KA
DURATION OF SHORT CURRENT : 3 Sec
SHORT CIRCUIT BREAKING CURRENT
SYMMETEICAL : 31.5 KA
ASYMMETRICAL : 37.2 KA
SC MAKING CURRENT : 80 KA(PEAK)
OUT OF PHASE BREAKING CURRENT : 0-0.35-CO-3 MIN - CO
OPERATING SEQUENCE : 6.3 BAR
SF6 GAS PRESSURE AT 20°C, 1013npa : 8.7 Kg
TOTAL MASS OF SF6 GAS : 1300 Kg
TOTAL MASS OF BREAKER :
REF. STD. : IEC – 56
YEAR : 2002
TYPE : FAF1 – 2
TRIP COIL : 110 V, DC
CLOSE COIL : 110 V, DC
MOTOR : 230 V, 50 HZ, AC
HEATER : 230 V,50 HZ, AC
OUTDOOR VACCUM CIRCUIT BREAKER:
MAKE : ALSTOM
TYPE : PCOB – 15
SL.NO. : 13127 / P1
VOLTS : 12 KV
BREAKING CAPACITY : 25 KVA
PHASE : 3
FREQUENCY : 50 HZ
MAKING CAPACITY : 62 KA (PEAK )
SHORT TIME RATING : 25 KA
SHUNT TRIP : 110 V DC
CLOSE : 110 V DC
MOTOR SUPPLY : 230 V AC
MECH. M : SPMX - 500 FORM
MONTH / YEAR : 05 / 02
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
2238 Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
25MVA POWER TRANSFORMER:
TYPE OF COOLING : ONAN
RATED POWER LV & HV : 25 MVA
RATED VOLTS
HV : 132 KV
LV : 11 KV
RATED LINE AMPS
HV : 109.5 A
LV : 13137 A
NUMBER OF PHASE : 3
MAXIMUM TEMP. RAISE OVER ON
AMBIENT OF 50°C
TOP OF OIL : 50°C
AVERAGE WINDING : 55°C
IMPEDANCE VOLTAGE
TAP 1 : 10.94%
TAP 9 : 10.28%
TAP 25 : 9.63%
MAKERS SL.NO. : B – 29622
REF. NO. : T – 6496
TYPE : DOUBLE
WOUND
VECTOR GROUP : YNd1
FREQUENCY : 50 HZ
INSULATION
HV SIDE KV : L1650AC275
LV SIDE KV : L175AC28
HVN KV : AC38
CORE AND COIL MASS : 29000 Kg
TANK AND FITTING MASS : 17000 Kg
MASS OF OIL : 14500 Kg
TOTAL MASS : 60500 Kg
TRANSPORT MASS(OIL FILLED) : 48000 Kg
DIAGARM DRG. NO. : A218223
YEAR : 2002
VOLUME OF OIL : 16800 Ltrs
25MVA POWER TRANSFORMER OLTC:
SL.NO : 5002696 / 2001
TYPE : MIII350 / 60 / B / 14273W
RESISTANCE : 4.3 OHMS
MAKE : BHEL
OLTC MOTOR:
VOLTS : 415 V
FREQUENCY : 50 HZ
KW : 1.1
CONTROL SUPPLY : 110 V, 50 HZ
POT : 1000 OHMS
2.5MVA DISTRIBUTION TRANSFORMER-1:
TYPE OF COOLING : ONAN
RATED POWER LV & HV : 2.5 MVA
RATED VOLTS
HV : 11 KV
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
2239 Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
LV : 0.43 KV
RATED LINE AMPS
HV : 131.2 A
LV : 3333.4 A
NUMBER OF PHASE : 3
MAXIMUM TEMP. RAISE OVER ON
AMBIENT OF 50°C
TOP OF OIL : 50°C
AVERAGE WINDING : 55°C
IMPEDANCE VOLTAGE HV / LV : 6.793 %
MAKERS SL.NO. : D – 3262
REF. NO. : TIP – 1001
VECTOR GROUP : DYN11
FREQUENCY : 50 HZ
INSULATION
HV SIDE KV : L175AC28
LV SIDE KV : L1AC3
HVN KV : L1AC3
CORE AND COIL MASS : 3040 Kg
TANK AND FITTING MASS : 2300 Kg
MASS OF OIL : 1140 Kg
TOTAL MASS : 6500 Kg
TRANSPORT MASS(OIL FILLED) : 5200 Kg
DIAGARM DRG. NO. : A328614
VOLUME OF OIL : 1315 Ltrs
YEAR : 2002
WTICT:
RATIO : 3333 / 175 AMPS
BURDEN : 10 VA
ACC.CLASS : 3
NCT:
RATIO : 4000 / 1 A
ACC. CLASS : PS
Vk : > 500 V
IMAG : < 30 MA AT Vk / 2
RCT@75 : < 14 OHMS
ESP TRANSFORMER–1:
SL.NO. : 0796 - 01 - 03 - 2001
TYPE : ADOR KARONA
KVA : 49.8
AC INPUT VOLTAGE : 415 V
AC INPUT CURRENT : 120 A
AC OUTPUT VOLTAGE : 70731 V
AC OUTPUT CURRENT : 0.700 A
FREQUENCY : 58 HZ
PHASE : SINGLE PHASE
DC VOLTAGE (PEAK) : 95000 V
DC CURRENT : 500 MA
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
2240 Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
ESP TRANSFORMER-2:
SL.NO. : 0795 - 01 - 03 – 2001
TYPE : ADOR KARONA
KVA : 49.8
AC INPUT VOLTAGE : 415 V
AC INPUT CURRENT : 120 A
AC OUTPUT VOLTAGE : 70731 V
AC OUTPUT CURRENT : 0.700 A
FREQUENCY : 58 HZ
PHASE : SINGLE PHASE
DC VOLTAGE (PEAK) : 95000 V
DC CURRENT : 500 MA
DISEL GENERATOR:
MAKE : CATTERPILLAR
SL.NO. : 9IRGS00058
RATING : 725 KVA
KW : 580
VOLT : 415
HZ : 50
POWER FACTOR : 0.8
R.P.M. : 1500
AMPS : 1009
DIRECTION OF ROTATION : CW
AMBIENT : 40°C
INSULATION CLASS : H
ENCL. TYPE : IP23
YEAR OF MFG. : 2002
SELF REGULATING BRUSHLESS ALTERNATOR:
TYPE : DSG 62M, NR 62 – 237
VOLT : 415
AMPS : 1009 A
CONST. : B24, B16 / B5
DUTY : S1
CAPACITY : 725 KVA
AMP : 40°C
P.F. : 0.8
ROTOR DIRECTION : CW
R.P.M. : 1500
HZ : 50
PHASE : 3
EXCITATION : 35 V
AMPS : 3.7
RIS DEGREE : N
INS. CLASS : H
ENCL. TYPE : IP23
AVR : LC1 / LC2