1

POWER HOUSE, MOTORS &

MOTORS C0NTROL

By
BABAR SALEEM
Reg. No. 2013-GCUF-03768
B-Tech (Pass)
Electrical Technology
Session: 2013-2015

Distance Learning Program

Government College University Faisalabad

Dedication
I dedicate my work to my parents who made me from
nothing to what I am today. Their prayers are with me at
every moment of my life and to my teachers who are the
become of knowledge. They helped me to determine the
path of glory and in last to those people who helped me
in fulfillment of goals developing personality and
knowledge and development of my knowledge
personality.

ACKNOWLEDGEMENT
First of All I thank Almighty Allah, The Compassionate and
The Most Merciful, who bestowed on me the potential and
ability to complete this Project. All and every respect is
for His Holy Prophet MUHAMMAD (Peace be upon him),
whose teachings enabled us to recognize out creator.

I wish to express my sincere gratitude to MR.

UBAIDULLAH project advisor for his support and
encouragement.

I am thankful to my seniors, colleagues and all my friends

who helped me directly or indirectly for their support.

Babar Saleem
B-Tech (Pass)
Electrical

FINAL APPROVAL
It is to certify that we gone through this project
Submitted by
Babar Saleem
Reg. No.2013-Gcuf-03768
Roll No.14017
B Tech. (Pass) Electrical
Our judgment is that this project is up to the standard to
warrant its acceptance by the
Govt. College University, Faisalabad
for B-Tech Pass degree in electrical Technology

PANNEL OF EXAMINERS
External Examiner :

____________________________

Coordinator:
Ubaidullah

Director Distance learning :

Naeem Mohsin.

Mr.

Dr.

Power House, Motors & Motor Control

system
Contents
1. Introduction of company
1.1. Department of company
2. Power House Gas Engine
2.1. Excitation System
2.2. Differential Protection
2.3. Synchronizing System
2.4. Advantages of Synchronization
3. Neutral Ground Resister (NGR)
4. Auto Load Shedding (ALS) System
4.1. ALS System for H.F.O. Generator
4.2. ALS System for Gas Generator
4.3. 1st and 2nd Priority Relays for ALS System
5. Substation
5.1. Vacuum Circuit Breaker (VCB)
5.2. Air Circuit Breaker (ACB)
5.3. Bus Bar
5.4. Operation of Circuit Breaker
5.5. Load Break Switch (LBS)
5.6. Power Factor
5.7. Capacitor Bank
5.8. Protective Relays
5.9. Magnetic Contactor
5.10. Fuses
5.11. Panels
5.12. Feeders
5.13. Transformers
6. Motor
6.1. Induction motor
7. Motor Starters
7.1. Direct Online (DOL) Starter
7.2. Star Delta Starter
8. Utility (UTY) Department
8.1. Compressors

1. Introduction of company

Al-Muqeet Textile mill established in 2007 . Al-Muqeet a composite textile mill,

initially operated on a very modest scale at industrial state Nooriabad Karachi.
1.1.

Department of Company

There are nine major departments working in Al-Muqeet Textile Mill is as under,
1)
2)
3)
4)
5)
6)
7)
8)
9)

2.

Mixing
Blow Room
Carding
Drawing
Simplex
Ring
Auto Cone
Power House
Electrical & Electronics

Power House Gas Engine

There are two gas engine generators in Al-Muqeet Textiles Mill Plant.
The rating of gas engine generators are as follow:

4000 KVA

50 HZ

11000 V

P.F 0.8

2.7 MW

210 A

1500 R.P.M
There are batteries for servo motor rotation. There is a jacket water motor for
cooling purpose temperature of jacket water.
The gas engines are controlled by SCADA panels and synchronizing in these
generators are on auto basis.
We prefer to use gas engines due to low per unit cost rather than H.F.O
and WAPDA supply.

2.1. Excitation System

When engine is start running and after achieving 85% speed i.e. 510
R-P-M 53x relay will energized. The relay will change its contacts.
Excitation is provided by batteries. When terminal voltages 85V,
the relay 84 will energized and change its contacts now self excitation
will start.

2.2.

Differential Protection

The scheme of differential protection is used the circulating current

principle. According to this current at two ends of protected section
are compared with the help of CTs.

Under normal condition current at two ends are equal. If current vary
on both ends due to any fault. Difference of current is arranged to pass
to through the corresponding relay coil.
The relay will energized and change its contacts thus the supply
passed to shunt trip coil of Circuit breaker , which cause to trip the
circuit breaker.
Identical sets of CTs are placed on each phases on both sides.
In Al-Muqeet Textiles Mill Plant differential protection is used to
protect engines and generators.

2.3.

Synchronizing System

To connect a generator with another generator in parallel or to connect

two generators with a single bus bar is called synchronizing.

The Conditions Required For Synchronizing:

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The conditions required for synchronizing are as follow:

1)
2)
3)
4)

The phase voltage of both generators should equal

The phase sequence of both generators should same
The phase angle of both generators should same
The frequency of new on coming generator must slightly higher
than the running system.

In Al-Muqeet Textiles Mill Plant:

When the load is on, 1 st generator and if we need more power. We
will start one more generator on no load. We increase the frequency of
new on coming engine from 0 to 50 HZ, according to first on load
running engine.
We see voltage of both generators producing on volt meter, which we
get from PT (Potential Transformer), which are installed on generation
cables.
On generator rotor, a techo generator is installed, which shows us the
frequency of rotor of on HZ meter.
The phase angle and phase sequence of three phases of both
generators will seen by synchroscope.
When these all conditions are cleared, we switch ON the VCB
(Vacuum Circuit Breaker) of new on coming generator to attach it
with bus bar.
After this we transfer load equally on both engine from GCP.
2.4.

Advantages Of Synchronizing:

The advantages of synchronizing are as follow:

1) Two generators can supply bigger load then a single
generator.
2) Having many generators in parallel increasing the reliability
of full system
3) The failure of any one generator of them does not cause a
total power lose to the load.
4) Having many generators operating in parallel allows one or
more of them to be removed from system for shut down
preventive maintenance.
5) If only one generator is used and and it is not operating at
near full load, then it will relatively inefficient.
With several smaller generators in parallel, it is possible to
operate a fraction of them.
The one that do operate are operating near full load and does
more efficient.

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3. Neutral Ground Resister (NGR)

In Al-Muqeet Textiles Mill Plant, power house department the neutral of all
H.F.O generators are attached with each other and then grounded through
NGR (Neutral Ground Resister).
NGR Neutral Ground Resister is used to limit the ground fault current.

4. Auto Load Shedding (ALS) System

ALS (Auto Load Shedding) system is installed in power house and substation
department. Whenever any heavy fault occurs on any running engine (Which
cause to stop the engine).
ALS system will cut OFF the load of selected load on ALS system
automatically.
4.1.

ALS System for Gas Generator

When a gas generator trips, the normally open contact of ALS
closes. The normally close contact 60K3 remains close as the
generator breaker is close.
Now relay R1 energizes and two inputs are sent to PLC.

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We know that for two inputs of PLC both 1 st & 2nd priority relays
will operates.

4.2.

1st and 2nd Priority Relays for ALS System

In ALS system when 1st priority relays operates

N.O (Normally Open) contacts 83-1X close and relay coils A & B energizes.
N.O contacts of A & B relays will close and energizes relay coils D & E.
These relays (D & E) when energizes. They energize the number of trip coils
of circuit breakers and cut the load from system.
This is how 1st priority operates.
In ALS system when 2nd priority relays operates
N.O contacts 83-2X closes and relay F energizes and the indication light of
ALS operates is ON.
The N.O contact of F relay will close.
The supply passes to relays R1 to R16, R1 to R16 relays will energizes.
These relays energize the number of trip coils of circuit breakers.

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5. Substation
Sub-Station is a central point between Power House and loads.
In Al-Muqeet Textiles Mill plant Sub-Station, we receive high voltages (11KV),
from Power House and WAPDA.
Ten we convert HT voltages to LT voltages (11KV to 400V) with transformers and
then forward it to loads.
The main power switchgear of loads are at Sub-Station, after this the supply pass to
departments. There are the panels, which have full control system of that machine.
The panels are based on star delta circuits; some are based on PLC and Inverter.
Following are the main purpose of Sub-Station:
1)
2)
3)
4)

Switching
Protection
Improving power factor
Converting the power

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Following are the switchgears for Sub-Station:

1)
2)
3)
4)
5)
6)
7)
8)

Circuit breakers
Fuses
Relays
Current transformers ( CT )
Potential transformers ( PT )
Load break switches ( LBS )
Power factor improving panels
Transformers

Following are the measuring instruments and indications of Sub-Station:

1)
2)
3)
4)
5)

Volt meters
Ampere meters
Ohm meters
CT & PT
Indication lights

5.1.

Bus Bar

Bus bar is such a conducting bar by which many feeders, distribution

circuits and supply sources are attached. Bus bar is working on
permanent voltages.
Bus bar is a bar of copper. Its main purpose is to conduct electricity.

5.2.

Operation of Circuit Breakers

Circuit breaker is an automatically operated switch in

case of fault.
It is designed to protect an electric circuit from damage caused by
over load and short circuit. Its basic function is interrupt current flow
in fault condition.
All circuit breakers have common features in their operation, although
details vary substantially depend on voltage class, current rating and
type of circuit breaker.
When current is interrupted, an arc is generated. This arc must be
contained cooled and extinguished in a controlled way. So that the gap
between the contacts can again withstand the voltage in the circuit.
Circuit breakers are usually able to terminate all currents very quickly,
typically the arc is extinguished between 30 ms and 150 ms after the
mechanism has tripped, depending on the construction of device.

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5.3.

Vacuum Circuit Breaker (VCB)

VCB have minimal arc (as there is nothing to ionize other than the
contact material). So the arc quenches when it is stretched a very
small amount. VCB are frequently use in our Sub-Station to 11 KV.
VCB used on HT side at Sub-Station and power house.
The rating of VCB as follow:
1) 11 KV
2) 630 A
3) 25 KA

5.4.

Air Circuit Breaker (ACB)

Air circuit breaker may use compressed air to blowout the arc or
alternatively the contacts are rapidly swung into a small sealed
chamber. The escaping of displaced air thus blowing out the arc.
ACB used on LT side at in Al-Muqeet Textiles Mill Sub-Station.
The rating of ACB as follow:
For 2000 KVA transformer
3200 A,

400 V

85 KA
For 2500 KVA transformer
4000 A,
85 KA

400v

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5.5.

Load Break Switch (LBS)

LBS is an additional protection, used before VCB. We have three LBS on HT side
Al-Muqeet Textiles Mill plant Sub-station. Which have ratings as follow:
11 KV,

400 V

12.5 KA
5.6.

Power Factor
The power factor of an AC power system is defined as the ratio of
Active power and Apparent power.
P.F = True power / Apparent power
In Al-Muqeet Textiles Mill plant Sub-Station, there are five power
factor panels. Two power factor improvement ( PFI ) panels are
installed between WAPDA supply. Three PFI panels are installed
between generation supply panels.
The ratings of power improving units are as following:
1)
2)
3)
4)
5)

750 KVAR
850 KVAR
850 KVAR
650 KVAR
850 KVAR

Following are the ratings of fuses used in power factor panels:

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125 A,

500 V

120 KA
Following are the rating of capacitor from PFI panels:
50 KVAR,
400 V

5.7.

Capacitor Bank

75 A

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5.8.

Protective Relays
Protective Relay is a device which is used between the main circuit
and circuit breaker in such a way that, in case of any abnormality the
relay sends the signal to the circuit breaker for tripping.
Faulty element will be separated by tripping of circuit breaker.

5.9.

Magnetic Contactor
The Magnetic Contactor is an electromagnetic device. It is used to
make and break the circuit.
It has 110 V DC or 220 V AC or 24 V DC supply for its coils. When
supply passes to coil of magnetic contactor, the coil will work like a
magnet and towing the core.
By this way the supply pass from power contacts of magnetic
contactor.
There are some auxiliaries contacts on contactor. Some are NO and
some are NC. When the supply passes to contactor coil, the contact
will change from NO to NC and NC to NO.

5.10. Fuses
This type of fuses are use in Al-Muqeet Textiles Mill plant SubStation for the protection of control circuit. This fuse consists of two
parts:
1) A base having two terminals
2) A fuse carrier
Cartridge fuse is tightened in a screwed fuse cap. The rating of this
fuse is 6 A.
5.11. Panels
In Al-Muqeet Textiles Mill plant, there are fourteen panels on HT
side in Sub-Station.

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Four panels for feeders, three panels for LBS. there are nine VCB
installed in HT side.
Relay, energy meters, fault indication lamps and breakers are
installed in panels. There sixty panels in LT side. Forty nine panels
are at A side and eleven panels at B side.
All load control switches are installed in LT side. Eight ACB and
four Bus Coupler are installed in LT side panels. There are five
power factor panels are installed in LT side. Two power factor panels
installed between WAPDA supply. Three power factor panels are
installed between generation supply.
5.12. Feeders
There are four feeders come in substation from power house. There
are two transformers on feeder no. 1, one transformer on feeder no.
2, three transformers on feeder no. 3 and two transformers on feeder
no. 4.
In feeder no. 3, there is an interlocking between wapda supply and
power house supply.
5.13. Transformers
Transformer is a static device. It is used to convert high voltage to
low voltage (11KV to 400V), without changing frequency.
In Al-Muqeet Textiles Mill plant, there are only Step Down
Transformers.
In power house department there are three auxiliary transformers.
These transformers are of 630KVA.
There are eight transformers in substation department. 1 to 6
transformers are of 2000KVA ratings. 7 and 8 transformers are of
2500KVA ratings.

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6. Motors
An electric motor is an electric machine that converts electrical energy into
mechanical energy.
In normal motoring mode, most electric motors operate through the interaction
between an electric motor's magnetic field and winding currents to generate force
within the motor.
In textiles industries the induction motor is commonly used. The detail of induction
motors are as follow:

6.1.

Induction Motor

An ac induction motor is popular in industry because of its simplicity and

ruggedness. In its simplest form, this motor is a transformer with the primary side
voltages connected to the Ac power voltage source and the secondary side shorted
to carry the induced secondary current. The name induction motor drives from
this induced secondary current. The stator carries a three phase winding and the
rotor is a simple design, commonly called a squirrel cage in which the copper or
aluminum bars are shorts circuited at both the ends by cast aluminum end rings.
The absence of rotor windings and brushes makes this motor design especially
reliable.
Rotor and stator of a induction motor.

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7. Motor Starters
7.1.

Direct Online (DOL) Starter

DOL starters are used in substation department for controlling
exhaust fans.
The functional detail of DOL is as follow:
Cartridge Fuse is installed in power circuit for the protection of
Motor.
The Contactor C energized by pushing the ON puss button and ON
push button will come back in its original condition which is
normally open.
During this, the normally open contact of Contactor C will close.
Which is parallel to ON push button.
Similarly the contactor will energize through its holding contact and
motor runs continuously even after leaving push button.
When we need to stop the motor, the OFF push button be pressed.
This cause to de-energize the contactor and motor will stop running.
The holding contact of contactor will be opened because of deenergizing of Contactor C. During running of motor, if motor is
overloaded, the contacts of overload will open and motor will stop
working.

7.2.

Star Delta Starter

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Star Delta Starter is used for motors which have

rating of 4KW or more than 4KW.
The functional detail of Star Delta Starter is as
follow:
The Contactor C energized by pushing the ON puss
button and ON push button will come back in its
original condition which is normally open.
During this, the normally open contact of Contactor C
will close. Which is parallel to ON push button.
Similarly the contactor will energize through its
holding contact. The supply passes to Timer and to
Star Contactor by the way of NC of Timer. Now the
motor is started running in Star. After the completion
of set time of Timer, the Timer will change its
contacts, which cause to ON the contactor of Delta
and OFF the contactor of Star. While all of this, motor
will run continuously.

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9. Utility (UTY) Department

In Al-Muqeet Textiles Mill Plant UTY department there are six compressor
units. The compressed air of these compressor is used in other departments
machines. The ratings of these compressors are equal to each other.
The ratings of these compressors are as follow:
P= 480 KW
A= 840 AMP
These compressors are controlled by Star Delta circuits.

7.1 Compressors
When all safeties are cleared, the supply card gives a signal to
contactor K 6. Contactor K 6 is energized and cause to energize
relay RM. relay RM will close its N.O contacts. The supply
passed to timer T1 and to contactor of star C3. The N.O
contacts of star contactor will close after energizing, the supply
pass to contactor C1. The motor will star running in star
connection.
After completion of timer set time, it will change its contacts
and supply pass to transiant contactor C4. Transient contactor
C4 will change its contacts and this cause to OFF the star
contactor.
The supply passed to delta contactor C2, through the way of
N.C contact of star contactor C3.
The motor is now running in delta connection.

7.3.Cooling Towers

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There are seven(7) Cooling Towers in UTY Department. The basic

purpose of Cooling Tower is to cool the water for AC, Chiller, Spot
Coolers and for the cooling Jacket water in HFO engines.
The motor of Cooling Tower Fans is auto and manually controlled
from the panels. The Star Delta circuit is used to operate Cooling
Tower Fan motors. The rated current of motors are 30A, 35A and 40A
for different Cooling Towers.
The hot water from AC is coming back in Cooling Tower, after cooled
down, the water will send to AC again. It is working like a cycle of
water.