Report For Ongc Edited

SUMMER TRAINING PROJECT REPORT ON
POWER GENERATION AND DISTRIBUTION AT
NEELAM COMLEX, ONGC Ltd., MUMBAI
Under the guidance of
Mr. Goutam Pattanaik
Chief Engineer (E),
Neelam & Heera Asset
Submitted by:
Vishal Singh Gourav
Department of Electrical Engineering
Malaviya National Institute of Technology

Jaipur
DECLARATION
We undersigned hereby declare that the project entitled POWER GENERATION AND
DISTRIBUTION AT NEELAM COMLEX, ONGC Ltd., MUMBAI is the original piece Of
work submitted by us under the guidance of Mr. Goutam Pattanaik, Chief Engineer, Neelam
Complex for the partial fulfillment of the requirement of B.Tech degree of Malaviya National
Institute of Technology Jaipur and isexclusively prepared and conceptualized by us and the
findings in this project report are based on the data collected by us and to the best of our
knowledge and belief this report has not been copied from any research submitted by anyone,
anywhere earlier.
Vishal Singh Gourav
Malaviya National Institute of Technology,
Jaipur
NEELAM ASSET, ONGC Ltd., MUMBAI Page 2

ACKNOWLEDGEMENT
I avail myself of the opportunity of offering our sincere thanks to all the members of the
Department of Electrical Engineering, Malaviya National Institute of Technology for
organizing the summer training in ONGC Ltd., Mumbai.
I take this opportunity to express my profound gratitude and deep regards to my Mentor Mr.
Goutam Pattanaik for his exemplary guidance, monitoring and constant encouragement
throughout the course of this training. The blessing, help and guidance given by him time to
time shall carry me a long way in the journey of life on which I am about to embark.
I am obliged to staff members of ONGC, for the valuable information provided by them in their
respective fields. I am grateful for their cooperation during the period of my Training.
Vishal Singh Gourav

Malaviya National Institute Technology,
Jaipur

CONTENTS
S.No. Topic Page
1 About ONGC... 6
2 About Neelam Complex 7
3 Offshore Platform... 9
4 Water Injection Platform 10
5 Electrical Generation And Distribution... 11
6 Synchronous AC Generator... 19
7 Emergency Generator. 20
8 Protection of Generator.. 22
9 Power Distribution 28
10 High and Low Voltage Switchgear. 30
11 Switchgear Components 31
12 Motors.. 36
13 Description of Our Visit to Motor Workshop 37
14 Study of Control Logic Implementation Scheme Of MOL Pump. 37
15 Battery and charger 41
16 Flame Proof Equipments....47
17 Conclusion49
18 References50

LIST OF FIGURES
S.No. Figure Page
1 Neelam Complex... 7
2 Power System at NLM... 9
3 Schematic Diagram of Process Platform... 10
4 Water Injection System.. 10
5 Typical Static AC excited generator with field flashing
from a permanent magnet generator..........19
6 Control Room 21
7 Local Control Panel... 21
8 Schematic Diagram of 110V DC Control and Protection of generator25
9 Schematic Diagram of AC Power Supply System. 26
10 Schematic Diagram Of Neelam Process Platform. 29
11 Contactor Relay31
12 DOL Starter 32
13 Implementation Of DOL Starter........ 33
14 Power Circuit of Star Delta starter......... 34
15 Implementation of Star delta Starter.. 35
16 Induction Motor 37
17 MOL Diagram..38
18 Main Oil Line Pump Connection............... 39
19 Battery and Charger Diagram.........46

About ONGC
Oil and Natural Gas Corporation Ltd. (ONGC) has been playing an important role to meet the
energy requirements of the country to meet the rapidly. Keshava deva malaviya realized the
importance of an indigenous petroleum in India and laid down the foundation of ONGC in
august 14th1956 .the scientists and engineers of ONGC fuelled by pioneering spirit, have made
ONGC the numerouno exploration and production company of Asia today.
The company later on became corporate on Feb, 1994. ONGC was the first corporate to register
a five digit profit figure in the year 2002-03. It contributes to economy of India about more than
70% of Indias crude oil production and more than 75% of Indias natural gas production.
Vision & Mission

To be global leader in integrated energy business through sustainable growth, knowledge
excellence and exemplary governance practices.
World Class
Dedicated to excellence by leveraging competitive advantages in R&D and technology

with involved people.
Imbibe high standards of business ethics and organizational values.
Abiding commitment to safety, health and environment to enrich quality of community
life.
Foster a culture of trust, openness and mutual concern to make working a stimulating and
challenging experience for our people.
Strive for customer delight through quality products and services.
Integrated In Energy Business
Focus on domestic and international oil and gas exploration and production business
opportunities.
Provide value linkages in other sectors of energy business.
Create growth opportunities and maximize shareholder value.
Dominant Indian Leadership
Retain dominant position in Indian petroleum sector and enhance India's energy availability.

ABOUT NEELAM COMPLEX
Figure:1 Neelam Complex
Neelam Process Complex commissioned on 21 st june 1994.

Three bridge connected platforms are:
NLW:- water injection, process control room, accommodation, IU compressor,
startup air comp., water maker, fire water pump ,utility generator & after storage
NLP :- well fluid processing, gas compression & dehydration, produced water
conditioning, oil pumping,power generation & eg fire water pump.
NLM-3:- 12 nos of wells,oil / gas launcher , receiver , LP & HP flare header.
NPC is connected with 13 nos of unmanned well head platform(11 oil + 2 wi)
HANDLING CAPACITY
Oil 1,28,460 BSTOPD ( 850 m3 /hr)
Produced water 1,45,500 BWPD ( 964 m3/hr)
Water Treatment for injection 2,29,000 BPD (1516.6 m3 /hr)
Power Generation 12.3 MW/TG
Gas compression capacity 5.1 MMSCMD

MAJOR FACILITIES
MOL Pumps Three 72480 BOPD each
COT Pumps Three 72480 BOPD each
Process Gas Compressors Three 1.7 MMSCMD each
Power Generators Three 12.3 MW each
Gas Dehydration System Two 3.6 MMSCMD each
Produced Water System Two 72635 BOPD each
MAJOR EQUIPMENTS
Equipment Make Population Capacity
Turbine Generator Rolls Royce 03 12.3 MW
PGC Dresser Rand 03 1.71MMSCMD
Main Oil Line Pump Wier 03 480 M3 / hr
Main Injection Pump Wier 05 380 M3 /hr
SWLP Wier 03 1200 M3/ hr
CRANES NPC AAERO 05 8,10,12,16 MT
CRANES UNMANNED PARM 12 12 MT
EG STEV.&STEW 02 2.1, 01 MW

POWER SYSTEM AT NLM
Figure-2 Power System at NLM
OFFSHORE PLATFORM:
Well Platform:
The function of a well platform is:

To gather produced fluid from wells.
To test liquid and gas flow rate of individual well after separation.
Transfer well fluids to the processing platforms through subsea flow lines.
Well cum Process Platform:
Description:
These are normally six to eight legged platforms with two decks. They also have helideck and
boat landing. The platform is equipped with processing, treatment and pumping facilities. The
living quarters, utilities, communication and other facilities are provided. Most of the process
platforms are attached to at least one well platform. On the Process platforms the produced
fluids from different well platforms are processed and sent for onward processing and
transportation to consumers.
The process facilities include the necessary equipment to:
Separate oil, gas and water.

Treat and pump oil to a sub sea off take pipeline.
Clean up and dispose off the produced.
Treat and compress gas to a sub sea off take pipeline.
Condition associated gas for fuel.
Dispose off excess gas by flaring.
Generation power.
Make portable water.

Fig.:3 Schematic diagram of Process platform
Water Injection platform

Water injection process platforms are also manned platforms where seawater is processed to
make it suitable for the purpose of injecting it into the reservoir. The cleaned and treated
seawater is pumped at high pressure for injecting into the reservoir through number of injector
wells. The other facilities installed on manned platforms are power generation, utility instrument
air system, firefighting facilities, material handling facilities, living quarters etc.
The processing scheme consists of drawing the raw seawater from a depth of about 30 meters by
seawater lift pumps. Sodium hypocloride is added in the pump suction as a sterilizer for all
biological growth in pump suction and processing equipment.
Fig:4 Water injection system

ELECTRICAL GENERATION AND DISTRIBUTION
GAS TURBINE DRIVEN GENERATOR

Two types of gas turbines are available in offshore, namely aero derivative and industrial type.
Gas turbines of various makes like Rolls Royce, GE, Alstom, Solar, Man GHH,
NuovoPignone are installed.
The calculated maximum demand power requirements for the Neelam process complex (normal
and emergency) is equal to 22.8MW.
The above power demand is made up as follow.
- NLP M.D load plus 10% 9.1 MW
allowance for future growth
- NLW M.D Load plus 10% allowance 11.7 MW
for future growth
- NLG M.D load plus 10% allowance 1.98 MW
for future growth
- NLM-3 M.D load 0.045 MW
Total 22.825 MW
This power requirement is met by three 12.3 MW, dual fuel gas turbine generator sets.
The turbo-generators are located in an adequately ventilated room on the second floor of the
SWGR/generator building.
The remote unit control panel incorporate a microprocessor based PLC with input, output and
analogue channels for sequence, monitoring and control of the unit. A common
automatic/manual synchronizing panel is provided in the control room.

SECTION 1 - TECHNICAL DATA
1.1 A.C. GENERATOR
Manufacturer GEC ALSTHOM Large Machines Ltd

Serial number H24004301-02-03
Frame size AG160M131
Specification lEC 34/1
Output 16117 kVA
Voltage . 6.6 kV. 3 phase, 50 Hz
Poles 4
Speed 1500 rev/min
Rated power factor 0.8 lagging
Rotation Clockwise viewed on driven end (DE)
Insulation Class F system
Enclosure IPW54 duct ventilated
Cooling ICA31
Air gap 17.5 mm nominal (at pole centre line)
Bearing (NDE)
Manufacturer Renk
Type EGZLQ22-250
Bearing (DE)
Manufacturer Renk
Type EGZLB22-250
Bearing lubricant
Viscosity ISO VG 32
Quantity 16 litres/min/brg
Temperature inlet oil 50-55''C
Anti-condensation heaters
Type Tubular
Supply 240 V, 1 phase, 50 Hz
Rating (generator) 3600 W
Rating (exciter) 400 W
Automatic voltage regulator

Manufacturer GEC ALSTHOM Vacuum Equipment Ltd
Type C10/120M

EXCITER
Serial numbers H24004301E-02E-03E
Frame size UAJ51M10
Type Brushless with permanent magnet generator
Rotation speed of rotating diodes 1500 rev/min
Rated output 62.2 kW. 102 V dc. 610 A dc
Permanent magnet generator

Manufacturer Moriey Electrical Engineering Co. Ltd.
Type 54/40 with 5 cm magnets
Duty AVR supply for generator
Rating 250 Hz/1500 rev/min
Ceiling rating 205 V, 18.2 A, 0.93 pF (effective)
Shaft earthing brush CMIS (Morgan)
Earth fault detector brush EL (National)
SCHEDULE OF APPROXIMATE WEIGHTS

Rotor 10530 kg
Stator 13681 kg
Bearing 430 kg each
Bearing stool 190 kg each
Exciter 500 kg
Exciter stool 260 kg
Generator housing cover 1200 kg
Baseplate 4500 kg
Miscellaneous 1090 kg
Total 33000 kg
SECTION 2 DESCRIPTION
2.1 GENERATOR
The generator is a brushless, horizontal shaft, salient pole synchronous machine of frame size
AG160M131. The 4 pole rotor incorporates a shaft mounted UAJ51M10 exciter and permanent
magnet generator (PMG). The rotor shaft is supported by oil lubricated sleeve bearings mounted
by stools to the fabricated steel baseplate. The machine enclosure to IPW54 is weatherproof and
duct ventilated. Ventilating air is circulated by fan blades secured to each end of the rotor shaft.
The a.c. exciter, outboard of the NOE bearing, comprises a foot mounted frame carried on an
extension to the baseplate. An overhung rotor is mounted to an extension of the shaft with a
rectifier hub assembly mounted outboard of the rotor. The mains and neutral terminals are
contained within a free standing cubicle.

2.2 STATOR
The stator frame is a fabricated steel structure which contains the stator coreand winding. The
frame construction comprises endplates of substantial section, with key bars welded to
horseshoe plates and collars, which in turn are welded to the frame plates to produce a very rigid
structure. The stator core is built up of segmental laminations. Slots on the outside of the
laminations locate on the frame key bars. The core is divided into packets by narrow steel
spacers, thus forming ventilation ducts leading from the stator bore to the outer periphery of the
core.
2.3 ROTOR
The rotor shaft is an accurately machined steel forging which is extended at the NDE to carry
the permanent magnet generator field system, exciter armature and rectifier hubs. Four pole
shoes are secured by means of screws directly to the shaft. The sets of insulated coils, located
beneath the pole shoe projection, are retained by vee blocks and insulating slides; each of the
vee blocks is secured directly to the shaft by two screws. The cables from the field winding are
taken through drilled holes in the NDE of the shaft to the exciter and rectifier assemblies. A
permanent resistance is connected across the field winding to prevent diode over voltages should
the generator inadvertently run asynchronously. Thirteen fan blades are bolted around the shaft
at each end (NOE and DE) to provide cooling air circulation.
2.4 BEARING ASSEMBLIES
The bearings are low pressure oil lubricated sleeve jounal bearings with loose oil ring. The case
housing is mounted on a support stool, the housing is bolted and doweled to the stool and the
stool bolted and dowelled to the baseplate. The housing is in two halves, bolted together, spilt
axially along the shaft centre line. The housing encloses and supports the spherically seated
white metal lined shells, which are also in halves. The housing shell seating is lined with
insulation to electrically insulate the shell and shaft from the housing, and prevent circulating
currents. Floating labyrinth seals to IP44 are fitted to each side of the bearing housing. At the
OE the bearing shell is earthed to the pedestal by means of a removable link. Oil from a separate
supply is fed via pipework to cool and lubricate each bearing. Two resistance temperature
detectors (RTDs) are fitted into the bottom half shell in each bearing. Two proximity detectors
and three accelerometers are supplied for each bearing.
2.5 LINE AND NEUTRAL TERMINALS
Line and neutral terminals are housed in a free standing cubicle.
2.6 AUXILIARY TERMINAL BOXES
Auxiliary terminal boxes with 'Klippon' type rail terminals are mounted to the machine baseplate
and exciter stool. These boxes provide terminations for the generator and exciter heaters,
generator temperature detectors, vibration detectors, rotor and shaft brush gear, and for the
exciter and permanent magnet generator. All terminal boxes are made of stainless steel and are
provided with removable gland plates. Each box is individually earthed to the machine
baseplate.

2.7 EXCITER
The brushless exciter and permanent magnet generator (PMG) assemblies are mounted at the
NDE of the machine, within the exciter enclosure. The footmounted exciter stator frame and
PMG frame are bolted and dowelled to the exciter stool, mounted on the machine baseplate. The
PMG field system and the exciter armature are fitted on the rotor shaft extension, outboard of
the NOE bearing. The PMG output and exciter field excitation supply cables are connected to a
terminal box mounted externally to the exciter stool. The diode-bridge rectifier assembly is
mounted on the outboard side of the exciter and is secured by studs to the armature core. The
armature generates a three-phase output which is supplied to the bridge rectifier unit. The d.c.
output from the rotating rectifier unit is routed via cable through a central hole in the rotor shaft
to the main field winding of the generator. A rotor earth fault brush arrangement and associated
terminal box is fitted to the exciter.
2.8 PROTECTION DEVICES
2.8.1 Twelve simplex resistance type temperature detectors are fitted into Linn slots in the
wound stator assembly to measure the stator winding temperature. The leads from the detectors
are taken via a terminal rail on the stator endplate to a terminal box at the NOE of the machine.
2.8.2 Three resistance type temperature detectors are fitted to measure the temperature of the
ducted air; two temperature detectors for the generator air inlet and one detector for the
generator air outlet.
2.8.3 One resistance temperature detector is fitted to the exciter air outlet.
2.8.4 Two resistance temperature detectors are located in the bottom liner of each bearing to
monitor bearing temperature.
2.9 ANTI-CONDENSATION HEATERS
Anti-condensation heaters are positioned beneath the main stator end windings; six beneath the
DE and six beneath the NDE end windings. The heater cables terminate in a terminal box
located on the machine base plate. Four anti-condensation heaters are positioned beneath the
exciter. The heater cables terminate in a terminal box mounted on the exciter stool.
SECTION 3 - OPERATING INSTRUCTIONS

GEC ALSTHOM Large Machines Limited did not supply the control system for the generator
detailed in this manual. However, general points on operation are made under the applicable
sub-headings.

3.1 AIR CIRCUIT
The air filters for the generator are not in GEC ALSTHOM Supply. However, they should be
checked for cleanliness/integrity at regular intervals to ensure that the generators are kept clean
and dry. The checking interval can vary depending on site conditions and needs to be
determined by the user from experience of site conditions.
3.2 ROUTINE OPERATIONAL CHECKS
3.2.1 Daily
1. Check for excessive vibration.

2. Observe lubricating oil pressure, adjust if necessary, and check oil flow.
3. Check bearing temperatures.
4. Check generator air inlet and outlet temperatures.
5. Check winding temperatures.
3.2.2 Weekly
1. Visually check that all machine covers and housings are secure.
2. Check all pipework and seals for leakage.
SECTION 4 - PREVENTIVE MAINTENANCE SCHEDULE

4.1 INTRODUCTION
It is important that a system of regular maintenance is adopted to ensure efficient operation of

the generator. The frequency with which maintenance work should be carried out can only be
decided from consideration of site conditions and the mode of operation of the plant. The
following example of a maintenance is given as a guideline and the intervals suggested could be
extended or reduced depending on site conditions.
It is also recommended that a Maintenance Record Card be prepared on which to record dates
and details of all maintenance and repair work carried out. The card is useful not only to the
maintenance engineer, but also to the manufacturer should the motor ever be returned to the
Works.
4.2 THREE-MONTHLY MAINTENANCE
Perform the three-monthly maintenance as follows:
1. Test the stator insulation resistance. This test should also be carried out at any time
immediately before putting machine into service.
2. Check all connections and all nuts and bolts, including foundation and holding down bolts.
3. Check that there is not excessive play in couplings.
4. Check brushes for wear.
4.3 SIX-MONTHLY MAINTENANCE
Perform the six-monthly maintenance as follows:
1. Measure and record the insulation resistance of all windings.

4.4 TWELVE-MONTHLY MAINTENANCE
Perform the twelve-monthly maintenance as follows:
1. Clean all the ventilating ducts and passages.

2. Clean the windings if necessary.
3. Inspect the windings and test the insulation resistance.
4. Check the slot wedges and winding supports for tightness.
5. Check connections from windings to terminals.
6. Check the bearing pedestal and pipework insulation.
7. Check bearing clearances.
8. Check the security of all terminals, cables, fixing bolts, couplings and guards.
9. Clean the generator.
10. Check air gaps, fan, air seal and oil seal clearances.
SECTION 5. FAULT DIAGNOSIS PROCEDURES
5.1 INTRODUCTION
The following paragraphs are intended as a guide to identifying and curing problems which may
arise during Manning.
5.2 VIBRATION
1. Run the generator unloaded to check that the load is not inducing vibration.
2. Check the alignment of the generator and drive equipment
3. Check the tightness of stator and bearing pedestal holding down bolts.
4. Check bearings for excessive wear or incorrect assembly.
5. Measure the stator/rotor air gap to ensure concentricity.
6. Check that the stator line currents and phase resistances are balanced.
5.3 MECHANICAL NOISE
1. Check that there is nothing ribbing or catching on the shaft or coupling.

2. Check the alignment of the generator and drive equipment
3. Check the correct assembly of the bearings and inspect the oil levels.
5. Check for foreign matter in the air gap.

5.4 MAGNETIC NOISE
Check all connections against the circuit diagram. See that there are no open circuits and that all
terminals and contacts are clean and tight. Check that the stator line currents and phase
resistances are balanced and that the insulation resistance is correct. Measure the stator/rotor air
gap to ensure concentricity
.
5.5 WINDING OVERHEATING
1. Check all connections against the circuit diagram. See that there are no open circuits and that
all terminals and contacts are clean and tight.
2. Check the line currents against the rated figure.
3. Check the air inlet and air outlet temperatures.
4. Inspect all filters, ducts, passages and vents for blockage
5. Inspect the stator and radial cooling ducts for blockage.

7. Check that the stator line currents and phase resistances are balanced
and measure the insulation resistance.
5.6 BEARING OVERHEATING
1. Check the oil flow.

2. Check the line-out to ensure that bearings are not being overloaded.
3. Check that the bearings are correctly assembled. Inspect for wear or damage.

SYNCHRONOUS AC GENERATOR
Figure:5 Typical static AC excited generator with field flashing from a permanent magnet
generator
WORKING:-

EMERGENCY GENERATOR
Emergency power to the platform is provided by a 1180KW diesel engine driven generator
located in the first floor of the SWGR/generator building. The generator is rated for 415V,
50HZ, 3 phase and supply power directly to the central bus section of the PCC.
This power is then distributed, via the bus-tie breakers to all the life support and critical loads
such as the turbo-generator auxiliaries, life support systems, lighting, ventilation systems,
battery systems, etc. Reference is made to Cooper operating and maintenance manual.
The emergency generator is controlled from a remote control panel located in the switchgear
room. Failure of total 6.6 KV normal power will start emergency generator automatically and
closing of breaker will be done manually when normal power supply returns, transformer, and
incomers will be synchronized with emergency generator and emergency generator ACB will be
tripped automatically.
The calculated emergency maximum demand power requirements for the NLP platform
complex are equal to 924.8 kW.
This power requirement is net by a diesel engine driven generator. The generator has a site
rating of 1180 KW at 0.8 power factor. The generator is automatically started in case of total
loss of normal power to the PCC.
EMERGENCY GENERATOR CONFIGURATION

The equipment provided by Stewart & Stevenson consists of a Stewart & Stevenson Model
16V149TA1180 Diesel
Generator Set, complete with remote vertical radiator, remote coolant expansion tank, and a
complete switchgear lineup. The generator set is rated to produce 1,180 kW of 50 Hz AC power
at 415V on a continuous basis.
DIESEL ENGINE
The prime mover of the diesel generator set is an Detroit Diesel 16V149TA engine. This is a
turbocharged, after cooled, V-16, two-cycle diesel engine, which has been specifically equipped
for use as a stationary power unit.
ENGINE COOLING SYSTEM

The system includes a remote vertical radiator with a cooling fan, The system is equipped with
alarm and shutdown temperature switches for overheat protection. The alarm make is at 205 F
(96 C), and the break is at 198 F (92 C). The shutdown set points are 210 F (99 C) make
and 205 T (96 C) break. A thermostatically controlled valve controls the amount of coolant
routed to the radiator. The valve set point is 171 F (77 C). This valve maintains the coolant
temperature near the set point.

AIR STARTING SYSTEM
The engine starting system consists of two air-driven starting motors. Either a nitrogen cylinder
bank or a compressor with receiver furnishes starting air. The compressor is driven by a 12 hp
Lister-Petter AC-2 Diesel Engine. The compressor driving engine is hand-started.
CONTROL PANELS
Figure:6 Control Room Figure:7 Local Control Panel
Local Control Panel
This panel is mounted on the engine-generator skid. The panel assembly is made up of two
compartments. The top compartment contains engine gauges and a pyrometer for measurement
of exhaust temperatures. The bottom compartment contains switches and lamps, a tachometer,
and an hourmeter. The lamps relate to engine warning and shutdown alarms and also include an
engine run indicator. Switches include start, stop, reset, mode selection, and lamp-test functions.
Remote Control Panel This panel is located in a control room, separated from the engine-
generator. The panel assembly consists of two compartments joined side by side. Each
compartment has a hinged door, which contains the switches, lamps, and other devices that must
be accessed by the operator frequently. Other components and wiring are enclosed within the
compartment.
In general, the components of the remote control panel relate to the electrical control of the
system and to the alarm or warning indicators of the annunciator.
Motor Control Station 1 (MCS-1) This unit contains controls and lamps used with the engine
electrical lube oil pumps. Located on the side of the engine-generator skid, this unit contains two
sets of control switches and lamps on the front panel. The pumps can be controlled manually or
automatically. In manual mode, the pumps are controlled individually and separately. For

automatic control of the oil circulating pump, the motor starts and stops when 415 VAC power
is applied and removed, respectively. Motor starters are not included in this unit.
Motor Control Station 2 (MCS-2") This unit contains controls and lamps related to the
cooling water radiator fan motor. The MCS-2 unit is located on the radiator skid. The fan motor
can be started or stopped manually or automatically. Manual controls are located on the front
panel of the MCS-2. The fan motor is automatically controlled through relay operation in the
Remote Control Panel. An ammeter on the front panel displays fan motor current This unit does
not include the motor starter.
LINE AND NEUTRAL TERMINATION BOX The line and neutral termination box contains
bus bar junctions that form the power connections to the generator. The line and neutral
termination box is attached to the generator. The line side bus bars connect to the switchgear.
The neutral side bus bars connect to the neutral cubicle.
NEUTRAL CUBICLE The neutral cubicle contains bus bar junctions and current
transformers that form the neutral side power connections to the generator. The neutral cubicle is
attached to the neutral outlet of the generator.
PROTECTION OF GENERATOR
Engine driven sets must be protected with adequate engine governors and protection against
excessive over speed. The output to the load of the generator should always be protected with an
overload protection device such as a circuit breaker or fuses. Circuit breaker or fuses must be
sized according to NEC/local codes and must be coordinated with the generator thermal damage
curves.
These are the following ways (ANSI codes) we use to protect transformers and generators from
faults:
87/G1
Generator differential protection (87/G1): the protection is provided with high speed, high
stability circulating current relays. The relays has a pick up range of 10 to 40% of 5A and shall
have suitable stabilizing for ensuring stability against external faults. The relays shall be tuned
to fundamental frequency to reject harmonics produced by CT saturation.
87/GT1
Generator-transformer differential protection (87/GT1): the diff. relays for the generator-
transformer has to be of sensitive high speed percentage bias type with harmonic restraint and
has CT ratio matching devices.
The relay should have all required restraints to make it inoperative for fault current,
magnetizing inrush current and abnormal magnetizing inrush current during short time over
voltage conditions.

87T1A
Unit auxiliary transformer differential protection (87T1A): percentage biased differential
relays are used along with ratio matching device. The relay shall not operate for magnetizing
inrush current. High set instantaneous over current relays shall be provided in series with the
previous relay, set for magnetizing inrush current, for fast protection from internal faults.
64GI
Generator stator earth fault protection (64GI): the stator earth fault protection shall consist of a
zero sequence voltage relay connected to the broken delta winding of generator voltage
transformer. The protection shall act to initiate a time-delayed signal only and hence the relay
shall be continuously rated for 110V.
The relay shall incorporate arrangements to make it insensitive to third harmonic voltages.
87TG
Generator inter-turn protection(87TG): the protection shall be by means of an instantaneous
over current relay. The relay shall incorporate filtering arrangements to make it inoperative for
third harmonics. The relay shall have suitable range to cover 20-50% of generator current.
64-1,64-2
Generator rotor earth fault protection(64-1,64-2): the first rotor earth fault of generator shall
be detected by means of super imposing of separate Dc bias on the field winding. The DC bias
shall be such that the faults at any point in the winding are covered by the protection. Also the
relay shall withstand the voltage encountered. Second rotor earth fault protection for
generators shall also be provided, with suitable relays common for two units.
The protection shall incorporate feature for compensating the effects of induced alternating
currents in rotor circuit and shall have minimum dead zone.
40G
Generator loss of field protection(40G): this protection shall be single phase off set impedance
type. The relays shall have impedance settings to cover the usual range of impedance of large
turbo generators.
21G
Generator backup protection(21G): the generator backup relay shall be of three phase
impedance type for one zone protection together with required auxiliary relays and two stage
timer to give backup protection for faults in the generator, main transformer and transmission
system.

46G
Generator negative sequence current protection(46G): the negative sequence current relays
shall protect the generator from damage by overheating due to sustained flow of unbalanced
phase currents, and the operating characteristics of the relay shall be adjustable to match I2Rt
thermal characteristics.
67-1G, 67-2G
Generator under power and anti motoring protection (67-1G, 67-2G): the step up transformer
back up earth fault protection current relays shall be of IDMT characteristics. One of the two
relays shall be set with higher time dial setting to provide second stage of protection.
51G
Generator overload protection(51G): one over current relay shall be provided to initiate an
overload alarm. The relay shall have high reset ratio and adequate continuous thermal rating.
59G
Generator over voltage protection(59G): suitable over-voltage relays preferably with
volt/cycle characteristics shall be provided.
50T1A
Back-up protection for unit auxiliary transformer(50T1A): Two instantaneous over current
relays with an external DC timer shall be provided for back-up protection for unit 6.6 kV bus
bar.
95G
Fuse failure protection(95G): This protection shall block the operation of all protections
associated with voltage circuits in the event of failure of a fuse of generator.
86G and 86GT

Lockout relays(86G and 86GT): lockout relays shall be provided for each generator unit which
will be multi contact , hand reset type. The latching mechanism shall be positive and
insensitive to vibration and shock

Figure:8 Schematic diagram of 110V DC control and protection of generators

Figure:9. Schematic Diagram of AC power supply system

DESCRIPTION
Three 1800KW MOL pump motors (PM-1380, PM-1390 & PM-1400)
Three 220KW COT pump motors (PM-1350, PM-1360 & PM-1370)
Two 2000KW L.P booster comp. motors (CM-1460/1490 & CM-1530/1560)
One 570KW fuel gas comp. motors (CM-4820)
Two 6. 6KV feeders to NLW platform
Three feeders to 6.6/0.433KV, 2000KVA transformers (TR-101, TR-102 and TR-103)
In addition to the above, the 6.6KV SWGR is also provided with a number of spare feeders.
The low voltage (415VAC) power requirements are met directly or indirectly from the PCC
(SWGR No. 301) which is located in the switchgear room and fed from the 6.6KV SWGR via
transformers TR-101, TR-102 and TR-103. The PCC also consist of three bus-sections which
may be connected together by two tie-breakers. Each section of bus has an incomer from a
transformer.
The incomers and bus-tie circuit breakers in the PCC are interlocked to prevent paralleling of
supplies. However, momentary paralleling of supplies has been made possible during the load
transfer operation, if required to change the supply for any bus section from one incomer to
another
The PCC consist of a switchgear section and MCC section. The MCC section consist of
combination motor starters and contactors serving the platform utilities. The switchgear section
consist of air circuit breakers and moulded case circuit breakers.
The major SWGR feeders from the PCC includes.
One feeder to normal MCC (SWGR No. 302)

Three feeders to turbine aux. MCCs (SWGR No. 308. 309. & 310)
Three feeders to gas comp. aux. MCCs (SWGR No. 303. 304. & 312)
One feeder to HVAC MCC (SWGR No. 306)
One feeder to NLM-3. platform MCC (SWGR No. 381)
Four feeders to space heater panels (SHP 1P, 2P, 3P & 4P)
One feeder to main lighting distribution board (SWGR No. 305)
Two feeders to power distribution panels (SWGR No. 307-1 & 307-2)
Three feeders to heat tracing panels
(SWGR No.- 314-1. 314-2 & 314-3)
One feeder to 240VAC Inst. level gauge panel (SWGR No. 311)
Dual feeders to 110VDC battery/charger units (BC-401A & B)
Dual feeders to 24VDC inst. battery/charger units (BC-402A & B)
One feeder to nav. aids battery/charger units (BC-403)

Synchronizing of the emergency generator is achieved by means of an auto/manual
synchronizing panel incorporated into the PCC. and it enables the synchronizing of the
emergency generator and the turbine generators to enable uninterruptable changeover of supplies
after black start or for load testing of the emergency generator.
In case the NLP emergency generator is out of service, emergency power may also be provided
from the NLW emergency generator by means of a 415V bridge connected cable feeder between
the NLW PCC and the NLP PCC. This connection is rated to enable back start of one NLP
turbo-generator.
Power Distribution
The turbine generators directly feed the 6.6KV. switchgear (No. 201) located in the switchgear
room which is below the generator room. The 6.6KV switchgear consist of three bus-sections
connected together normally closed by two tie-breakers. Each section of bus has an incomer
from a turbo-generator. All circuit breakers are of the vacuum type. The 6.6KV SWGR-201
directly feed the following.
Voltage Drop
For feeder cables sizing, the maximum designed voltage crop is as follows.
-Lighting and power distribution 1% of nominal line to

boards line voltage
- Lighting points 2% of nominal voltage
- Motors (running) 3% of nominal line to
line voltage
- Motors (starting) 20% of nominal line to line
voltage
- D.C systems 3% of nominal voltage
The system voltage drop during motor starting is designed to satisfy the following requirement.
- Voltage at bus bars during the largest motor acceleration is not less than 85% of nominal value.
- The voltage at motor terminal is sufficient to permit motors to accelerate their loads to full
speed without overheating.

Figure:10 Schematic Diagram(Neelam Process platform)

HIGH AND LOW VOLTAGE SWITCHGEAR
All Switchgear and associated equipment have a rating at least equal to the maximum possible
load under any circuit configuration including provision for 10% future load growth. All
switchgear.motor control centers, etc. are placed in non-hazardous ventilated buildings.
All A.C switchgear/motor control centers are free standing, dead front metal clad/enclosed with
drawout type modules.
All the switchgear/MCC's are provided with indication. metering and protection devices as
detailed in the following one line and schematic diagrams.
NLP-P-50-102 (3 sheets) 6.6 KV SWGR No. 201
NLP-P-50-103 (3 sheets) 415 V SWGR No. 301 (PCC)
NLP-P-50-104 (6 sheets) 415 V SWGR No. 302 (Normal MCC)
NLP-P-50-105 (2 sheets) 415 V SWGR No. 303, 304. 312 (Gas

Comp. Aux. MCC)
NLP-P-50-106 (1 sheet) 415 V SWGR No. 308. 309. 310 (T/G Aux.
MCC)
NLP-P-50-107 (2 sheet) 415 V SWGR No. 306 (HVAC MCC)
All moulded case circuit breakers are rated duty P2 to IEC 157-1 and are of the current limiting
type. MCCB's which are part of motor starters are selected for motor duty type. The 6.6 KV
SWGR is of Westinghouse type "VAC-CLAD-W" metal-clad switchgear with type "75-VCP-
W500" vacuum circuit breakers. Reference is made to Westinghouse operating and maintenance
manuals for H. V. Switchgear.
The L.V SWGR/MCCs are of HEECO type H8PU.011" equipped with Merlin Gerin ACBs &
.MCCBs. Stromberg starter and overload units. Reference is made to HEECO operating and
maintenance manuals for L.V switchgear.
TRANSFORMERS
Three 6.6/0.433KV cast resin dry type 2000 KVA step down transformers feed the 415V
switchgear. The transformers supply buses 1B, 2B and 3B of PCC (SWGR No. 301), via bus
ducts.
The transformers natural cooled capacity is greater than the maximum expected sustained
demand plus 10% spare capacity for future load growth.
The transformers have 9% impedance in order to keep the fault level at the PCC to a realistic
level. Reference is made to Westinghouse operating and maintenance manuals for transformers.

FEEDERS
The feeder rating under design ambient conditions are as follows.
- Feeders are sized to-withstand without damage the maximum short circuit thermal and
mechanical stress conditions for the full clearance time of the protective device.
- The selected continuous current rating of power feeders under the worst circuit configuration is
at least equal to the maximum demand plus an allowance of 10% for future load growth.
- The continuous current rating of transformer feeders and secondary bus duct are at least equal
to the rating of the transformer.
- The continuous current rating of distribution board feeders are at least equal to the maximum
demand plus 10% allowance for future load growth.
- The continuous current rating of motor feeders are at least equal to 125% of the motor full load
current.
- Feeders to welding outlets are rated to carry 40% the total connected outlet ratings, when
two welding receptacles are connected in the same circuit.
SWITCHGEAR COMPONENTS
POWER CONTACTORS:-
Contactor is a mechanical switching device capable of making, carrying and breaking currents
under normal circuit conditions including operating overload conditions.
Figure:11 Contactor Relay

A contactor has two separate electrical circuits.
1. Main Circuit
2. Control circuit
1. Main circuit:-the main circuit involves power contacts and handles the power drawn by
the load. The main circuit mainly consists of contacts and terminals.
2. Control circuit:- the control circuit involves coil & auxiliary contacts. Auxiliary contacts
are in built and are used for interlocking, signaling etc.
STARTERS:
There are 2 types of starter we used:
1. Direct on-line(DOL) Starter

2. Star-Delta Starter
1. DOL-Starter:
Motor stator windings are permanently connected in delta. Full 3-phase line voltage is applied at
starting. The starting current drawn by the motor is about 6-8 times the rated current of the
motor.
Figure12 DOL starter

Figure:13 Implementation Of DOL Starter
2. STAR-DELTA STARTER:
First motor stator windings are connected in star. Motor windings get phase voltage although
full 3-phase line voltage is switched on. Thus, it is reduced voltage starting.
Motor is allowed to run in STAR till such a time it has reached 80% of the rated speed. After
this, motor is reconnected in DELTA. Full voltage is applied to each winding. Motor continues
to run in DELTA.

Power circuit of star-delta starter:
Figure:14 Power circuit of star-delta starter
Sequence of contactor operations:
1. Star contactor pick-up.

2. Hold-on contactor pick-up. Motor starts in star.
3. Star contactor opens.
4. Delta contactor pick-up. Motor switched from star to delta.

Fig16. Implementation of star delta starter

Advantages of star-delta starter:
- Voltage dip during motor starting is low.
- Sensitive mechanical system drives could get damaged from the high starting torque of
DOL starting which can be limited by star-delta starter.
- Starting KVA required by the motor are low. This reduces the requirement of source
capacity.
Limitations of star-delta starter:

- Starting torque is low. It may not be possible to start some of the loads.
- Acceleration time of the motor increases.
- Cost of the control gear required is higher compared to DOL starter.
MOTORS:
All motors are 3 phase Induction motors continuous maximum rated with the exception of
specialized crane and hoist motors.
Three phase motors installed outdoor are totally enclosed. fan cooled and weatherproof with
IP55 enclosure protection to IEC standard.
Motor installed in hazardous area are classified as suitable for the area classification by a
recognized testing authority.
With the exception of motors for specialized service, all motor have class "F" insulation with
temperature rise limited to class "B".
Motor windings are tropicalized and are fully impregnated for marine service.
All motors 3.7KW and above are provided with 240V, single phase anti-condensation heaters
interlocked to switch on only when the motor is not running.
All motors are suitable for direct on-line starting.
Frame sizes of motors are in accordance with IEC standards except where other standards are
agreed.
All motors are provided with-local start/stop push button located in a control station or in the
packaged units local control panel. Automatically operated/interlocked motors are also equipped
with auto/manual selector switches to enable manual starting of motors for testing.
Local control stations/panels are also equipped with ammeters for motors rated 3.7KW and
above.

Description of Our Visit to Motor Workshop:
Figure16 Induction Motor
Before Opening Induction Motor, following Observation is taken about motor:
Power Rating.
Speed in RPM.
Voltage Rating.
Ampere Rating.
Frequency rating.
Total slots in rotor.
Total coils and coils set.
Coil Pitch.
Coil turn.
Wire Parallel.
Winding Size.
Conductor Size.
Weight of one coil.
Total Weight of coils.
Study of control logic implementation scheme of Main Oil Line Pump:-

For Implementation of Main Oil Line Pump, we use following Electrical Equipments:
1. Relays (ex. R174, R172, R135, R146 etc.)

2. Contactors ( ex. NO,NC)
3. Interlocks.
4. Indicating Bulbs.
5. Diodes.
6. Cooler Fan (ex. Cooler fan A & Cooler fan B)
7. Heater

Figure17. MOL Diagram

Figure:17 Main Oil Line Pump Connection
Operating Mechanism:-
R124 is used for low suction pressure of Pump. It will open on low suction pressure.
R126 is used for mechanical seal failure of Pump. It will open on seal failure.
R174 is controlled by Center Control Panel.
If above these three relays are working than relay R172 will ON. If any one of these relays is
open than the contact of relay R172 will also open.
R172 is working than main motor is running.
When motor is operating then it will get heated. So for cooling purpose we use two cooler fan A
& B.
At a time only one cooler fan works. If it fails then other works.
R 142 is used for cooler fan A and R146 is used for cooler fanB. Two blub(red & green)
with each relay is connected for checking relay is on or off. If red blub glows than it
indicates that relay is ON. If green blub glows it indicates that relay is OFF.
R131 is for manually selection (not from center control panel).
R134 is availablefor remote start.
R135 is used for start acknowledge from CCP.
R135 is connected to the main supply by two contactors NO and NC. When we press NO
Contact, R135 starts working. When Contactors of R116 is closed and R146 is on, then
supply will pass through R116 and R135 starts working. When Contactors of R116 is
open, then current will bypass.
R175 is connected to high voltage switchgear to start main motor.
R175 works when R115, R172,R131 or R135 are on.
SOCKET OUTLETS
Three type of socket outlets are provided in the NLP platform as follows.
Indoor type convenience outlets
They are of the industrial type metal clad, flush mounted -15 amps round
pins shutter type to BS5773: 1979. Each outlet is suitable to 240 volts
These are provided in indoor the outlets are located in non-hazardous
area, the switchgear rooms, workshop, control room. etc.
Outdoor type convenience outlet
They are of the flame-proof type suitable for outdoor installation in Class
1. Div. 1 Group D area. The socket are supplied complete with plugs.
Made of copper-free aluminum and rated for 250VAC, 1 phase, 3-wire 20
AMPS. These are provided in outdoor areas and the generator room.
Welding outlets
415V. 3 phase, 4 wire, 5 pole welding outlets rated for 60 AMPS are
provided in the process and work area. The outlets are supplied complete
with plugs and are suitable for installation outdoor in class 1, Div. 1,
Group D area.
A minimum of two outlets are provided per deck and they are installed on the basis of reaching
any point in the structure, where welding may be required with 15 meter long cable.

GROUNDING AND BONDING
All equipment is grounded and bonded in accordance with the general requirement of NEC
article 250-94 and 250-95. However, the following sizes of grounding wires are used.
L.V motors 35 mm2
H.V motors 70 mm2
Equipment overcurrent 0-500 AMP 35 mm2
Equipment overcurrent 2001-4000 AMP 300 m2
The maximum resistance to ground is not more than 0.1 CHM.
Ground conductors are soft drawn, stranded copper conductors with green PVC insulation.
BATTERIES AND CHARGERS

The NLP platform is equipped with the following battery and battery charger system located in
the NLP battery and switchgear rooms respectively.
24V DC for instrumentation (DCDB-402)
Battery : Dual -BAT-2A & BAT-2B 210 AH each
Charger : Dual BC-2A & GC-2B 240 AMP each
110V DC for EM.Lighting.SWGR control & EM. L.O.P
(DCDB-401)
Battery : Dual -"BAT-401A" & "BAT-401B" 2880 AH each
Charger : Dual "BC-401A" & "GC-401B" 800 AMP each
15.6V DC navigational aid system (SWGR No. 313)
Battery : Single - "BAT-403" 968 AH
Charger : Single - "BC-403" 150 AMP

All the battery chargers and batteries are sized to satisfy the maximum load requirements, plus
10% allowance for future load growth, under the worst operating condition and for the designed
life of the platform.
All the battery chargers are of the constant voltage type with current limiting features.
The chargers are capable of maintaining their rated output even with the batteries disconnected.
All chargers are provided with facilities to inhibit boost charging when receiving remote voltage
free signals. This feature is used to inhibit boost charging during failure of the battery room
HVAC system in order to reduce the quantity of hydrogen generated during battery charging.
All chargers are equipped with MCCBs with shunt trip in the battery circuits to enable the
automatic isolation of the batteries from the chargers in case of fire in the battery room. Under
such conditions, the chargers may continue 10 operate without any noticeable change to their
output parameters.
Charging of the Nickel Cadmium Battery:-
The different terms associated with charging of vented Ni- cad battery are:-
1. Commissioning charge or initial Charge:-
It is the first charging of the battery after the electrolyte is filled. It is done at a normal rate for
long duration as per the recommendations of the manufacturer. The cells are filled with
electrolyte of recommended sp. Gravity and rested for 12 hours. After the rest the fall in level of
electrolyte is made up by adding electrolyte to marked level.The charging is done at a current
equal to 20% of the AH rating of the cell. The charging is continued until the recommended AH
input for first charging is given. Normally the manufacturers recommend 200 to 300% of the
rated AH value as the first charge input.
2. High rate charge / Boost charge / Equalize charge
This is the charge given to a battery after a discharge to ensure the replenishing of lost energy
(during discharge) is quickly restored to the battery so that it is ready for another discharge. The
normal recommendation of the manufacturers is that a voltage calculated.
At 1.6 V(H-type) to 1.7 V(L type) per cell is to be applied to the battery with a current limit
equal to 20% of AH rating.
For very quick charging an initial current level of 40%of the AH rating can be used until gassing
(1.47 to 1.5V) and the current may be reduced to 20% of AH rating for further charging.
3. Float charge:
A fully battery if kept on open circuit will undergo self-discharge at about a rate of 5% per
month. To maintain a fully charged battery in fully charged state, we need to apply a voltage
which is higher than the open voltage of the battery draws a small current to makeup for the self
discharge. The current is approx of the order of 2mA per the cell. Earlier times the chargers are
controlled to maintain specified constant value of current for maintaining the battery in full
charge condition without a limit of the voltage.

This kind of charging is called trickle charging presently the chargers are controlled to maintain
a constant voltage (between 1.40V to 1.42V per cell) and the charging is called float charging.
The batteries are kept on float charge without any time limit.
BATTERY CHARGERS:-
A Battery Charger is generally a static power converter that rectifies AC power intoregulated
DC power and uses it to charge a battery and supply loads. The charger supplies the required
charging current to the battery {either float or boost current) at the required voltage.All
secondary batteries require at least two types of charging-
High rate (quick) charge:
A discharged battery requires recharging quickly so that it is ready for the next discharge. How
quickly the recharge is done depends on the type of the battery &the ambient temperature.
Float charge/ Trickle charge:
A charged battery if left in open condition (not connected to load) loses its charge gradually due
to self discharge. The self discharge depends on the type & AH size of the battery, its age and
the ambient temperature, The charge loss per day will be asmall percentage of the rated AH but
will add up to considerable value in a month.
To keep the battery always in a fully charged condition, it should be connected to acharger that
gives continuous small current to the battery that is sufficient to make up the self discharge. The
charger shall have a voltage that is higher than the battery open circuit voltage to force current
into the battery.
A float cum boost charger is a DC power source that performs both types of charging
depending on the state of charge of the battery It is capable of changing its operation mode
between float charging and boost charging as per the battery requirement. The change of state
can be manual (by a control switch) or automatic
It is normal practice to provide a third voltage level substantially higher than the open circuit
battery voltage (approx 25 to 30%higher) in the charger to perform equalizing charge to a
battery and commissioning charge of a new battery. The commissioning or equalize charge
mode is not of a regular use and hence is always by a manual command.

Basic requirements of a float cum boost charger:
1. Rectifier operation:
Battery charger should convert the commonly available AC power (from single phase or 3 phase
AC utility system) to DC power. Battery charger output shall be a regulated DC voltage (within
+ /- %) at a pre selected value of float or boost or commissioning charge voltage even when
input voltage & frequency are varying (more than 10%for voltage &5% for frequency). Hence
battery charger is essentially a controlled rectifier.
2. Current delivery capability:
Battery charger shall be capable of supplying the high rate charging current to the -
battery. It should additionally supply the load current if load is parallel to the charger &battery.
3. Charging mode selection:
It should have a selection facility (a control switch or soft keys) to change between float, high
rate & equalize (commissioning) charge modes.
4. Voltage adjustment:
It should have a facility to adjust (by three potentiometers or set by soft keys) the DC out
voltage in any of the three modes (float, boost and equalize) of charging. The adjustment should
be independent of each other.

5. Total current limit:
It should have a facility to adjust or set the output total current limit independent of the charging
mode.
6. Battery current limit:
It should have a facility to adjust (by three potentiometers or set by soft keys) the battery current
limit in any of the three modes (float, boost and equalize) of charging. The adjustment should be
independent of each other.
7. Power Factor:
The Power factor at the input is approximately equal to the triggering angle. It can be improved
by freewheeling diode in 4the DC output.
8. Output ripple voltage filter:
The output voltage of a charger/rectifier contains an AC voltage superimposed on the DC

voltage. This AC component voltage is called the ripple voltage in output. The ripple voltage is
measured in RMS. The ripple generated in a charger depends on the type of rectifier & the
triggering angle. To reduce it to the permissible limit normally L-C filter is used in the output of
charger. Battery connected to the rectifier helps in reducing the ripple voltage.
Approximate values of maximum generated RMS ripple of chargers (before filter circuit);
Single phase Thyristors Bridge: 80% of max. DC
Three phase full control (6 pulses) bridge: 27% of max. DC
Three phase half control (3 pulses) bridge: 35% of max. DC
Three phase 12 pulse bridge: l2% of max. DC
Single L-C filter is used to reduce the ripple down to 1%. If ripple less than this value is desired
(Telecom roads require 0.1% ripple). Double L-C filters are used.
All the batteries are of the nickel cadmium type mounted on shock and earthquake-proof racks.

.
Figure19. Batteries and Charger Diagram

FLAME PROOF EQUIPMENTS
Lighting and Electrical Equipment for use in Hazardous
Atmospheres to IEC standards
ONGC uses lighting and power distribution equipment suitable for use in areas where
flammable atmospheres may occur. The proper use of protected apparatus is a specialist subject.
Methods of Explosion Protection for Electrical Equipment:

The ignition of flammable atmospheres can be initiated by sparks or hot surfaces arising from
the use of electrical power. Other possible sources of ignition are electrostatic effects and
frictional sparking. The hot surfaces involved can be those of enclosures, components and light
sources. Under fault conditions electrical connections may become over-heated and cause arcs
or sparks. In addition, sparks may be the result of the discharge of stored energy or from
switching contacts. A number of standard methods of protection against ignition have been
established and these have been codified in construction standards. These design codes enable
manufacturers to make apparatus of a uniform type and have it tested by certification authorities
for compliance with the standards.
The methods of protection are summarized in Table 1:
Methods of Explosion Protection

Method Type of Protection
Designed to prevent any ignition from arising Ex e Increased Safety
Ex N or Ex nA Non Sparking
Designed to limit the ignition energy of the circuit Ex i Intrinsic Safety
Designed to prevent the flammable mixture Ex m Encapsulation
reaching a means of ignition Ex p Pressurization
Ex o Oil immersion
Ex N or Ex nR Restricted Breathing
Designed to prevent any ignition from spreading Ex d Flameproof Enclosure
Ex q Powder Filling
Classification of Hazardous Areas and the Use of Protected Apparatus

Codes of practice have been established for the classification of the potential hazards, the
selection of suitable equipment to protect against the hazards, and their installation and their
maintenance. The codes of practice will list the methods of protection which, used individually
or in combination, may be employed to attain an acceptable degree of safety.

The hazardous areas are classified in Table according to EN 60079-10:
Hazardous Area Classification

Zone Description
Zone 0 Zone in which an explosive atmosphere is continuously present for long periods.
Zone 1 Zone in which an explosive atmosphere is likely to occur in normal operation,

typically between 10 and 100 hours per year.
Zone 2 Zone in which an explosive atmosphere is not likely to occur in normal operation,
and if it occurs it will exist only for a short time, typically less than 10 hours per
year. (Zone 2 is often referred to as the remotely hazardous area.)
Surface Temperature Rating and Gas Groupings:

Any flammable mixture can be classified for explosion protection under two main
characteristics; temperature of ignition by a hot surface and the spark energy to ignite the
mixture. The spark energy of ignition is also related to the intensity of explosion. This property
is crucial to the design of the joints in flameproof enclosures (Ex d) and the energy level of
intrinsically safe (Ex i) apparatus. Other characteristics are the specific gravity and flash point,
which are used in the determination of the area classification.
Surface Temperature For Ignition:
The surface temperature rating is measured in the most onerous design attitude at the most severe
supply voltage condition within the design tolerance. Usually this is +10% of rated voltage for
lighting and with any fault or overload condition which could normally occur in service. A
normal overload condition for motors is the starting or stalled condition and, for luminaires, the
end of life of a lamp. In the case of Ex d, Ex m, Ex q and also restricted breathing Ex nR and dust
proof enclosure methods, the maximum temperature is measured on the external surface.

CONCLUSION
Being a student of Electrical Engineering branch, I would like to say that this training program
was an excellent opportunity for us to get to the ground level and understand the importance of
electrical engineering at offshore oil platforms. Detailed understanding of power distribution and
control at the Neelam platform was an experience that we would have never gained through
going straight into a job.
The main objective of the training at Neelam asset of ONGC was to get an opportunity to
identify, observe and practice how engineering is applicable in the offshore oil platforms.. It was
not only to get experience on technical practices but also to observe management practices and
to interact with fellow workers.
I feel I got the maximum out of that experience. Also I learnt the way of work in an
organization, the importance of being punctual, the importance of maximum commitment, and
the importance of team spirit. In my opinion, I have gained lots of knowledge and experience
needed to be successful in a great engineering challenge, as in my opinion.

REFERENCES
Offshore Operation Guide of ONGC.

http://www.ongcindia.com/wps/wcm/connect/ongcindia/home/
MANUFACTURERS DATA BOOK VOLUME 109 FOR NEELAM PROCESS
PLATFORM COMPLEX.
MANUFACT. DATA BOOK_ VOL_109 Battery & UPS

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SUMMER TRAINING PROJECT REPORT ON

POWER GENERATION AND DISTRIBUTION AT

NEELAM COMLEX, ONGC Ltd., MUMBAI

Under the guidance of

Mr. Goutam Pattanaik

Chief Engineer (E),

Neelam & Heera Asset

Vishal Singh Gourav

Department of Electrical Engineering

Malaviya National Institute of Technology

Vishal Singh Gourav

Malaviya National Institute of Technology,

NEELAM ASSET, ONGC Ltd., MUMBAI Page 2

Vishal Singh Gourav

NEELAM ASSET, ONGC Ltd., MUMBAI Page 3

2 About Neelam Complex 7

4 Water Injection Platform 10

5 Electrical Generation And Distribution... 11

10 High and Low Voltage Switchgear. 30

13 Description of Our Visit to Motor Workshop 37

14 Study of Control Logic Implementation Scheme Of MOL Pump. 37

15 Battery and charger 41

16 Flame Proof Equipments....47

NEELAM ASSET, ONGC Ltd., MUMBAI Page 4

S.No. Figure Page

NEELAM ASSET, ONGC Ltd., MUMBAI Page 5

Vision & Mission

Dedicated to excellence by leveraging competitive advantages in R&D and technology

Integrated In Energy Business

Dominant Indian Leadership

NEELAM ASSET, ONGC Ltd., MUMBAI Page 6

Figure:1 Neelam Complex

Neelam Process Complex commissioned on 21 st june 1994.

Oil 1,28,460 BSTOPD ( 850 m3 /hr)

Produced water 1,45,500 BWPD ( 964 m3/hr)

Water Treatment for injection 2,29,000 BPD (1516.6 m3 /hr)

Power Generation 12.3 MW/TG

Gas compression capacity 5.1 MMSCMD

NEELAM ASSET, ONGC Ltd., MUMBAI Page 7

MOL Pumps Three 72480 BOPD each

COT Pumps Three 72480 BOPD each

Process Gas Compressors Three 1.7 MMSCMD each

Power Generators Three 12.3 MW each

Gas Dehydration System Two 3.6 MMSCMD each

Produced Water System Two 72635 BOPD each

Equipment Make Population Capacity

Turbine Generator Rolls Royce 03 12.3 MW

PGC Dresser Rand 03 1.71MMSCMD

Main Oil Line Pump Wier 03 480 M3 / hr

Main Injection Pump Wier 05 380 M3 /hr

SWLP Wier 03 1200 M3/ hr

CRANES NPC AAERO 05 8,10,12,16 MT

CRANES UNMANNED PARM 12 12 MT

NEELAM ASSET, ONGC Ltd., MUMBAI Page 8

Figure-2 Power System at NLM

The function of a well platform is:

Well cum Process Platform:

The process facilities include the necessary equipment to:

Separate oil, gas and water.

NEELAM ASSET, ONGC Ltd., MUMBAI Page 9

Water Injection platform

Fig:4 Water injection system

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