Q.1 In Case of grid supply fail in KCW substation. How can the restore the grid in blackout condition?

Solution:-

Ultratech cement Kotputli is having following power Sources: -

(1) Grid Power Supply (132KV having maximum demand 10 MVA)

(2) Captive Power Plant (2*23 MW)
(3) DG Set (2*2.5MW)
(4) Portable DG Set for Kiln Auxiliary (500 KVA)

In present, We maintain our plant load from TPP and run with grid in islanded mode. When We are running in parallel
with grid and suddenly blackout condition occurred due to failure of both TG and Grid.

Following steps are taken to resume the power into the plant.

(1) Our prime responsibility to resume kiln auxiliary power to save kiln shell barging. So we start our portable DG
set (500KVA) for kiln auxiliary as kiln is highly temperature (1400ºc) operated equipment. It will be damaged
without rotation.
(2) Then we will start DG set (2*2.5 MW) for TPP auxiliary and provide them power to run both the TG.
(3) When both the TG will run and start giving sufficient generation, We will check 132KV incomer breaker, it will be
trip due to under voltage protection to avoid backup feeding at grid.
(4) When 132KV supply resumed from grid, we will “ ON “ 132KV line breaker and after it we will “ ON “132 KV
Transformer-1 & 2 breaker both primary and secondary side.
(5) After charging complete bus, We will synchronized the grid with TPP with the help of TPP Operation team. As
shown in SLD, We are having Tie breaker available at our MRSS (Switchyard). TPP operation is only authorized to
synchronize the grid with the consultation of cement electrical team. After synchronizing the grid we will stop
our portable DG set (500 KVA) and DG set (2*2.5 MW) and our whole plant load will shift on TPP.
 Operating Procedure:
 Ensure all operations are made from TPP CCR SCADA system or GCP panel.
 Check for the Grid supply, if 110 KV grid is available switch ON the EC-05 breaker in switch yard in dead
bus mode.
 Then switch ON the EC-16 breaker in TPP substation in dead bus mode and charge the 11 KV bus in TPP
by switching ON the bus couplers.
 Switch ON the EC-13 distribution transformer -3 Feeder from 11 KV switch board at TPP substation
 Switch ON the Distribution transformer- 3 Incoming breaker at LT PCC and ensure power is available at
MLDB. And switch on plant lighting system.
 Switch ON all distribution and inverter transformer breaker and give clearance for operation.
 If Grid is not available, then switch ON the 2x 2.2 MW DG incomer breaker EC-15 at TPP substation and
Follow step 4, 5 and 6.

 Later when boiler and TG is normalised and attains the rated speed switch ON the AVR supply and
ensure 11 KV voltage at EC-1 or EC-28 Incomer.
 Switch ON the synchronscope
 Select auto/manual mode for Synchronization.
 Check running bus and incoming bus voltage and frequency in voltmeter and double frequency meter
also check the same auto synchronizer.
 Select correction signal for the incoming Machine if synchronized in manual mode.
 Match the voltage and frequency of incoming machine with running bus by increase/decrease push
buttons.
 Ensure synchronscope LED is rotating in clockwise direction and with very less speed.
 Ensure that incoming Machine should in DROOP mode.
 While both source Voltage and frequency matched, then press start synchronization push button.
 Select Breaker will be close automatically if synchronization is being done in auto mode.
 Press the TNC switch to issue the closing command while synchronscope green indication glow or almost
in standstill condition if synchronization is in manual mode.
 After synchronizing the machine, put synchronization in off condition.
 Maintain P.F. manually as per machine requirement.
4.1 Case-1: Load Shedding when System is running in islanded mode and either TG1 or TG2 tripped.
 This load shedding scheme will work when TG is running in islanded mode with grid and one TG got
tripped.
 TG trip DO is a combination of TG breaker contact, overcurrent element and Under Frequency element.
 TG trip DO & TG parallel contact will initiate the load shedding scheme and all relays will activate and
tripping command release to RM main drive , RM fan1 &2 , CM main drive 1&2, CM Fan 1&2, CM I/C-1
&2 Coal Mill fan, Coal Mill Main Drive , Crusher & MPSS I/C2 immediately to save kiln outage.
 This scheme is wired at MPSS load Shedding panel (compartment-1) and drawings is attached below
(Annexure-1)
Note: - After initiate the whole scheme, to resume all tripped power section, either switch off the Main DC
MCB of MPSS load shedding panel (Comp-1) or Wait for start-up tripped TG.

4.2 Case-2: Load Shedding to control maximum demand during Import condition.
 This scheme will work when TG is running parallel with grid and one TG got tripped.
 This scheme is wired at MPSS load Shedding panel (compartment-2) and drawings is attached below
(Annexure-2)
  MD Controller scheme is a combination of two different logic provided in Satac Meter at 132 KV Line
panel. Logic details is as under:
 132KV Line CRP Panel Satac Meter Relay-1 logic setting:
MW: - 1.9 MW ON
0 MW OFF
Current: - 65 Amp ON
60 Amp OFF
Time Delay: - 0.3 Sec ON
 132KV Line CRP Panel Satac Meter Relay-1 Logic Setting:
MW: - 21.9 MW ON
18.9 MW OFF
Time Delay: - 0 Sec ON
 132KV Line CRP Panel Satac Meter Realy-2 Logic Setting:
MW: - 1.9 MW ON
0 MW OFF
MVA: - 9 MVA ON
7 MVA OFF
Time Delay: - 1 Sec ON
 When grid import MVA exceed Satac relay-2 setting limits, Scheme will start tripping load as follow:
1. Coal Mill Fan & Crusher will immediately after initiating MD scheme.
2. If import is not decreased up to desired level than after 3.2 Sec, Cement Mill -1 & 2 Main drive will be trip.
3. If import is not yet decreased up to desired level than after 5 sec, Raw Mill Main Drive will be trip.
4. If MD is not reached up to desired level than after 10 Min, Preheater Fan-2 will be trip.

 When either grid current or Grid Import MW exceed Satac relay-1 setting limits, Scheme will start tripping
of load as follow:
1. Coal Mill Fan, Cement Mill -1 & 2 Main drive & Raw Mill fan-2 will trip immediately.

4.3 Case-3: Load Shedding to control maximum demand during export condition.
 This scheme will work when TG is running parallel with grid and any plant section has tripped & grid export
increased Maximum demand 10 MVA.
 This scheme is wired at MRSS TPP Tie Panel (HTP No 5) and drawings is attached below (Annexure-3)
 Logic setting of foresaid scheme is provided on MRSS 11KV I/C -1 & 2 Satac Panel. Logic setting is as follow:
Trigger On Ar. Hi. P.E Export KW
Logic On 11.986 MW
Logic Off 8.996 MW
Trip Relay Relay-1
On Delay 300 sec

 When Export increased up to desired value, Scheme will operate and trip command will release to MRSS
TPP Tie panel master trip relay and breaker will trip.

4.4 Case-4: Load Shedding through SCADA to control maximum Load on TGs in both Island and synchronized
condition.
 This scheme will work when TG is either running parallel with grid or Island condition and any plant section
has tripped.
 There are 4 Nos of mode for this load shedding which are: Manual Mode, Auto mode-1, 2 & 3.
 In Manual Mode TG/RSEB trip DO is a combination of TG/RSEB breaker contact and Load Selection at
SCADA.
 Whatever load selected in TG1, TG2 and RSEB cases it will get tripped during the tripping of the TG/RSEB
breaker respectively as per selection.
  In Auto Mode-1 Trip command will be given to Raw Mill and Cement Mill 1&2, Likewise in Auto mode-2 Trip
command will be given to Coal Mill, Crusher and RMSH and in Auto mode -3 Trip command will be given to
Transformer-3 and 4 (TPP BOP load).
 Presently only manual mode is in line and is in practice.
 Pls find the Mimic snap shot as below.

4.5 Case-5: Load Shedding through SCADA Panel Hard Wiring to control maximum Load on TGs in both Island
and synchronized condition.

 This scheme will work when TG is either running parallel with grid or Island condition and any plant section
has tripped.
 In this scheme there are three nos selector switch for TG-1 , TG-2 and RSEB. Each switch has 3 nos of
position that is 0, 1, and 2. At Position “0” system is out of line and at Position ‘1”of “2” different contactors
(K1 to K6) are assigned for further tripping of Raw Mill, Cement Mill, Coal Mill and RMHS.
 Load shedding is assigned as per below in case of each selection.

Hard Wire load shedding scheme Assigned Contactor

Position “1” Position ”2” Position “0 Position-1 Position-2

TG-1 Raw Mill Raw Mill / Cement Mill TG-1 K-1 K-2

TG-2 Raw Mill Raw Mill / Cement Mill Off line TG-2 K-5 K-6

RSEB No Selection Coal Mill and RMHS RSEB K-3 K-4