MIDWAY REPORT: PROJECT SEMESTER

On

PROJECT: OPERATION, MAINTENANCE AND SYNCHRONIZATION OF DG

SET AT A SUBSTATION.

Submitted by
Kanishtha Sharma
102004062

Under the Guidance of

Host Mentor Faculty Mentor

Sonu Gurra Dr. Deepti Mittal
JE/MRS Associate Professor, EIED
PLW Patiala TIET

2024
Electrical and Instrumentation Engineering Department
Thapar University, Patiala
(Declared as Deemed-to-be-University u/s 3 of the UGC Act., 1956)
Post Bag No. 32, Patiala – 147004
Punjab (India)
1
 ACKNOWLEDGEMENT
I am deeply grateful to Indian Railways, PLW Patiala, for providing me with the invaluable
opportunity to undertake my internship as an integral part of my academic journey. The
experience gained during this internship has immensely enriched my understanding of
practical applications in the field of electrical engineering, complementing the theoretical
knowledge acquired through my academic studies.

I extend my heartfelt appreciation to Mr. Sonu Gurra, my esteemed host mentor at Indian
Railways, whose unwavering guidance, support, and mentorship have been instrumental
throughout my internship. His expertise, encouragement, and constructive feedback have not
only enhanced my learning experience but also contributed significantly to the success of my
internship project.

I would like to express my gratitude to the entire team at Indian Railways, PLW Patiala, for
their cooperation, assistance, and valuable insights during my tenure. Their willingness to
share knowledge, provide resources, and offer assistance whenever needed has been truly
invaluable.

I am mindful of the fact that Indian Railways, PLW Patiala, is fully informed of the content
included in this acknowledgement, which is being formally submitted to my academic
institution, Thapar Institute of Engineering and Technology. I sincerely appreciate their
collaboration and support in this regard.

Furthermore, I would like to acknowledge the unwavering support and guidance provided by
Dr. Deepti Mittal, my academic mentor at Thapar Institute of Engineering and Technology.
His encouragement and mentorship have been a constant source of inspiration throughout my
academic and professional journey.

Once again, I extend my heartfelt gratitude to Indian Railways, PLW Patiala, and Mr. Sonu
Gurra for their support and mentorship during my internship. Their contributions have been
invaluable in shaping my learning experience and preparing me for future endeavors in the
field of electrical engineering.

Kanishtha Sharma
102004062

2
 INTRODUCTION
In today's interconnected world, uninterrupted power supply is crucial for the seamless
operation of critical systems and infrastructure. Power outages can result in significant
disruptions, leading to financial losses, safety concerns, and operational inefficiencies.
Recognizing the importance of reliable backup power solutions, the project focuses on the
implementation of an automatic DG (Diesel Generator) set backup system.

The primary objective of this project is to enhance the resilience of the existing power
infrastructure by deploying an automated backup system that seamlessly transitions into
operation during power outages or emergencies. Specifically designed to serve as a backup
for another generator, the automatic DG set backup system ensures continuity of power
supply, mitigating the impact of unforeseen disruptions and ensuring uninterrupted operations
of essential services.

The need for an automatic backup system arises from the limitations of manual intervention
in responding to power outages. While traditional backup systems rely on manual startup
procedures, they often suffer from delays in activation, human errors, and inefficiencies in
coordination with primary power sources. By automating the backup process, the project
aims to eliminate these shortcomings, enabling rapid and reliable deployment of backup
power when needed.

The automatic DG set backup system encompasses a range of technological components,

including sensors, controllers, actuators, and monitoring devices. These components work in
concert to detect power outages, initiate startup sequences, synchronize with the primary
generator, and seamlessly transfer the load to the backup power source. Real-time monitoring
and remote access capabilities provide operators with visibility and control over the backup
system, facilitating proactive management and maintenance.

In summary, the project represents a proactive and strategic investment in ensuring the
reliability and resilience of the power infrastructure. By implementing an automatic DG set
backup system, the project aims to safeguard against disruptions, protect critical operations,
and maintain continuity in the delivery of essential services. Through collaborative efforts
and innovative solutions, the project endeavors to establish a robust backup power framework
that meets the evolving needs of modern infrastructure management.
3
 Fig1.DG set system, PLW

Fig2.Diesel Engine, PLW

4
 OBJECTIVE
The primary objective of the project, "Implementation of an Automatic Diesel Generator
(DG) Set Backup System," is to enhance the resilience and reliability of the existing power
infrastructure by deploying an automated backup system that seamlessly transitions into
operation during power outages or emergencies. This objective encompasses several specific
goals and outcomes, outlined in detail below:

1. Upgrade to Automatic Backup System

The project aims to upgrade the existing manual backup system to an automatic setup.
This involves replacing manual startup procedures with automated processes,
reducing reliance on human intervention, and improving response times during power
outages.

2. Enhance Reliability and Efficiency

By implementing an automatic DG set backup system, the project seeks to enhance

the reliability and efficiency of the backup power supply. This includes ensuring rapid
activation of the backup system, minimizing downtime, and maximizing uptime for
critical infrastructure and services.

3. Seamless Transitions between Power Sources

The project aims to ensure seamless transitions between primary and backup power
sources. This involves synchronization of the automatic DG set with the primary
generator system, enabling smooth transfer of electrical load during switchover events
without disruption to operations.

4. Improve Resilience of Critical Infrastructure

A key objective of the project is to improve the resilience of critical infrastructure and
services against power outages and emergencies. By providing a reliable backup
power supply, the automatic DG set backup system helps mitigate the impact of
unforeseen disruptions and ensures uninterrupted operations of essential services.

5. Optimize Operational Continuity

The project seeks to optimize operational continuity by minimizing the downtime

associated with power outages. By automating the backup process and reducing
response times, the automatic DG set backup system enhances operational continuity
for businesses, facilities, and services that rely on continuous power supply.

6. Enhance Safety and Security

Another objective of the project is to enhance safety and security by providing a

reliable backup power supply during emergencies. This helps ensure the availability
of essential services, such as healthcare facilities, emergency response centers, and

5
 critical infrastructure, even in adverse conditions.

7. Facilitate Scalability and Adaptability

The project aims to facilitate scalability and adaptability by designing the automatic
DG set backup system to accommodate future growth and changes in demand. This
includes designing a modular and flexible system architecture that can be easily
expanded or upgraded as needed.

8. Promote Sustainability

The project aligns with goals of sustainability by promoting efficient use of resources
and minimizing environmental impact. By optimizing the reliability and efficiency of
the backup power supply, the automatic DG set backup system helps reduce energy
waste and greenhouse gas emissions associated with power outages.

METHODOLGY
1. Requirements Analysis

Conduct a comprehensive analysis of the requirements for the automatic DG set

backup system, considering factors such as power capacity, load characteristics,
operational constraints, and regulatory compliance.

2. System Design

Develop a detailed design for the automatic DG set backup system, outlining the
architecture, components, interfaces, and functionality. Considerations should include
system redundancy, scalability, fault tolerance, and integration with existing
infrastructure.

3. Component Selection

Evaluate and select appropriate components for the automatic DG set backup system,
including sensors, controllers, actuators, monitoring devices, and communication
interfaces. Consider factors such as reliability, performance, compatibility, and cost-
effectiveness.

4. Installation and Integration

Execute the installation of the selected components according to the system design
specifications. Integrate the automatic DG set backup system with the existing
infrastructure, ensuring compatibility, interoperability, and seamless operation with
the primary generator.

5. Software Development

Develop or configure the necessary software components for the automation,

monitoring, and control of the backup system. This may include programming logic

6
 for startup sequences, synchronization algorithms, fault detection, and remote access
functionalities.

6. Testing and Validation

Perform rigorous testing of the automatic DG set backup system to validate its
functionality, reliability, and performance. This includes functional testing of
individual components, integration testing of the entire system, and simulation of
various operating scenarios to ensure robustness.

7. Commissioning and Optimization

Commission the automatic DG set backup system by fine-tuning parameters,

optimizing control algorithms, and validating system behavior under real-world
conditions. This involves adjusting settings, calibrating sensors, and verifying proper
synchronization with the primary generator.

8. Training and Documentation

Provide training to operators and maintenance personnel on the operation,

maintenance, and troubleshooting procedures for the automatic DG set backup
system. Develop comprehensive documentation, including user manuals, technical
specifications, and maintenance schedules.

9. Monitoring and Maintenance

Implement a proactive monitoring and maintenance program to ensure the ongoing

reliability and performance of the automatic DG set backup system. This includes
regular inspections, preventive maintenance tasks, software updates, and performance
monitoring to identify and address potential issues promptly.

10. Continuous Improvement

Establish mechanisms for continuous improvement and optimization of the automatic

DG set backup system. This may involve collecting feedback from users, analyzing
system performance data, and implementing enhancements or upgrades to further
enhance reliability, efficiency, and resilience.

7
 Fig3.Control Panels for DG set

WORK DONE TILL NOW

PROJECT 1: Automating Backup Power: Implementation of Automatic DG Set
System.

The project, "Implementation of an Automatic Diesel Generator (DG) Set Backup System,"
has made significant progress in several key areas, including the study of required data,
selection of components, and installation of the automatic control system. Below is a detailed
overview of the work completed thus far:

1. Study of Required Information: Conducted a comprehensive study to gather

necessary data related to the existing power infrastructure, including the primary
generator system, electrical load characteristics, and operational requirements.
Analyzed historical power outage data, downtime records, and critical infrastructure
dependencies to identify key performance indicators and system requirements for the
automatic DG set backup system.

Fig 1.Symbols for transportation and storage of packed generators

2. Component Selection: Collaborated with engineering and procurement teams to

evaluate and select components for the automatic DG set backup system. Learnt about
basic control panels working, relay operations, vacuum circuit breakers working and
operations according to the load fluctuations and voltage regulation. Some of the
components are:
1.Diesel Engine: The diesel engine utilized in our project is a robust and reliable
power generation solution manufactured by Perkins, a renowned company known for
its high-quality engines. This particular diesel engine is rated at 1500 kVA (kilovolt-

8
amperes) or 1200 kW (kilowatts) and operates at standard electrical parameters of 11
kV voltage, 50 Hz frequency, and 0.8 power factor. Its robust design, high
performance, and compatibility with standard electrical parameters make it a suitable
choice for powering a wide range of applications with confidence and reliability.

Fig2.Diesel Engine

2.Alternator: The salient pole alternator utilized in the DG (Diesel Generator) set
project is a specialized type of synchronous generator designed to produce alternating
current (AC) electrical power at 11 kV voltage. The stator (the stationary part of the
generator) consists of a core made of high-grade laminated electrical steel. The stator
core is wound with multiple coils of insulated copper wire to create the stationary
armature windings. The rotor is mounted on a shaft and positioned inside the stator. It
features salient poles made of laminated steel, which are wound with field windings to
create the magnetic field required for power generation. As the rotor rotates, the
magnetic field induced by the field windings cuts across the stationary armature
windings in the stator, inducing an alternating current (AC) voltage in the stator
windings through electromagnetic induction. The salient pole alternator used in the
DG set project is designed to produce AC electrical power at 11 kV voltage. This
voltage level is commonly used for medium to high-power applications in industrial
and commercial settings.

Fig3.AC Generator and its specifications

9
3.CRM Panel: CRM panel, in a DG (Diesel Generator) set, typically refers to a Control
and Relay Panel specifically designed to monitor and control the operation of the DG
set. The panel provides control functions for starting, stopping, and monitoring the
operation of the DG set. It typically includes controls such as start, stop, manual/auto
mode selection, and emergency shutdown.The panel monitors various parameters and
conditions of the DG set to ensure safe and efficient operation. The CRM panel
may feature automatic start/stop functionality, which allows the DG set to start and
stop automatically based on pre-defined conditions or signals. Overall, a CRM panel
plays a crucial role in the safe and efficient operation of a DG set by providing
control, monitoring, protection, and automation functions.

Fig 4.CRM Panel

3. NGR Panel: An NGR (Neutral Grounding Resistor) panel, in the context of a DG

(Diesel Generator) set, is a component used to limit the fault current that may flow
through the neutral point of the generator system. The NGR is a resistor connected
between the neutral point of the generator and ground. Its purpose is to limit the fault
current that flows through the neutral point in the event of an earth fault or
unbalanced load conditions. The NGR panel houses the NGR and associated
components required for its operation. It provides a means to connect and disconnect
the NGR from the neutral point of the generator as needed. During normal operation,
the NGR allows a small amount of current to flow through it to maintain the neutral
point at or near ground potential.

10
 Fig 5. NGR Panel

4. Vacuum Circuit Breaker: A vacuum circuit breaker (VCB) is a type of circuit

breaker used in electrical power systems to interrupt or break the current flow in the
event of a fault or abnormal condition. Unlike traditional circuit breakers that use air
or gas to extinguish the arc formed during interruption, VCBs use a vacuum as the arc
quenching medium. During normal operation, the contacts of the VCB are in the
closed position, allowing current to flow through the circuit. The moving contact is
held in place by a mechanism such as a spring or electromagnetic actuator. When a
fault or abnormal current condition occurs in the electrical system, the protective relay
associated with the VCB detects the fault and sends a trip signal to the circuit breaker.
In a vacuum circuit breaker, the arc quenching process occurs in a vacuum-sealed
chamber. The absence of air or gas prevents the arc from being sustained, and the
vacuum quickly extinguishes the arc by removing the ionized particles and heat.

Fig 6. Vacuum Circuit Breaker

11
 5.Over Current Relay: An overcurrent relay is a protective device used in electrical
systems to detect and respond to abnormal current conditions, such as overloads or
short circuits, by initiating a trip signal to disconnect the circuit and prevent damage
to equipment or injury to personnel. The overcurrent relay continuously monitors the
current flowing through the electrical circuit it is protecting. It is connected in series
with the circuit, allowing it to sense the current passing through. Overcurrent relays
are equipped with adjustable settings that determine the threshold at which they will
operate. In many cases, overcurrent relays include a time delay feature to prevent
nuisance tripping during temporary current surges or starting currents.

Fig 7. Over Current Relay

3. Documentation and Reporting: Documented all activities related to the study of required
data, component selection, and installation of the automatic control system. Generated
detailed reports outlining the findings of the data study, rationale for component selection,
and procedures for installation and integration. Compiled technical documentation, including
equipment manuals, wiring diagrams, and installation instructions, to facilitate future
maintenance and troubleshooting.

In summary, significant progress has been made in the project, with key milestones achieved
in the study of required data, selection of components, and installation of the automatic
control system for the DG set backup system. The completion of these activities lays a solid
foundation for the successful implementation and operation of the backup system,
contributing to enhanced resilience and reliability of the power infrastructure.
The project commenced with the installation of an automatic control system for the DG set.
The automatic control system includes sensors, actuators, controllers, and monitoring devices
to automate the operation of the DG set based on predefined parameters and user-defined
settings. The installation process involved mounting the control panel, wiring connections,
and configuring the control logic.

1.7 APPROACH
The project follows a systematic approach to design, implement, and test the automatic DG
set backup system. The approach includes:
• Requirement analysis to understand the needs and specifications of the backup system.
• Design and selection of appropriate components and technologies for automation.
• Installation and integration of the automatic control system with existing infrastructure.
• Rigorous testing and validation to ensure compliance with performance standards.
• Commissioning and optimization to fine-tune the system for optimal operation
12
 Fig 8. DG set supply area distribution

1.8 RESULT AND CONCLUSION

The automatic DG set backup system demonstrated robust performance during testing and
real-world operation. Key results include:
1.Seamless transition to backup power during power outages.
2.Accurate monitoring and control of generator parameters.
3.Efficient synchronization with the primary generator system.
4.Minimal downtime and improved reliability of power supply.
So far, all the expected outcomes are achieved.

13
Project 2: Substation Maintenance of Indian Railways, Patiala

INTRODUCTION
The Substation Maintenance project for Indian Railways in Patiala addresses the critical
need for ensuring the reliable and efficient operation of electrical infrastructure within the
railway network. Substations play a pivotal role in the distribution and transmission of
electrical power, supplying traction power for trains, lighting, signaling, and other
essential railway operations. Effective maintenance of these substations is essential to
minimize downtime, ensure safety, and maintain operational continuity.

Fig 1.PLW Substation, Patiala

Fig 2.Lightning Arrestors and Transformer

14
 OBJECTIVE
The primary objectives of the project are as follows:

1.Ensure the reliability, safety, and efficiency of electrical infrastructure within the railway
network in Patiala.

2.Conduct preventive maintenance activities to identify and address potential issues before
they escalate into critical failures.

3.Enhance the longevity and performance of substation equipment, including transformers,

switchgear, relays, and protective devices.

4.Minimize downtime and operational disruptions by proactively addressing maintenance

needs and optimizing equipment performance.

5.Comply with regulatory requirements, industry standards, and best practices for electrical
infrastructure maintenance and safety.

6.Enhance the skills and capabilities of maintenance personnel through training and skill
development initiatives.

7.Establish a culture of continuous improvement and proactive maintenance to sustain the

long-term reliability and efficiency of the electrical infrastructure.

Fig 3. 66/11 kV Power Distribution system in PLW

15
 METHODOLOGY
The methodology for achieving the project objectives involves the following key steps:

1.Assessment and Planning: Conduct a comprehensive assessment of substation

infrastructure, identify maintenance needs, and develop a preventive maintenance plan.

2.Equipment Testing and Calibration: Test and calibrate primary and secondary electrical
equipment to verify accuracy, functionality, and compliance with specifications.

3.Replacement of Aging Equipment: Identify and replace aging or obsolete equipment to

ensure reliability, efficiency, and compliance with regulatory requirements.

4.Inspection and Testing: Inspect high-voltage components, conduct dielectric tests, partial
discharge measurements, and infrared thermography to assess insulation integrity and detect
potential faults.

5.Documentation and Reporting: Document all maintenance activities, generate reports

summarizing findings and recommendations, and maintain accurate records for regulatory
compliance and audit purposes.

6.Training and Capacity Building: Provide training to maintenance personnel on best

practices, safety protocols, and equipment operation and maintenance procedures to enhance
skills and capabilities.

By following this methodology, the project aims to achieve its objectives of ensuring the
reliability, safety, and efficiency of the electrical infrastructure within the railway network in
Patiala. Through proactive maintenance planning, equipment testing, replacement of aging
components, and collaboration with stakeholders, the project endeavors to minimize
downtime, enhance operational reliability, and sustain the long-term performance of the
substation infrastructure.

WORK DONE TILL NOW

Work Done Till Now for Maintenance in Substation Project:

Our maintenance efforts in the substation project have been focused on ensuring the reliable
operation of various equipment critical to the functioning of the electrical distribution system.
Here's an overview of the equipment in the substation and the maintenance tasks performed:

1. Transformers: Transformers are vital components in the substation responsible for

voltage transformation and power distribution. Maintenance tasks include regular
inspections for signs of overheating, oil leakage, and insulation degradation. Oil
sampling and analysis are conducted periodically to assess the condition of
transformer insulation and identify potential issues.

16
 Fig 4. Transformer

2. Circuit Breakers: Circuit breakers are used to interrupt the flow of current in the event
of a fault or overload condition. Maintenance tasks include mechanical and electrical
inspections to ensure proper operation and contact resistance. Lubrication of moving
parts and calibration of trip settings are performed as part of routine maintenance.

Fig 5. SF6 Circuit Breaker

3. Switchgear: Switchgear comprises various electrical devices used to control, protect,

and isolate electrical equipment in the substation. Maintenance tasks include cleaning
of contacts, insulation resistance testing, and thermal imaging to detect hotspots.
Tightening of connections and inspection of operating mechanisms are carried out to
prevent failures.

Fig 6. Switchgear

4. Protection Relays: Protection relays monitor electrical parameters and initiate

protective actions in response to abnormal conditions. Maintenance tasks involve
testing relay settings, verifying functionality through secondary injection tests, and
17
 firmware updates as necessary. Regular calibration and coordination studies are
conducted to ensure proper protection coordination and system reliability.

Fig 7. Protection Relay

5. Busbars and Conductors: Busbars and conductors form the backbone of the electrical
distribution system, transmitting power between various components. Maintenance
tasks include visual inspections for signs of corrosion, damage, or loose connections.
Thermographic surveys are conducted to identify potential hotspots caused by loose
connections or high resistance.

Fig 8. Busbars and Conductors

6. Battery Backup Systems: Battery backup systems provide emergency power to critical
control and protection equipment in the event of a power outage. Maintenance tasks
include regular capacity testing, visual inspections for signs of corrosion or leakage,
and replacement of aging batteries. Charging systems are checked to ensure proper
functioning and battery health.

Overall, our maintenance efforts in the substation project are aimed at minimizing downtime,
ensuring operational safety, and extending the lifespan of critical equipment. By conducting
routine inspections, testing, and preventive maintenance tasks, we strive to maintain the
reliability and efficiency of the electrical distribution system.

18
 RESULT AND CONCLUSION
Results:

The Substation Maintenance project for Indian Railways in Patiala has yielded significant
results, contributing to the reliability, safety, and efficiency of the electrical infrastructure
within the railway network. Key results include:

Improved Reliability and Efficiency: Through preventive maintenance activities, equipment

testing, and replacement of aging components, the project has improved the reliability and
efficiency of substation equipment. This has resulted in reduced downtime, fewer operational
disruptions, and enhanced operational continuity for railway operations.

Enhanced Safety and Compliance: By conducting inspections, testing, and calibration of

high-voltage components, the project has enhanced safety and compliance with regulatory
requirements and industry standards. This has reduced the risk of electrical faults, equipment
failures, and safety incidents, ensuring the safety of railway personnel and passengers.

Optimized Maintenance Practices: The project has optimized maintenance practices through
documentation, reporting, and training initiatives. By maintaining accurate records,
generating reports, and providing training to maintenance personnel, the project has
established a culture of continuous improvement and proactive maintenance, leading to more
effective and efficient maintenance operations.

Conclusion:

In conclusion, the Substation Maintenance project for Indian Railways in Patiala has
achieved its objectives of ensuring the reliability, safety, and efficiency of the electrical
infrastructure within the railway network. By implementing preventive maintenance
activities, equipment testing, replacement of aging components, and collaboration with
stakeholders, the project has enhanced the reliability, safety, and efficiency of substation
equipment, minimized downtime, and optimized maintenance practices.

Moving forward, it is essential to sustain the momentum of the project by continuing to

implement proactive maintenance activities, investing in training and capacity building
initiatives, and fostering a culture of continuous improvement and collaboration. By doing so,
Indian Railways in Patiala can maintain its position as a reliable and efficient transportation
network, ensuring the safety and satisfaction of passengers and stakeholders for years to
come.

19
Fig4. Daily Log Sheet PLW, Patiala

Fig5. Daily Consumption PLW, Patiala

20