Tuesday, March 31, 2020

ELECTRICAL SYSTEM Questions & Answers

ELECTRICAL SYSTEM

• What are the design objectives of Electrical System?

a. To evacuate generated electrical power.
b. To provide required power to SUT, UT, DG, UPS, and CUPS.
c. To provide required emergency power from onsite DG, UPS & CUPS.
d. To provide Fast transfer in event of Class IV failure. Emergency transfer in
events of Class III and Class II failure.
e. Load shedding in event of one DG available.
f. To provide un-interruptible or few milli seconds interrupted power supply by
UPS and un-interruptible power supply by CUPS.
g. To provide operational flexibility by providing required qualities of requirement.
h. To provide isolation, Alarms, indication, protection of the system.
i. To provide fire protection.
j. To provide surge and lightning protection.
k. To provide adequate lighting.
l. To provide equipment earthing, system earthing, and personnel protection.
m. To provide necessary electrical and physical isolation of electrical equipments.
• What are the design guidelines for electrical system?

a. All safety related equipments are in control building, SRPH and are designed for
SSE conditions. As per studies seismic condition is not there within 5 kms and
nearest zone is away from 20 kms.
b. Safety related equipments are separated from suitable fire barriers of 3 hrs rating
by horizontal and vertical clearances and from turbine building which are houses
high energy rotating equipments and where potential for fire is exist.
c. Separate switchyard control is provided in case of non-availability of main
control room with line and bus coupler protection and bus bar protections.
Control room posses SUT, UT, GT, Generator and all classes of power supply
control and protections.
d. Protection panels of Generator, GT, and UT are separated from SUT in physical
to have system flexibility.
e. SCADA is provided in CER, TB and in switchyard separately.
f. EMTR for each A and B groups are separated.
g. Control supply for switchyard is separated from operating island.
h. To reduce fault level in lighting circuits separate 280-kVA transformer is
provided.

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Predictive (preventive) maintenance on Induction Motor. Questions & Answers


Predictive (preventive) maintenance on Induction Motor.

1. What are the reasons for high current in motor?

a. High frequency – at 51 Hz current will be 105% of the normal current.
b. Low frequency – at 47.8 Hz current will be 102% of the normal current.
c. High voltage.
d. Under voltage.
e. Mechanical over loading.
f. Process requirement.

2. What are the reasons for unbalanced current in motor?

a. Loose power cable connection.
b. Voltage unbalance.
c. Short-circuited turns of coils of winding.

3. What are the reasons for vibration in the motor?

Vibration could be because of mechanical faults and electrical faults.
1. Mechanical faults.
a. Wrong alignment of the motor on foundation.
b. Wrong installation.
c. Improper fitting of bearing and cooling fans.
d. Periodic impulse loads such as reciprocating compressors.
e. Pulley of heavy weight which cause bending of motor shaft resulting in non
uniform air gap.
f. Damage of bearing or bad bearing.
g. Bad coupling.
h. If the axial alignment of the motor and the driven machine is incorrect and
rotor is allowed to contact its axial stops, high axial vibrations may occur,
together with high bearing temperature high and even bearing failure.
i. Machine base and foundation problem.
j. Under sized bearing.

2. Electrical faults.

a. Air gas dissymetry.
b. Broken rotor bars.
c. Slackened stator core.
d. Slackened rotor core.
e. Interturn short in the rotor winding in the two-pole machine.
f. Unbalance in rotor winding.
g. Unbalance power supply voltages.
If the vibration is because of electrical fault, de-energise the machine and
watch the vibration as it runs down.

The possible vibration frequencies observed are
a. Twice the power supply frequency – it indicates that the vibration is developed
by unbalanced power supply voltages, unbalanced air gap, unbalance in rotor
winding, slackened stator core etc.
b. Multiple of power frequency – the stator and rotor slots co-ordinate to develop
radial lines of force to deform and pulsate the cores.
c. Twice the slip frequency – magnetic unbalance due to unbalance air gaps,
slackened rotor core, interturn short in the rotor-winding etc. of two-pole
machine.
d. Beat (Humming) – in case of two-pole machine the beat is developed when
the vibration of twice as much as power frequency developed between the
stator and rotor is superimposed on the vibration of twice the slip frequency
developed due to irregular air gap.
4. What are the reasons for winding temperature high in the motor?

For motors having class – B insulation the temperature should not be more than
110°C and for motors having class – F insulation the temperature should not be more
than 130°C. In case temperature is more, then the following could be the possible
reasons.
1. Electrical overloads.
a. Over and under voltage.
b. Over and under frequency.
c. Voltage unbalance. Voltage unbalance create unbalance of currents and
increase in temperature which will be 2*(% voltage unbalance)* (% voltage
unbalance)*.
(% Voltage unbalance) = 100 * maximum deviation from average voltage
average voltage.
For instance if voltages are 390V, 410V & 440V,
% Voltage variation = 100*(440-390+410+440) (440-390+410+440) = 6.45%.
3 3
Therefore increase in temperature rise = 2*(6.45)*(6.45) = 83°C (approximately).
d. Voltage transients and interruptions.
e. Loose connection at motor terminals.
f. Unbalance current.
g. Single phasing (if OLR protection is not working).
h. Long acceleration cycle.
i. Unusual system grounding conditions.

2. Mechanical overloads.

a. Locked rotor.
b. Heavy starting.
c. Bearing problem.
d. Overload in continuous duty and intermittent duty.
3. Environmental overloads.
a. Excessive temperature of cooling medium or ambient temperature.
b. Restricted flow of cooling.
c. Reduction in the density of cooling medium.
d. Heat transfer from machine parts connected to the motor.
4. Others.
a. Excessive number of switching operations.

5. What are the reasons for bearing temperature high?

Temperature of bearing should not be more than 90°C. In case temperature is higher
than the 90°C the following could be the possible reasons.
a. Inadequate lubricants inside the bearing.
b. Faulty bearing.
c. Bearing is jammed.
d. Over greasing.
e. Improper grade of lubricant.

6. What are the reasons for abnormal sound or noise?

Motors in general should run very quietly and no abnormal noise is desired.
However if noise is there, it could be because of following reasons.
a. Windage noise – the noise due to ventilating system, (whistling noise).
b. Bearing noise – the noise due to its rolling contact.
c. Unusual noise – some defects inside the motor (example – motor bar failure).
d. Deep heavy growling noises – some electrical fault.
For permissible limits of noise levels for rotating electrical machines IS: 12065:1987
is being reffered.

7. What are the reasons for harmonics in the motor?

Generally even harmonics are not expected to be present in three phase motors.
Triple-n harmonics like 3rd, 9th, 15th etc. are also not expected. The dominant odd
harmonics expected are 5th, 7th, 11th and 13th etc.
Presence of strong 2nd harmonics indicates unbalance voltage, unbalance winding
impedance, rotor defects, magnetic imbalance, faulty rotor skewing etc.
Very strong 3rd harmonics indicates magnetic saturation, ground leak currents,
overloads etc. Overloading causes overheating, resulting in non-linear magnetization

which gives high 3rd harmonic winding faults, short circuits. Hot spots in rotor or
stator also may indicate higher harmonics.

8. What are the possible reasons for not coming of rated speed during start?bable
causes

a. Starting load is too high.
b. Broken rotor bars (look for cracks near rings).
c. Open primary circuit.
d. Voltage is too low.

9. What are the possible reasons for motor to take long acceleration time?

Following may the possible reasons for motor to take long acceleration time.
a. Excess loading.
b. May be rewound motor with poor quality of winding conductor having high
resistance.
c. Defective squirrel cage rotor.
d. Applied voltage is too low.

10. What are the points contributes in insulation resistance of the motor?

If the measured insulation resistance of the motor is less than 1 Mฮฉ / kV with a
minimum of 1Mฮฉ, when the machine is cold it is to be dried out before full voltage
is applied to the terminals of the motors and the drying out is to be continued as long
as the insulation resistance rises or until a sufficiently high value that is not less than
1 Mฮฉ / kV with minimum of I Mฮฉ at 75°C is reached.
While proceeding for point as above said, following factors are to be kept in mind
which affect the insulation resistance measurement. They are,
a. Surface condition.
b. Moisture.
c. Temperature.
d. Magnitude of test voltage.
e. Duration of application of test voltage.
f. Residual charge in the winding.
g. Ageing of the insulation.
h. Mechanical stresses.

11. What are the minimum recommended PI values for AC and DC rotating machines?

Following minimum recommended PI values criteria is to be followed.
a. 1.5 for class – A insulation.
b. 2.0 for class – B insulation.
c. 2.5 for class – F insulation.

12. What is the minimum recommended absorption coefficient value for AC and DC
rotating machines?

Absorption coefficient = IR value for 60 seconds = 1.3 (minimum recommended value)
IR value for 15 seconds
Tips:
a. IR value decreases some what with an increase I applied voltage. However for
machines in good condition substantially the same IR is obtained for any test
voltage up to the peak value of the rated operating voltage.
b. If the IR value decreases significantly with an increase in applied voltage it is an
indication of imperfections or fractures of the insulation aggravated by the
presence of dirt or moisture or may be due to the effects of dirt or moisture alone,
or may result from numerous other phenomena not necessarily associated with
any defect or weakness.
c. IR value for good dry winding continue to increase for hours with constant test
voltage continuously applied, however a fairly steady value is usually reached in
10 to 15 minutes. If the winding is wet or dry or dirty the steady value is usually
reached in 1 or 2 minutes after the test voltage is applied.
d. The recommended minimum IR value for AC and DC machines is determined by
the following empirical relationship.
IR = kV + 1
Where IR = recommended minimum IR in mega ohms at 40°C of the entire
machine winding and kV = rated machine voltage in kilo volts.
Temperature correction is to be applied, if winding is not at a temperature of
40°C.
e. IR of the one phase of three phases winding with other two phases earthed, is
approximately twice that of the entire winding. Therefore when the three phases
are tested separately, the observed insulation resistance of each phase should be
divided by two to obtain a value which after correction for temperature, may be
compared with the recommended minimum value of IR.

13. What is use of Tan – Delta test? And what are the recommended values?

The very purpose of this test is to detect moisture content, voids, cracks and
deterioration in the insulation and same is to be conducted on HT motors.
Based on the guidelines given in the article ‘Diagmistic testing on the winding
insulation’ by J. S. Simon (IEE vol. 127 may 1980) the contamination level of motor
winding is to be assessed from the given Tan – Delta value.
Starting Tan – Delta values Degree of contamination
0 – 4%. Low void content.
4 – 6%. Clean.
6 – 10%. Some dirt.
10 – 14%. Dirt and moisture.
14 – 16%. Gross contamination.
Question and answers Electrical Maintenance Unit
- 193 -
16 – 20%. Heavy deposit of oil dirt.
Above 20%. Severe oil and carbon contamination.

14. What are important guidelines for conducting HV test?

Based on the recommendations given in IS: 4029:1977 decided DC test voltage
= (2E+1kV) 1.6 * M
Where E = rated voltage.
2.6 = AC to DC conversion factor.
M = derator factor which is a function to be decided on the basis of the age and
condition of equipment.
The DC voltage applied in steps and the leakage current recorded at each step. A plot
leakage current Vs test voltage is to be plotted as the test progress.
Some recommendations of IS : 4029 : 1977.
a. The HV test made on the windings on acceptance shall as far as possible not be
repeated. If however a second test to be made at 80% of the voltage given by the
empirical formula given above.
b. Test voltage for completely rewound motor = full test voltage for new motor.
c. Partially rewound or overhauled motor = 75% * full test voltage for a new motor.
d. Before the test for the old parts of the winding shall be carefully cleaned and
dried.
e. Before attempting of HV DC test a minimum PI value of motor should be
obtained.

15. What are the uses of high voltage surge test?

This test gives distinct wave forms giving indications of various defects such as,
a. Turn to turn short in same phases.
b. Coil to coil short in same phases.
c. Partial phase to phase short.
d. Complete phase to phase short.
e. Improper coil connections.
f. Reverse coil connections.
g. Open coil connections.
h. Short to ground partial.
i. Short to ground complete.

16. What is the thumb rule for motor current?

Thumb rule for NO LOAD current of motors.
Type of enclosure No. of poles % No Load current of rated current
TEFC 2 15 – 20
TEFC 4 30 – 35
SPDP 2 25 – 30
SPDP 4 35 – 40
SPDP 6 to 8 50 – 55
SPDP 10 80
Note: TEFC (Totally enclosed fan cooled) motors are low inductive having low
active material in comparison to SPDP(Screen protected drip proof) motors.
Thumb rule for calculating positive sequence and negative sequence current in
motors.
a. Positive sequence current: Average of all three phases currents.
b. Negative sequence current: Maximum deviation of any of the phase currents from
the average.

17. How you evaluate the insulation condition based on PI value?

Evaluation of insulation condition based on PI value
PI value Insulation condition Recommendation
1.0 – 1.5 Bad Drying is mandatory
1.5 – 2.0 Doubtful Drying is recommended
2.0 – 3.0 Adequate No drying is needed
3.0 – 4.0 Good No drying is needed
> 4.0 Excellent No drying is needed

18. What are the conditions monitoring for the motor bearings?

Bearing oil analysis is a useful tool in determining bearing performance and possible
deterioration. Periodic checks for oil colour, viscosity and acidity can aid in
preventing or anticipating bearing failure.
Oil analysis tests
Symptoms Possible cause Test Cost
Viscosity Water or high Water content Low
temperature ASTM 445 viscosity Low
ASTM 974 neutralization number Low
ASTM 664 neutralization number Moderate
Viscosity change
colour change
Oxidation
ASTM 2296 neutralization number Moderate
Spectroscopy Low
Particle count Moderate
Direct reading ferrography Moderate
Particles Bearing
deterioration or
foreign matter
Analytical ferrography High

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Station grounding Questions & Answers

Station grounding

1. What is grounding?

It is an electrical connection with the general mass of earth through an earth
electrode.

2. What is difference between earthing and grounding?

Both have same meaning. The term earthing is used in U.K. and grounding in U.S.A.
ground means earth.

3. What are types of grounding?

There are two types
a. System grounding.
b. Equipment grounding.

4. What does mean by system?

Grounding of neutral point of equipment is called system grounding. For instance
grounding of generator neutral, transformer neutral etc.

5. What does mean by equipment grounding?

Grounding of non-current carrying metallic parts is called equipment grounding. For
instance no-current carrying parts include the following:
a. Motor body, switchgear metal enclosure, transformer tank, conduits of wiring etc.
b. Support structures, tower, poles etc. in the neighborhood of electrical circuits.
c. Sheath of cables.
d. Body of portable equipment such as iron, oven, etc.

6. What is the important of system grounding?

It is important because:
a. Earth fault protection is based on the method of neutral earthing.
b. System voltage during earth fault depends on neutral earthing.
c. It is a protection against arcing grounds, unbalanced voltages with respect to earth
and lighting.

7. What is the important of equipment grounding?

Equipment earthing ensures safety.

8. How safety could be ensured by equipment grounding?

In order to enumerate this, let us first find out the effects of current and voltage
developed during fault condition.


9. What is the permissible body current limit?

The magnitude and duration of current conducted through a human body at 50 Hz
should be less than those did that cause ventricular fibrillation.
(Ventricular fibrillation is considered to be the main cause of death due to electrical
shock). These below given data are also applicable for current limits to human body.
Current magnitude Physiological effect Description
1 mA Threshold of
perception
A current at which a person is just able to
detect a slight tingling in his hand or finger
1 – 6 mA Unpleasant to sustain This is often termed as let go currents. Do not
impair the ability of a person holding an
energised object to control his muscles and
release it.
6 – 9 mA Threshold of muscular
contraction.
These are threshold values, since 10.5 mA
current and 16 mA current are the let go values
for women and man respectively.
9 – 25 mA Muscular contraction May be painful and can make it hard or
impossible to release energised objects grasped
by the hand.
25 – 60 mA Muscular contraction Make breathing difficult.
60 – 100 mA Ventricular fibrillation Ventricular fibrillation, stoppage of heart or
inhibition of respiration might occur and cause
injury or death if time is more than 1 sec.
Hence the grounding equipment shock current can be kept below the value sufficient
to cause injury or death by lowering the step and touch potential.

10. How fibrillation current functions?

Fibrillation current is actually function of individual body weight.
For 50 kgs body weight: fibrillation current (IB) = 0.116/ยช ts (Limited to 0.03 – 3
sec. Range)
Where ts = duration of current exposure in sec.
Note = Above equation results = 116 mA for 1 sec. and 367 mA for 100 sec.
For 70 kgs body weight: fibrillation current (IB) = 0.157/ยช ts
Note = Above equation results = 157 mA for 1 sec. and 496 mA for 100 sec.
Above times are very - very important from the point view of clearing the fault.
Above limit dictates that grounding should e such that current magnitude through
human body should not increase the specified values.
In order to ensure above following have been done.
1. Current conductor have been burried in ground
a. At the depth of 600 mm in switchyard. Depth 600 mm is normally selected
because of freezing or drying out, the Resistivity of upper layers could vary
with seasons, while the Resistivity of lower soil layers remains nearly
constant.
b. Horizontal grid conductors are more effective in reducing the danger of high
step and touch voltages on the earth surface by creating equipotential surface
during fault conditions.
c. At the depth of 800 mm else where. Here depth is kept more because to care
for under grounding services. Example laying of power cables, drainage etc.
2. 25-mm dia copper rod electrodes have been driven in soil.
a. Upto 5 meters depth in 220 kV switchyard.
b. Upto 3 meters elsewhere.
Why only 5 meters and 3 meters depths have been selected is that the
resistance is diminishes rapidly with the first few feet of driving, but less so at
depths greater than 2 to 3 meters in soil of uniform resistivity.
These lengths are adopted in selecting the ground electrodes.
3. 4-inch layer of gravel in 220 kV switchyard has been used. Purpose of using
gravel is by doing steps 1,2 above tough and step potential are computed and
compared with tolerable potential and found as given below.
Potential Computed value Tolerable value
Tough 550 V 665V
Step 2.a switchyard with crushed rock surface 230V 2165 V
Step 2.b elsewhere with natural soil 166V 168.5 V

11. Why grounding is necessary?

The purpose of grounding is to maintain the surface under and around a station ate as
nearly zero potential as possible with reference to absolute earth so that operating
staff who walk in the station yard and tough equipments are ate earth potential and
when faults occur there is safety to staff and equipments.

12. What are the harms of under grounded system?

a. Step and tough potential will increase more than maximum tolerable value.
b. Under single line to ground fault the voltage to earth of the two healthy phases
rises from their normal phase to neutral voltage to full line voltage, which may
result in insulation break down.
c. The capacitive current in two healthy phases increases ยช3 times the normal value.
d. The capacitive current in the faulty phase is 3 times its normal value.
e. Experience shows that capacitive current in excess of 4 amps may be sufficient to
maintain an arc in the ionized path of the fault and this persistent arc phenomenon
is called ARCING GROUND, which ultimately cause high voltage build up.
Some time these voltage builds up to 5 to 6 times its normal value, which results
in break down of insulation.
f. Being fault current low, it is difficult to isolate fault.

13. How system grounding and equipment grounding achieved?

System grounding is obtained by grounding the neutral through resistance, through
transformer and through effective or solidly grounding.
Equipment grounding is obtained by Grounding of non-current carrying metallic
parts equipment. For instance no-current carrying parts include the following:
a. Motor body, switchgear metal enclosure, transformer tank, conduits of wiring etc.
b. Support structures, tower, poles etc. in the neighborhood of electrical circuits.
c. Sheath of cables.
d. Body of portable equipment such as iron, oven, etc.

14. What does mean by grounding electrode, grounding system, and grounding
resistance?

Grounding electrode: A conductor driven in the earth and used for collecting ground
current from or dissipating ground current into the earth.
Grounding system: Comprises all interconnected grounding facilities in a specific
area.
Grounding resistance: The resistance offered by the ground when power frequency
current is discharged to the ground through a particular grounding electrode or
grounding system.

15. How grounding resistance could be measured?

There are few methods, which can give approximately true value. These are
described below.
a. Fall of potential method: This method is applicable for small grid or sub station
where induction effect of voltage is less.
b. Measurement of earth resistance by 61.8% distance rule:
c. Alternate – 1 of fall of potential method: This method is influenced by induction
effect.
d. Alternate – 2 of fall of potential method:

16. How value of grounding resistance could be kept constant?

While measuring of grounding resistance is more than computed design value 0.11ฮฉ,
then following are recommended to reduce it. Add in water the following highly
conductive substances and pour into treated pit.
a. Sodium chloride (Nacl), known as common salt.
b. Calcium chloride (Ca CL2)
c. Sodium carbonate (Na2 CO3)
d. Copper sulphate (Cu SO4)
e. Soft choke and
f. Salt and charcoal in suitable proportions.

17. What is the effect of moisture content on earth resistivity?

The moisture content is expressed in percent by weight of dry soil. Dry earth weights
about 1440 kg per cubic meter and thus 10% moisture content is equivalent to 144 kg
of water per cubic meter of dry soil. So about 20% moisture, the resistivity is very
little affected. Below 20%, the resistivity increases very abruptly with the decrease in
moisture.

18. What is the effect of salt content in moisture on resistivity?

The resistivity decreases and the salt content is expressed in percent by weight of the
contained moisture. It will be noted that the curve flattens off at about 5% salt
content and a further increase in salt content gives little decrease in the soil
resistivity.

19. What is the effect of temperature on earth resistivity?

The temperature co-efficient of resistivity for soil is negative, but it is negligible for
temperature above freezing point. Below 0°C the water in the soil begins to freeze
and introduces a tremendous increase in the temperature co-efficient, so that as the
temperature becomes lower the resistivity rises enormously.

20. What does mean by neutral floating or neutral displacement?

When a ground fault occurs, there is a tendency of neutral shift with consequent
change in voltage on the un-faulted phases. This phenomenon is called neutral
floating or neutral displacement.

21. Why grounding of power cable is needed? How it should be done?

a. The magnetic fluxes produced by the three phases in a multi core power cable
almost cancel put each other, since the vector sum of these currents at any instant
is zero and practically there is no residual magnetic flux around the cable.
In case of single core cable, the magnetic flux induces the voltage in the metallic
sheath.
b. When the cable conductor is carrying alternating current, for safe and reliable
operation, the metallic sheath must be grounded. If the metallic sheath is at one
end the potential of the unearthed end could be much above the earth potential. If
both ends are grounded, a circulating current is induced in the metallic sheath.
c. The maximum acceptable induced voltage under normal load current operation is
limited by corrosion and safety considerations.
d. Code of practice of earthing (IS 3043) as well as electricity council London
recommended permissible induced voltage level of 65 Volts.
Hence keeping above all points in mind metallic sheath and armour of all multi core
power cables shall be earthed at both end equipment and switchgear end. Sheath and
armour of single core power cable shall be earthed ate switchgear end only. The
sheaths of shielded control cables should be grounded at both ends to eliminate
induced potentials.

22. In 220 kV switchyard why lightning arrestor should be properly grounded?

a. During lightning, surges should be discharged to ground, otherwise it will
puncture the equipment insulation and it is possible only when lightning arrestor
is grounded properly.
b. In order to make it effective, the ground terminal of lighting arrestor should be
connected direct to the tank of transformer. This will eliminate voltage build up
due to earth resistance. For example for each ohm of earth resistance the voltage
build up for 5000 Amps discharge current is 5 kV. Soil resistivity a should be
minimum and may be it is 3.5 ohm per meter.

23. Why grounding mat is important near ground switch operating handle and
disconnecting switch operating handle?

Equipment operating handles deserve special attention because of the higher
probability for co-incidence of adverse factors. For example,
a. Hand operation equipment such as grounding switches and disconnecting
switches requires the presence of operator near a grounded structure at a point
where opening of an energised circuit can some times result in an arc to the
structure or perhaps mechanical failure and electrical break down of a switch
insulator. A large percentage of fatal accidents from voltage gradients are in fact
associated with operating handles. Hence in order to avoid above problems
following should be an additional safety factors:

1. Use closer mesh in the vicinity of operating handle area (150-mm approx.) and
operating handle shall be directly connected to the earthing mat.
2. Use higher resistance surfacing such as crushed rock or both in order to bring
down the values of touch potential and step potential.

24. Why fences grounding are important?

Because the most dangerous touch contacts involves and outside the fence are
usually accessible to the general public. In order to minimise the effect of step
potential and touch potential following two philosophies could be adopted.
a. Inclusion of the fence within the ground grid area and
b. Placement of fence outside the ground grid area – not safe to use.
With this effective area is increased and reduces ground grid resistance substantially
and maximum ground – grid voltage rise as well. In this case the perimeter conductor
of grid normally either follow the fence line, or parallel to it at a short distance about
0.5 m – 1.5 m outside. In either case, the perimeter ground conductor and fence are
bonded electrically at frequent intervals.

25. What are the specifications for procurement of grounding conductor and grounding
rods?

Grounding conductor, pad, rods etc. should have following specifications:
a. Copper : 91.8 to 94.9%
b. Zinc : 2.0 to 3.0%
c. Tin : 0.8 to 1.5%
d. Lead : 2.0 to 2.5%
e. Iron : 0.5 to 1.0%
Impurities must be limited to the percentage specified below:
a. Nickel : 0.3% maximum.
b. Antimony : 0.3% maximum.
c. Manganese : 0.04% maximum.
d. Phosphorous : 0.04% maximum.

26. Why copper is only preferred as material for grounding?

An advantage of use of copper is in addition to their high conductivity, has the
advantage of being resistant to underground corrosion. Copper is cathodic with
respect to other metals that are likely to be burried in the vicinity.
Disadvantages of use of copper are,
a. Grid of copper forms a galvanic cell with burried steel structures, pipes and any
of the lead based alloys that might be present in cable sheaths, it is likely be
hasten the corrosion of the latter.
b. Use of tinned copper conductor accelerates and concentrates the natural corrosion
of metal in small area however cell potential with respect to steel and zinc
reduces by about 50% and practically eliminates this potential with respect to
lead.

27. What should be the frequency of measurement of earth resistivity?

As per IS: 3043, 1987, measurement of earth resistivity should be carried out
annually or biannually and value should be recorded.

28. What should the statutory provision of earthing?

a. Earthing shall generally be carried out in accordance with the requirement of
India electricity rule 1956, as amended from time to time and the relevant
regulations of the electricity supply authority concerned.
b. All medium voltage equipment shall be earthed by two separate and distinct
connections with earth. In the case of high and extra high voltages, the neutral
points shall be earthed by not less than two separate and distinct connections with
earth, each having its own electrodes at the generating station or substation and
may be earthed at any other point provided no interference is caused by such
earthing. If necessary, the neutral may be earthed through suitable impedance.
c. As for as possible all earth connections shall be visible for inspection.
d. All connections shall be carefully made. If they are poorly made or inadequate for
the purpose for which they are intended, loss of life or serious personal injury
may result.
e. Each earth system shall be so devised that the testing of individual earth electrode
is possible. It is recommended that the value of any earth system resistance shall
be such as to confirm with the degree of shock protection desired.
f. It is recommended that a drawing showing the main earth connection and earth
electrodes be prepared for each installation.
g. No addition to the current carrying system, either temporary or permanent shall
be made which will increase the maximum available earth fault or its duration
until it has been ascertained that the existing arrangement of earth electrodes,
earth bus-bar etc. are capable of carrying the new value of earth fault current
which may be obtained by this addition.
h. No cut-out link or switch other than a linked switch arranged to operate
simultaneously on the earthed or earthed neutral conductor and the live
conductors, shall be inserted on any supply system. This however, does not
include the case of a switch for use in controlling a generator or a transformer or a
link for test purposes.
i. All materials fittings, etc. used in earthing shall conform to Indian standard
specifications, wherever these exist.

29. What maintenance of earth electrodes should be done?

The neighbouring soil to the earth electrode shall be kept moist where necessary, by
periodically pouring water through a pipe where fitted along with it or by pouring
water in the immediate vicinity of the earth electrode.
Periodical visual inspection of all earth electrodes connection wherever available,
shall be carried out to ensure their rigidity and other signs of deterioration.

30. In case new installation is to be done, what basic guidelines should be followed for
grounding?

a. Earthing conductors in outdoor areas shall be burried 500 mm below finished
grade level unless stated otherwise.
b. Minimum 6000 mm spacing between rod pipe electrode shall be provided unless
stipulated otherwise.
c. Earthing conductor around the building shall be burried in earth at a minimum
distance of 1500 mm from the outer boundary of building.
d. Earthing conductors embedded in the concrete floor of the building shall have
approximately 100-mm concrete cover.
e. Earthing conductors along their run on columns, beams, walls etc. shall be
supported by suitable cleats at intervals of 750 mm.
f. Earthing conductors crossing the road shall be either installed in hume pipes or
laid at greater depth to suit the site conditions.
g. Whenever earthing conductors cross underground service ducts, pipes, trenches,
under ground service ducts, pipes, trenches, tunnels, railway track etc. it shall be
laid 800 mm below them.
h. Earthing conductor shall be burried 1000 mm outside the switchyard fence. Every
alternate post of the fence and gates shall be connected to earthing loop by one
lead.
i. Each earthing lead from the neutral of the power transformer shall be directly
connected to a rod or pipe or plate electrode treated earth pit, which in turn shall
be connected to station earthing.

31. How much resistance human body has?

Resistance of internal body tissues (Not including skin) : 300 ฮฉ.
Resistance of body including skin : 500 to 3000 ฮฉ.

32. What is the effect of voltage frequency and current on resistance of the human body?

a. For touch voltages upto approximately 50V the value of impedance of the skin
varies widely with surface area of contact, temperature, respiration etc. even for
one person.
b. For higher touch voltages in order of approximately 50V to 100V the skin
impedance decreases considerably and becomes negligible when the skin breaks
down.
c. Wet hand contact resistance becomes very low at any voltage.
d. With increase in frequency, impedance of skin decreases.

33. What are the paths of current through the body?

A value of 1000 ฮฉ is selected for the calculations that follows as representing the
resistance of a human body from hand to both feet and also from hand to hand or
from one foot to other foot.
Above paths includes vital organs such as heart.
a. Path from hand to foot is much more dangerous than foot to foot, since current
flow through heart during foot to foot current flow will be much less than the
current flow from hand to foot approximate ratio is 25:1
b. However deaths have occurred during foot to foot current flow. Hence can not be
ignored.

34. What are the effects of re-closure shock?

During re-closure, when fault is persisting a person might be subjected to the first
shock which would not permanently injure him, but would upset and disturb him
temporarily.
Next, a single fast automatic re-closure could in a second shock initiated within less
than 500 ms from the start of first. It is this second shock, occurring after a relatively
short interval of time before the person has recovered, that might cause a serious
accident. With manual re-closure the possibility of exposure to a second shock is
reduced since the time interval may be substantially greater.

35. State DC/AC equivalent factor (K).

Ratio of direct current (DC) to its equivalent rms value of alternating current (AC)
having the same probability of inducting ventricular fibrillation.
K = I DC fibrillation / I AC fibrillation (rms).
K = 3000 mA / 100 mA
K = 30 mA
Threshold of let-go is unlike AC there is no definable threshold of let-go for DC for
current magnitude below approximately 300 mA. Only the making and breaking of
current leads to painful and cramp like contractions of muscles.
Above approximately 300 mA, let-go may be impossible or only possible after
several seconds or minutes of shock duration. Below approximately 300 mA a
sensation of warmth is felt in the extremities during the flow of current. Above 300
mA unconsciousness frequently occurs.

36. Why AC is more dangerous than DC?

Because the excitatory action of current (stimulation of nerves and muscle, induction
of cardiac atrial or ventricular fibrillation) are linked to the changes of current
magnitude especially when making and breaking of the current. To produce the same
excitatory effects the magnitude of direct current flow of constant strength in 2 to 4
times greater than that of alternating current.


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Reactor general Questions & Answers

Reactor general

1. What are V1 and V2? How they are connected? What is the harm in opening F/M
vault door during reactor operation?

The reactor building is divided into two areas. They are V1 and V2.
V1 – Dry volume area.
V2 – Wet volume area.
V1 area includes F/M vault, boiler room, and entire dome area. Rest of the areas in
the reactor building is V2 area. V1 and V2 are connected by vent shaft through
suppression pool.
F/M vault is a V1 area and F/M maintenance bay is a V2 area. Usually when there is
an accident in F/M vault the pressure is relieved through boiler room through
suppression pool and the uncondensed gases to V2 area. When the reactor is in
operation and if we open the F/M vault door, suppose of there is an accident in F/M
vault the pressure released directly goes to F/M maintenance area, which is a V2
area. Thus pressurizing the entire building.

2. What is the purpose of inlet manifold inside calandria? What is the material used for
that?

The purpose of inlet manifold is to introduce heavy water to the calandria with low
velocity to avoid mixing. That is stratified flow of D2O is obtained b inlet manifold.
Thus the temperature is kept minimum. It is made of zircalloy.
3. Why bi-directional flow is chosen for PHT system?

Bi-directional flow is chosen for PHT system because,
a. Uniform temperature gradient is facilitated so there will be no differential thermal
expansion.
b. It facilitates fuelling even when the reactor is working, which facilitates uniform
neutron flux and this intern gives rise to maximum fuel burns up.

4. What is the purpose of end-shield?

The purposes of end-shield are,
a. To permit access to F/M vault during shut down.
b. To provide tight clamping for fuelling machines.
c. To support the calandria tubes and also system.


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Nuclear system Questions & Answers

Nuclear system

1. What is the purpose of moderator D2O?

The purposes of moderator D2O are,

a. To thermalise neutrons to maintain criticality.

b. Emergency core cooling when PHT fails.

c. Structural cooling.

2. What is the cooling water used in moderator heat exchanger during normal

operation? And during class IV failure?

During normal operation process LP water is used in moderator heat exchangers,
which transfers heat to seawater. During class IV failure firewater is used for the
moderator heat exchanger.

3. During loca how the cooling of fuel bundle is achieved?

During loca there is provision for taking D2O from the moderator system, which is
connected to PHT system for fuel cooling and there is one more option for the
cooling of the fuel from the fire water system.
4. How coolant flow is maintained in the event of loss of power to the PHT system?

When the PHT power fails, it takes two minutes for DG to come to full power. The
circulation is maintained by flywheel, which increases the de-acceleration and
maintains the flow for two minutes.
If there is a station blackout the flow is maintained by thermo-symphoning by which
more denser cold water comes down and less denser hot water goes up by convection
method.

5. What are the materials in contact with PHT system?

Piping – carbon steel.
Pressure tubes – zircalloy-2
Fuel cladding – zircalloy-2
End shield – stainless steel. Etc.

6. What are the main futures of PHT system?

a. Impeller – To reduce the water flow.
b. Self-injection Hx – Cools the water in case of leakage.
c. Gland supply – Cools the seals.
d. Primary and secondary seals – sealing the pump.
e. Thrust bearing – To take the axial thrust.

7. What are the purposes of bleed condenser?

The purposes of bleed condenser are,
a. To cool the bleed water, which goes to bleed cooler.
b. To provide cool hot water to the PHT purification system.

8. What is header level control?

For the purpose of maintenance of PHT pipe valves, boiler inlet valve the level of the
coolant should be below the valve to prevent the coolant coming out of the system.
This is called the header level control and achieved by means of manual operation of
valves and shutdown cooling pump.

9. In MAPS Unit # 1 end-shield cooling system has got heaters. Why?

Unit # 1 end-shield is made of nickel steel, which had a nil ductility temperature of
-100°C while commissioning. After 30 years of operation this will rise to +32°C,
because of radiation exposure. To avoid the failure of end shield of MAPS Unit # 1
the temperature of the end-shield should be maintained at 68°C always. MAPS 1
end-shield cooling system is operating at elevated temperature. But in MAPS Unit #2
this problem is not existed because in this unit end-shields are made up of stainless
steel.

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Nuclear reactor theory Questions & Answers

Nuclear reactor theory

1. State the law of conservation of mass and energy.

Mass and energy are interchangeable. When mass is lost there is a substantial gain in
energy and when energy is lost there is a increase in mass.
Energy = mass*C2
E = MC2
Where C is the conversion factor = 3*1010 (velocity of light)
C2 = 9*1020

2. Which of the following material is good moderator? Why?

a. H2 b. D2 c. H2O d. D2O e. Beryllium f. Graphite.
The functions of a good moderator are
a. It has to thermalise neutrons effectively.
b. There should be only a minimum absorption of neutrons.
c. It should not be toxic.
d. It should not be inflammable.
In case of Hydrogen (H2) though it is a effective sheatherer it cannot be used as a
moderator because it is a gas and there is a lot of distance between atoms. A neutron
cannot meet the nucleus in a definite manner.
For D2 also the same problem as this is also gas and it cannot be used as a moderator.
In case of H2O it is a good scatterer but is absorbs neutrons. Its moderation ratio is
72. So it cannot be used as a moderator.
In case of D2O though it is not as effective scatterer as that of H2O it has minimum
absorption of neutrons. It has a moderating ratio of 21000. This is an ideal
moderator.
In case of Beryllium it is a toxic material. Therefore cannot be used.
Graphite absorbs neutrons and is inflammable and therefore cannot be used.
So from the above statements the D2O is the good moderator material.
3. The activity of an Iodine – 131 is 10 curies. After how many half-lives will it come
down to 625 millicuries?

Activity of an Iodine – 131 = 10 curies
To find number of half-lives for coming it to 625 millicuries,
10 * 1st  = 5 (1st half-life)
5*  = 2.5 (2nd half-life)
2.5 *  = 1.25 (3rd half-life)
1.25 *  = 0.625 (4th half-life)
So during 4th half-life the Iodine – 131 reduces to 625 millicuries.

4. What do Atomic number and mixture mean?

Atomic number: The atomic number of an atom is the number of protons in that
atom.
Example – Hydrogen has one proton and its atomic number is one (1).
– Uranium has 92 protons and its atomic number is 92.
Mixture: It is a substance formed by different elements and these elements can be
separated by physical methods.
Example – Air is a mixture of oxygen and nitrogen and these can be separated by
physical methods.

5. What is the weight of a proton?

1.00759 amu (atomic mass unit)

6. What is the energy of a thermal neutron?

0.025 eV (energy volt)

7. What is the charge of an alpha particle?

2+.

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D20 handling Questions & Answers

D20 handling

1. What is the instrument name used for accurate measurement of IP?

Infra red spectro photometer.

2. How D20 vapour is recovered?

Dryer recovers D20 vapour.

3. What is the amount of D20 used in moderator?

140 tonnes.

4. Name the heavy water plants in India.

a. Nangal.
b. Kota.
c. Baroda.
d. Tuticorn.
e. Talcher.
f. Thal (under construction).
g. Hazira (under construction).
h. Malugum (under construction).

5. Define reactor grade and down graded D20.

Reactor grade D20: If the isotopic purity of a given D20 is more than or equal to
99.7% then the D20 is reactor grade D20.
Down grade D20: If the isotopic purity of a given D20 is less than 99.7% then the
D20 is downgraded.

6. What precautions should be taken while working in high tritium areas?

Use respirators, plastic suits, VP suits if concentration of tritium is very high. Avoid
getting hurt while working because tritium may go through the skin by sweat to the
blood. If by chance there is tritium intake in the body drink lots of fluids.

7. Why spillage of D20 is to be avoided?

Cost consideration: D20 very costly and very valuable. Cleaning of spillage also cost
and extra manpower to be deployed.
Tritium hazard: D20 contains tritium, which when spilled becomes tritiated vapour
and finds access through human body. Tritium is a radioactive material. It is a beta
emitter.

8. What is ice plugging?

If there is a need to repair a valve of D20 PHT system, there are no other valves to
shut of D20. So we use plastic bags on pipes and it has dry ice. Then liquid nitrogen
is poured inside the bag. Due to the low temperature the D20 inside pipeline
solidifies preventing any flow of D20 when valve is removed. This is called the ice
plugging.


9. Name the methods by which D20 leak can be detected.

a. By beetles.
b. D20 losses through stack monitoring.
c. Tritium monitoring.
d. In heat exchangers the leakage can be found by taking samples of process water
from all heat exchanges and counting the tritium activity.

10. Name the D20 recovery methods.

a. Manual mopping and vacuum cleaning.
b. Active drainage recovery.
c. Vacuum mopping recovery.
d. Dryers recovery.
e. Vapour recovery.

11. Name the features for reducing D20 leaks.

a. Reduce valves and fittings in the pipelines.
b. Use welded joints instead of flanged joint.


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First aid Questions & Answers

First aid


1. What is the golden rule of first aid?

Do first thing first, artificial respiration, stop bleeding and treat shock. Do not
attempt too much, reassurance, avoid crowing and transfer.

2. What do you mean by diagnosis?

Determining the nature and courage of a disease.

3. For a bleeding what is the first aid?

Take care to stop the bleeding by giving pressure.

4. What is the first aid for bone injury?

Support the injured part and painkillers.

5. What is the first aid for burn cases?

Water, warm fluids should be given when the victim is conscious.

6. How we can differentiate the bleeding from artery and vein?

By the colour of the blood which is bleeding.

7. What is the first aid for chlorine inhaled victims?

Remove the victim from the source, fresh air and artificial respiration if necessary.

8. What is the first aid for dog bite?

Suck the wound and spite out.

9. What is the first aid for snakebite?

Bath the wound and constrictive bandage. Give warm drinks and rest to the patient
and artificial breathing if necessary.



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Fire fighting Questions & Answers

Fire fighting

1. How combustion takes place?

For combustion to take place three elements are needed. They are fuel, heat and
oxygen. This is called the triangle fire. Combustion can not survive without these
three. Remove any one of them, combustion ceases to take place. So wherever fuel,
oxygen and heat is there together combustion takes place.

2. How many types of extinction media’s are used in fire fighting?

a. Sand.
b. Water.
c. Foam.
d. Carbon – di – oxide.
e. Dry chemical powder.
f. Halons.

3. What are the classifications in fire?

a. Class A – Ordinary fire like burning of paper, wood etc.
b. Class B – Oil fire like burning of petrol, diesel, LPG etc.
c. Class C – Gas and dust fire like burning of butane, acetone, natural gas etc. and
burning of dust like uranium dust, sodium dust etc.
d. Class D – Metal fire like burning of uranium, thorium, sodium etc.
e. Class E – electric fire example transformer or switchgear fire etc.

4. How many types of fire extinguishers are there and state their suitability?

a. Soda acid type – suitable for Class A type of fires.
b. Foam type – suitable for Class A and Class B type of fires.
c. Carbon-di-oxide type – suitable for Class B, Class C and for Class E type of fires.
d. Dry chemical powder – suitable for Class B, Class C, Class D and Class E fires.
e. Halons BCF (bromo chloro difluoro methane) – suitable for Class A, Class B,
Class C and Class E types of fires.

5. At what areas of risk the Co2 flooding system, mulsifyre systems are provided?

Co2 flooding system is provided in diesel generator and turbine oil tank area.
Mulsifyre system is provided in generator transformer, start up transformer and unit
transformer areas.

6. What are the equipments kept inside the hose boxes?

a. Double female adapter (1 No).
b. Delivery hose pipe (50 feet – 2 Nos).
c. Branch pipe (1 No).
d. Valve wheel (1 No).
e. A hose box key (situated in a cabinet at side of hose box).

7. How water is used in a fire?
Water is used as a cooling effect in a fire.


8. How foam is used in a fire?

Foam is used as a blanketing effect in a fire.

9. Which extinguisher you use for electronic equipment fire?

Co2 or DCP type fire extinguisher can be used on fire involving electronic
equipments.

10. What you mean by starvation method?

Starvation method means elimination of fuel from the fire.

11. What is the name of powder used in Dry Chemical Powder extinguisher?

Sodium-bi-carbonate.

12. What you mean by cooling method?

Cooling method means elimination of heat from the fire.

13. What you mean by blanketing method?

Blanketing method means elimination of oxygen from the fire.

14. Why Co2 is used on Class E fire?

Co2 is a non-conductor of electricity.


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Instrumentation fundamentals Questions & Answers


Instrumentation fundamentals


1. What are the classifications of industrial instrumentation?

a. Information gathering instrumentation.
b. Regulating instrumentation.
c. Protective instrumentation.

2. What are the units of pressure?

Pounds / inch2 and kg / cm2.

3. What is the use of BAROMETER?

Barometer is used to measure atmospheric pressure.

4. What are the methods used to measure the flow?

Mechanical (float) type and ultrasonic type methods are used to measure the flow.

5. What is the equivalent of atmospheric pressure?

One atmospheric pressure is equal to 10 meters of water column or 760 mm of
mercury.

6. What method is used to measure the level?

Bubbler method is used to measure the level.

7. State some elements of pressure measurement.

Manometer, Diaphragm gauges, Bellows, Strain gauges etc.

8. State some elements of flow measurement.

Orifice, Venturi tubes, flowrator (rotameter) etc.

9. State some thermocouple.

Copper – constantan, Iron – constantan.

10. What is the purpose of instruments?

The purpose of instruments is to measure, safeguard the process for efficient plant
operation.
Instruments are very accurate and fast acting. This accuracy and speed is not possible
by human. Also in some places there may be too much heat for man to work or some
where there may high radiation field. In such cases instruments provide remote
operation.

11. What is primary element and what should be its response?

Primary element is one, which senses the condition of process, and converts it to
some other form, which can be measured accurately. Example in a bourden gauge
the pressure if changed to the uncoiling (displacement), which can be measured.
The response of primary element is that it should convert the condition in to some
other form, which can be interpreted and measured easily.

12. Name some process variables, which are appropriate for our plant with examples.

Process variables with examples, which are appropriate to our plant, are
a. Flow – flow of D2O in PHT system.
b. Temperature – temperature of coolant in PHT system.
c. Level – moderator level.
d. Speed – speed of turbine.
e. Voltage – voltage generated by main generator.
f. Neutron flux – number of neutrons produced in reactor during operation.
g. pH – pH of moderator.

13. What is use of 2/3 logic in our plant?

All our protection instruments (system) are triplicated to have following uses.
a. To increase system integrity.
b. To decrease faulty trips.
c. Maintenance can be done on one protective instrument without shutting down the
whole system.
We don’t want our plant (reactor) to trip just because one instrument failed. So we
have triplication (2/3 logics) in protection instruments. The trip signal will pass if
only two out of three switches operate. Of only one operates there will be no trip.
This logic is used to trip the reactor in our plant.

14. What is resistance temperature detector (RTD) and mention some examples?

Resistance temperature detector is an instrument, which is used to measure
temperature. This uses the property that the resistance of a metal changes (increases
of decreases) with temperature. This is very accurate. These will be a wire, which
will senses the temperature and changes its resistance as the temperature changes.
This varying in resistances if measures by an external electronic or electrical circuit
calibrated to measure temperature.
Different types of RTD’s are Platinum, copper, nickel.

15. What is recorder and how it is useful to our plant?

Recorder is an instrument, which gives instantaneous values as well as records the
values.
Recorder can show us where a fault has occurred if reactor trips. It also gives us past
information recorded in it. It saves human effort because an operator cannot sit and
record the information required and it is very difficult task to an operator.


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