Genting Lanco Power (India) Private Limited

Lanco Kondapalli Power Plant - Phase 3

Isolation Normalisation and Switching of Low Voltage ISP/OP3/04
Systems
Issue No. : Issue Date : Revision No. : Revision Date : File No. PAGE

1 14/05/16 0 - POP0304 1 of 14

ISOLATION NORMALISATION AND

SWITCHING OF LOW VOLTAGE SYSTEMS
ISP/OP3/04

Prepared by: Checked by: Approved by: Issued by :

06/05/16 07/05/16 09/05/16 10/05/16

V. Jagadish K. Ranga Rao S. Anand G. Vishnu Murthy

PSM-II Sr. Operations Manager General Manager MR
 Genting Lanco Power (India) Private Limited
Lanco Kondapalli Power Plant - Phase 3
Isolation Normalisation and Switching of Low Voltage ISP/OP3/04
Systems
Issue No. : Issue Date : Revision No. : Revision Date : File No. PAGE

1 14/05/16 0 - POP0304 2 of 14

INDEX

Sl.NO. DESCRIPTION PAGE

NO.
1 PURPOSE 3
2 SCOPE 3

3 TERMINOLOGY, DEFINITIONS & ABBREVIATIONS 3

4 RESPONSIBILITY 4

5 TOOLS AND EQUIPMENT 4

6 PROCEDURE 4

7 SAFETY AND ENVIRONMENTAL CHECKS 6

8 REFERENCES 6

9 RECORDS 6

Prepared by: Checked by: Approved by: Issued by :

06/05/16 07/05/16 09/05/16 10/05/16

V. Jagadish K. Ranga Rao S. Anand G. Vishnu Murthy

PSM-II Sr. Operations Manager General Manager MR
 Genting Lanco Power (India) Private Limited
Lanco Kondapalli Power Plant - Phase 3
Isolation Normalisation and Switching of Low Voltage ISP/OP3/04
Systems
Issue No. : Issue Date : Revision No. : Revision Date : File No. PAGE

1 14/05/16 0 - POP0304 3 of 14

1. PURPOSE

To establish a procedure for Isolation and Switching of Low Voltage System.

2. SCOPE

It covers Low Voltage Switching at LKPP Station and Intake Water Pump
House.
Any Switching below 6.6 kV System Voltage Level is covered in this
procedure.

3. TERMINOLOGY, DEFINITIONS & ABBREVIATIONS

AC Alternating Current
DCS Distributed Control System
DC Direct Current
DG Diesel Generator
Sr. OM Senior Operations Manager
GM General Manager
GTG Gas Turbine Generator
LKPP Lanco Kondapalli Power Project
MCC Motor Control Centre
MR Management Representative
OE Operations Engineer
OP Operation
PCE Plant Control Engineer
PSM Plant Shift Manager
ISP Integrated Management System

Prepared by: Checked by: Approved by: Issued by :

06/05/16 07/05/16 09/05/16 10/05/16

V. Jagadish K. Ranga Rao S. Anand G. Vishnu Murthy

PSM-II Sr. Operations Manager General Manager MR
 Genting Lanco Power (India) Private Limited
Lanco Kondapalli Power Plant - Phase 3
Isolation Normalisation and Switching of Low Voltage ISP/OP3/04
Systems
Issue No. : Issue Date : Revision No. : Revision Date : File No. PAGE

1 14/05/16 0 - POP0304 4 of 14

SVR Static Voltage Regulator

UPS Uninterrupted Power Supply
WI Work Instruction

4. RESPONSIBILITY

The Plant Shift Manager is responsible for the execution of this procedure.
The Sr. Operations Manager is responsible for the maintenance of this
procedure.
5. TOOLS AND EQUIPMENT

415V Breaker Operating Handle

415V Breaker Handling Trolley

Screw Driver

6. PROCEDURE

All permits are to be checked for clearance before doing any switching as
per ISP/GM/01.
Record of the switching time, will be made in the Logbook by the Plant
Control Engineer as per the format..
This ISP is based on C & S Switchgear Instruction Manual.

6.1 415V switch gear

415V Boards Incomer & Inter-connector Breakers will be closed/opened from

DCS. For paralleling and closing, synchronization check will be used.

Prepared by: Checked by: Approved by: Issued by :

06/05/16 07/05/16 09/05/16 10/05/16

V. Jagadish K. Ranga Rao S. Anand G. Vishnu Murthy

PSM-II Sr. Operations Manager General Manager MR
 Genting Lanco Power (India) Private Limited
Lanco Kondapalli Power Plant - Phase 3
Isolation Normalisation and Switching of Low Voltage ISP/OP3/04
Systems
Issue No. : Issue Date : Revision No. : Revision Date : File No. PAGE

1 14/05/16 0 - POP0304 5 of 14

Normally the Board Inter-connector Breaker will be in service position and

remote selected so that if any Incomer Supply is lost, it will close on under
voltage.
415V Load Breakers closing and opening will be decided by process
condition and it will be through DCS.
415V MCC Supply Isolators will be operated from local after switching OFF
the load fed from this.

6.3 DC System

All system switching is from local near the chargers.

125VDC Chargers of GTG are in parallel, sharing the load.

Station and Switchyard 220V DC Batteries are having Float Cum Boost
Charger . Normally Float Charger will be in service, if Battery voltage drops
below the Float Level, Boost Charger will come into service on Auto. These
Battery Chargers are having two incoming supplies one from Essential
Services Board, which is having DG Backup. Other supply is from Station
Aux. MCC for Station battery charger and Switchyard ACDB for Switchyard
battery charger.

6.4 UPS

All system switching is from local near the UPS.

Any one UPS can be isolated at any time as one UPS is capable of feeding
total load.
These UPS-1 supply is taken from Essential MCC SEC-A ( 4.13R ) and UPS-
2 & SCVS Supply are taken from Essential Services MCC Sec-B (12.13F &
15.15R ) respectively which are having DG backup.
6.5 Operation procedure for 415V switch gear change over’s

Prepared by: Checked by: Approved by: Issued by :

06/05/16 07/05/16 09/05/16 10/05/16

V. Jagadish K. Ranga Rao S. Anand G. Vishnu Murthy

PSM-II Sr. Operations Manager General Manager MR
 Genting Lanco Power (India) Private Limited
Lanco Kondapalli Power Plant - Phase 3
Isolation Normalisation and Switching of Low Voltage ISP/OP3/04
Systems
Issue No. : Issue Date : Revision No. : Revision Date : File No. PAGE

1 14/05/16 0 - POP0304 6 of 14

Bus-1 supply changeover from incomer-1 to incomer-2 through bus

coupler:

 Ensure both incomers are in service.

 Ensure incomer1 and bus coupler breakers are in remote and DC supply
healthy.
 Keep trip selector switch in incomer-1.
 Close the bus coupler breaker, Ensure incomer-1 breaker open.
 Ensure healthiness in both bus-1 and bus-2.

Bus-2 supply changeover from incomer-2 to incomer-1 through bus

coupler:

 Ensure both incomers are in service.

 Ensure incomer-2 and bus coupler breakers are in remote and DC supply
healthy.
 Keep trip selector switch in incomer-2.
 Close the bus coupler breaker, Ensure incomer-2 breaker open.
 Ensure healthiness in both bus-1 and bus-2.

6.6 Operation procedure for 415V breaker rack in and rack out
415V breaker rack in procedure:

 Check for breaker off condition.

 Keep DC supply in off position.
 Push and hold the shutter opening slide pin.
 Insert Rack IN/OUT handle and release hand on slide pin.
 Turn the handle clockwise.
 After few turns TEST position will be displayed.
 Continue turning till SERVICE position is displayed.
 Observe for service position lamp indication.
 Remove the RACK IN/OUT handle.
 Switch ON DC supply and ensure breaker Service, TC Healthy LEDs
glowing and breaker is ready for operation.

Prepared by: Checked by: Approved by: Issued by :

06/05/16 07/05/16 09/05/16 10/05/16

V. Jagadish K. Ranga Rao S. Anand G. Vishnu Murthy

PSM-II Sr. Operations Manager General Manager MR
 Genting Lanco Power (India) Private Limited
Lanco Kondapalli Power Plant - Phase 3
Isolation Normalisation and Switching of Low Voltage ISP/OP3/04
Systems
Issue No. : Issue Date : Revision No. : Revision Date : File No. PAGE

1 14/05/16 0 - POP0304 7 of 14

415V breaker rack out procedure:

 Check for breaker off condition.

 Keep DC supply in off position.
 Push and hold the shutter opening slide pin.
 Insert Rack IN/OUT handle and release hand on slide pin.
 Turn the handle Anti clockwise.
 After few turns TEST position will be displayed.
 Continue turning till ISOLATE position is displayed.
 Remove the RACK IN/OUT handle.

6.7 Operation procedure for 415V switch gear isolation and normalization of
one complete bus
415V switch gear complete bus-1 isolation procedure:

 Ensure incomer-1 and bus coupler are in off condition.

 Keep DC supply of incomer-1 and bus coupler off.
 Incomer-1 up stream breaker at 6.6KV switchgear kept open and rack
out.
 Rack out incomer-1 and bus coupler breakers.
 Keep Bus-1 AC control supply selection in Incomer-1/ Independent.
 Ensure power supply and control supplies are completely dead.

415V switch gear bus-1 normalization procedure:

 Close incomer-1 upstream breaker at 6.6KV switchgear.
 Rack in incomer-1(415 Volts) breaker.
 Made on DC supply of incomer-1.
 Ensure Bus-1 AC control supply is on Incomer-1 / Independent.
 Close the incomer-1 breaker.
 Ensure power supply and control supply healthiness in bus-1.
 Rack in the bus coupler breaker and then switch ON DC control supply.
 Ensure bus coupler breaker in healthy condition.

Prepared by: Checked by: Approved by: Issued by :

06/05/16 07/05/16 09/05/16 10/05/16

V. Jagadish K. Ranga Rao S. Anand G. Vishnu Murthy

PSM-II Sr. Operations Manager General Manager MR
 Genting Lanco Power (India) Private Limited
Lanco Kondapalli Power Plant - Phase 3
Isolation Normalisation and Switching of Low Voltage ISP/OP3/04
Systems
Issue No. : Issue Date : Revision No. : Revision Date : File No. PAGE

1 14/05/16 0 - POP0304 8 of 14

6.8

Operation procedure for Taking changing supply from UPS to SVCS

And back.
Transfer of Load from Inverter to SCVS:

 Ensure Auxiliary Supply Frequency is between 49 Hz – 51 Hz

 Check that static bypass supply isolator (Q2) is in closed condition and
SCVS input/output voltages are showing normal
 Press ‘INV’ button on module mimic indicator unit of respective UPS#1
or 2
 Confirm operation by pressing ‘ENTER’ button for ‘1’ second
 Ensure that ‘LOAD ON INVERTER’ indication goes OFF and ‘LOAD ON
BYPASS’ indication is glowing at module mimic indicator. Also ensure
that the same status is being displayed at control panel screen.
 Now Load is transferred to static bypass supply

Details of UPS isolators and switches.

 Q1 – Input MCCB
 Q2 – Bypass supply (from SCVS) Isolator
 Q3 – Maintenance Bypass Isolator
 Q4 – Output isolator
 BCB#1 – Battery Circuit Breaker for UPS#1
 BCB#2 – Battery Circuit Breaker for UPS#2

Prepared by: Checked by: Approved by: Issued by :

06/05/16 07/05/16 09/05/16 10/05/16

V. Jagadish K. Ranga Rao S. Anand G. Vishnu Murthy

PSM-II Sr. Operations Manager General Manager MR
 Genting Lanco Power (India) Private Limited
Lanco Kondapalli Power Plant - Phase 3
Isolation Normalisation and Switching of Low Voltage ISP/OP3/04
Systems
Issue No. : Issue Date : Revision No. : Revision Date : File No. PAGE

1 14/05/16 0 - POP0304 9 of 14

Load Transfer From SCVS to Inverter:

If both charger and inverter are not in service

 Ensure the System Frequency is between 49 Hz and 51 Hz.

 Ensure that no fault/alarm related to charger and inverter is persisting at
control panel display.
 Switch ‘ON’ main 415V incoming supply at Essential SWGR.
 Switch ‘ON’ charger input MCCB (Q1).
 Wait for 20 seconds and close respective Battery circuit breaker (BCB)
at Battery current sharing cubicle and ensure that battery unavailable
indication got extinguished at module mimic indicator.
 Ensure that charger unit has come in service and system voltage is
within limits
 Ensure that ‘LOAD ON BYPASS’ indication goes OFF and ‘LOAD ON
INVERTER’ indication is glowing at module mimic indicator. Also
ensure that the same status is being displayed at control panel screen
 Ensure ‘NORMAL OPERATION’ status is displayed at screen.

Prepared by: Checked by: Approved by: Issued by :

06/05/16 07/05/16 09/05/16 10/05/16

V. Jagadish K. Ranga Rao S. Anand G. Vishnu Murthy

PSM-II Sr. Operations Manager General Manager MR
 Genting Lanco Power (India) Private Limited
Lanco Kondapalli Power Plant - Phase 3
Isolation Normalisation and Switching of Low Voltage ISP/OP3/04
Systems
Issue No. : Issue Date : Revision No. : Revision Date : File No. PAGE

1 14/05/16 0 - POP0304 10 of 14

If inverter alone is not in service:

 Ensure that DC bus voltage is ≥ 459V under BATTERY measurement
menu.
 Ensure that no fault/alarm related to inverter is persisting at control
panel display
 Press ‘INV’ button on module mimic indicator unit of respective UPS#1
or 2
 Confirm operation by pressing ‘ENTER’ button for ‘1’ second.
 Ensure that ‘LOAD ON BYPASS’ indication goes OFF and ‘LOAD ON
INVERTER’ indication is glowing at module mimic indicator. Also
ensure that the same status is being displayed at control panel screen.
 Ensure ‘NORMAL OPERATION’ status is displayed at screen.

Details of UPS isolators and switches.

 Q1 – Input MCCB
 Q2 – Bypass supply (from SCVS, three phase supply) Isolator
 Q3 – Maintenance Bypass Isolator( from SCVS, single phase supply)
 Q4 – Output isolator
 BCB#1 – Battery Circuit Breaker for UPS#1
 BCB#2 – Battery Circuit Breaker for UPS#2

Isolation Of SCVS:

 Ensure that UPS – 1/2 is in service.

 Switch ‘OFF‘ static bypass supply isolators (Q2) at UPS#1 and 2
 Switch ‘OFF’ incoming supply MCB of SCVS.
 Switch ‘OFF’ Main 415 V power supply to SCVS at Essential SWGR.

Power supply sources:

 UPS-1 input power supply from Essential switchgear Sec-A.(4.13R)
 UPS-2 input power supply from Essential switchgear Sec-B (12.13F)
 SCVS input power supply from Essential Switchgear Sec-B (15.15R)

Prepared by: Checked by: Approved by: Issued by :

06/05/16 07/05/16 09/05/16 10/05/16

V. Jagadish K. Ranga Rao S. Anand G. Vishnu Murthy

PSM-II Sr. Operations Manager General Manager MR
 Genting Lanco Power (India) Private Limited
Lanco Kondapalli Power Plant - Phase 3
Isolation Normalisation and Switching of Low Voltage ISP/OP3/04
Systems
Issue No. : Issue Date : Revision No. : Revision Date : File No. PAGE

1 14/05/16 0 - POP0304 11 of 14

Operation procedure for UPS changeover, normalization and isolation

To take UPS – A or B into Service without power initially supplied to

6.9 the load:

 Ensure that ‘Q1’, ‘Q2’, ‘Q3’ and ‘Q4’ Isolators are at ‘OFF’ position.
 Ensure that respective Battery circuit breaker (BCB) at battery current
sharing cubicle is at OFF position.
 Switch ‘ON’ main 415V incoming supply at Essential SWGR.
 Switch ‘ON’ charger input MCCB (Q1).
 Wait for 20 seconds and ensure that green LEDs are glowing for input
AC supply and inverter output. Also ensure that system status is
displayed in the screen.
 Close output power switch (Q4) and ensure that output on inverter LED
is glowing.
 Check and ensure that load on UPS is not high (Not more than three
LEDs on bar graph).
 Close Static bypass input power isolator (Q2) and ensure that “BYP.
SCR FAILURE” and “INV. UNSYNCHRONIZED” alarms are not
displayed at screen. Also ensure static bypass input LED is glowing at
module mimic indicator.
 Ensure that DC bus voltage is ≥ 459V under BATTERY measurement
menu.
 Close respective Battery circuit breaker (BCB) at Battery current sharing
cubicle and ensure that battery voltage shown by bar graph is indicating
normal (Not less than four LEDs). Also ensure that battery unavailable
indication got extinguished at module mimic indicator.

Details of UPS isolators and switches.

 Q1 – Input MCCB
 Q2 – Bypass supply (from SCVS, three phase supply) Isolator
 Q3 – Maintenance Bypass Isolator( from SCVS, single phase supply)
 Q4 – Output isolator
 BCB#1 – Battery Circuit Breaker for UPS#1
Prepared by: Checked by: Approved by: Issued by :

06/05/16 07/05/16 09/05/16 10/05/16

V. Jagadish K. Ranga Rao S. Anand G. Vishnu Murthy

PSM-II Sr. Operations Manager General Manager MR
 Genting Lanco Power (India) Private Limited
Lanco Kondapalli Power Plant - Phase 3
Isolation Normalisation and Switching of Low Voltage ISP/OP3/04
Systems
Issue No. : Issue Date : Revision No. : Revision Date : File No. PAGE

1 14/05/16 0 - POP0304 12 of 14

 BCB#2 – Battery Circuit Breaker for UPS#2

To take UPS – A or B into Service without interrupting power to the load

from maintenance bypass

 Ensure Maintenance bypass isolator (Q3) is closed.

 Close output power isolator (Q4) and static bypass power isolator (Q2). By
doing this, UPS load will be supplied through static bypass source through
static transfer switch.
 Wait for 20 seconds and ensure that bypass supply healthy is indicated by
module mimic indicator. Also ensure that ‘LOAD ON BYPASS’ is displayed
at screen along with other status messages.
 Switch ‘ON’ main 415V incoming supply at Essential SWGR.
 Switch ‘ON’ charger input MCCB (Q1).
 Wait for 20 seconds and close respective Battery circuit breaker (BCB) at
Battery current sharing cubicle and ensure that battery unavailable indication
got extinguished at module mimic indicator.
 Ensure that charger unit has come in service and system voltage is within
limits.
 Open maintenance bypass isolator (Q3) and ensure that ‘LOAD ON
INVERTER’ is indicated at module mimic indicator.
 Ensure ‘NORMAL OPERATION’ status is displayed at screen.
Details of UPS isolators and switches.
 Q1 – Input MCCB
 Q2 – Bypass supply (from SCVS, three phase supply) Isolator
 Q3 – Maintenance Bypass Isolator( from SCVS, single phase supply)
 Q4 – Output isolator
 BCB#1 – Battery Circuit Breaker for UPS#1
 BCB#2 – Battery Circuit Breaker for UPS#2
Isolation of UPS – 1/2:

 Ensure that in case any one of the UPS is to be isolated the other is in
working condition.
 Press ‘INV’ button on module mimic indicator unit of respective
UPS#1 or 2
Prepared by: Checked by: Approved by: Issued by :

06/05/16 07/05/16 09/05/16 10/05/16

V. Jagadish K. Ranga Rao S. Anand G. Vishnu Murthy

PSM-II Sr. Operations Manager General Manager MR
 Genting Lanco Power (India) Private Limited
Lanco Kondapalli Power Plant - Phase 3
Isolation Normalisation and Switching of Low Voltage ISP/OP3/04
Systems
Issue No. : Issue Date : Revision No. : Revision Date : File No. PAGE

1 14/05/16 0 - POP0304 13 of 14

 Confirm operation by pressing ‘ENTER’ button for ‘1’ second.

 Ensure the load has been transferred to the other UPS.
 Switch ‘OFF’ static bypass supply isolator (Q2) of respective UPS,
which is to be isolated.
 Switch ‘OFF’ respective Battery circuit breaker (BCB) at Battery
current sharing cubicle.
 Switch ‘OFF’ Charger input power MCCB (Q1) of respective UPS,
which is to be isolated.
 Switch ‘OFF’ main 415V incoming supply at Essential SWGR.

Note: After isolation of UPS, before attempting to work on UPS

internals, wait for at least ‘5’ minutes for internal DC bus bar
capacitors to discharge.

Details of UPS isolators and switches.

 Q1 – Input MCCB
 Q2 – Bypass supply (from SCVS, three phase supply) Isolator
 Q3 – Maintenance Bypass Isolator( from SCVS, single phase supply)

 Q4 – Output isolator
 BCB#1 – Battery Circuit Breaker for UPS#1
 BCB#2 – Battery Circuit Breaker for UPS#2

SAFETY AND ENVIRONMENTAL CHECKS

1. Only authorized and trained persons are involved in normalization
procedure.
2. All equipments involved in the procedure are readily identifiable by
Clear description on English and standard nomenclature as per drawing.
3. At a time only one operation is permitted.
7.0 4. Use proper personal protective equipments such as shoes, gloves and
helmets.
5. There is a hazard of electrical shock and/or whenever in or around
electrical equipment power. Both main and control voltages must be switched
Prepared by: Checked by: Approved by: Issued by :

06/05/16 07/05/16 09/05/16 10/05/16

V. Jagadish K. Ranga Rao S. Anand G. Vishnu Murthy

PSM-II Sr. Operations Manager General Manager MR
 Genting Lanco Power (India) Private Limited
Lanco Kondapalli Power Plant - Phase 3
Isolation Normalisation and Switching of Low Voltage ISP/OP3/04
Systems
Issue No. : Issue Date : Revision No. : Revision Date : File No. PAGE

1 14/05/16 0 - POP0304 14 of 14

off before working inside the equipments.

6. When a thorough inspection or work is required on a circuit breaker, It
must be removed from the cubicle. The bus bar should be de energized and
ground when the work is to be done on switch gear.

REFERENCES
GE Switchgear Instruction Manual
ISP/GM/01 Health and Safety Management
ISP/OP3/19 Maintenance of Log by Operation
W01/ISP/OP3/04 Isolation and Switching of Low Voltage Systems –
Activities by Plant Control Engineer
W01/ISP3/OP3/04 Isolation and Switching of Low Voltage Systems –
8.0 Activities by Operation Engineer

9. RECORDS

Work Permit ISP/GM/01

PCE Log

Prepared by: Checked by: Approved by: Issued by :

06/05/16 07/05/16 09/05/16 10/05/16

V. Jagadish K. Ranga Rao S. Anand G. Vishnu Murthy

PSM-II Sr. Operations Manager General Manager MR