Energy audit tata power solar

AMITKUMARSENAPATI
2010
TATABPSolarIndiaLimited,Bangalore
Under existing conditions, 6% increase in India's Gross
Domestic Product (GDP) would impose an increased
demand of 9 % on its energy sector. So there is a heavy
requirement of utilising renewable source of energy. The
total scope of utilization of solar energy in India is 178
Billion MW. We can be self sufficient in energy by being
able to harness the solar energy. We are still unable to
completely utilize solar energy in large scale due to the
efficiency of production and the set-up cost associated.
This project elaborates the various facilities and utilities of
the Solar Cell Manufacturing Unit. This project also takes
into consideration the various ways of effective utilization
of energy.
We here at TATA BP Solar manufacture cell at 32 MW per
annum.
TATA Consulting Engineers Limited
C/o TATA BP Solar India Limited
Plot No. 43(P) & 44(P)
Bangalore-560100
9241796839

2 | P a g e T A T A C o n s u l t i n g E n g i n e e r s L i m i t e d
TATA BP Solar India Limited
Acknowledgement
First of all I would like to thank TATA Consulting Engineers Limited for considering me capable
enough to be part of the organization and helping me develop my skills by providing training ,
which I consider as matchless in any Indian Industry.
My special thanks to Mr. Satish Koneru for his valuable comments during the preparation of this
project. My hearty regards to my earlier Project Managers – Mr. Sathish M. Rao & Mr.
K.Ramamurthy for providing me with adequate support during the course of this project.
Thanks to Mr. Rajnish Chaudhary, Mr. Nachiyappan & Mr. Srinivas of TATA BP Solar India Ltd.,
who supported me all along the project.
Preface
With the growing scope of harnessing of Solar Energy in India . It has become essential for us to
capitalize on this area. Energy as a whole has become a key word across industries to have the
leading edge over other competitors.
The purpose of this project is to inspire our Organization to also look into Energy management &
Energy Audit as a potential initiative toward achieving the strategic objective .Taking reference of
the Solar Cell Manufacturing Plant , I have taken utmost care to benefit the reader to understand the
basics of Conserving Energy in all industrial areas.
The Project has been presented in a structured manner which will allow the reader to have a clear
understanding of the object.
For Queries :
Name : Amit Kumar Senapati
E.mail : aksenapati@tce.co.in
aksenapati232@gmail.com
Ph.No.:9241796839

INDEX
Sl.No. Contents Pg.No.
1.0 Executive Summary 6-7
-Company Profile 6
-Basics 6-7
2.0 Electrical Tariffs 7-11
-Electricity Billing in Depth 7-8
-Tariff in TATA BP Solar 8
-Stepwise approach for controlling maximum demand 9
-Power factor improvement & benefits 10-11
3.0 Electrical Equipment Description 11-77
-Transformer 11-16
-Electric Motors 16-34
-Different losses of Motors 17-18
-Minimising motor losses 18-23
-TATA BP Load details 24-34
-Lighting 34-39
-Basic terms for lighting 34-36
-Recommended illuminance level. 36-37
-Design Lux level for TATA BP 38-39
-Building Management System 39-52
-BMS Details for HVAC for TATA BP 39-40
-BMS Details for Non HVAC in TATA BP 41-45
-BMS HVAC Architecture 46
-Fire Alarm System Architecture 47
-Chiller Operation 48-50
-Operation & control philosophy 48-49
-Start up sequence of Chillers 49-50
-Heat Exchanger operation 50
-Process Cooling Water 51-53
-General Description 51
-Pressure differential control 52
-Temperature control 52

-Networking 53-56
-Basics 53
-Typical PLC Communication 54-55
-MODBUS Communication 55
-Hardware system maintenance 55
-Software system maintenance 55-56
-Uninterrupted Power Supply 56-59
-Basics 56
-Description of UPS System in TATA BP Solar 57
-Modes of Operation 58
-Various Alarm Indications 58-59
-Air Exchange requirement in TATA BP 59
-Batteries 59-60
-Basics 59
-benefit of OPzS Batteries(installed in TATA BP) 60
-Diesel Generator 61-70
-Engine technical specification 61
-Voltage Regulation 62-63
-Design & Construction 63-66
-Auto change over sequence 66-69
-Waste Heat Recovery 70
-Fire Protection System 71-77
4.0 Utility Description for a Solar Power Plant(TATA BP) 78-93
-Ultra Pure Water 78-82
-Pure Air Plant 83-85
-Compressed Dry Air 86-91
-Scrubber System 92-93
5.0 Solar Cell Manufacturing Process(TATA BP) 94-106
-Introduction 94
-Basic Concept 94-97
-Manufacturing Process 97-106
6.0 Energy Conservation 107-110
-Energy saving for the plant 107
-Scope of energy conservation in Industrial Plant 107
-Energy Assessment of DG 107-108

-Energy Saving Measures for DG Sets 108-109
-Improvement required in TATA BP Solar 110
7.0 Conclusion 111

EXECUTIVE SUMMARY
Company Profile :
TATA BP Solar India Ltd., is a pioneer in the solar energy domain. With a past history of
producing quality products, it has made a reputation of being a leader in Solar Products.
Basics
Energy Needs of Growing Economyi
Economic growth is desirable for developing countries, and energy is essential for economic
growth. However, the relationship between economic growth and increased energy demand is
not always a straightforward linear one. For example, under present conditions, 6% increase in
India's Gross Domestic Product (GDP) would impose an increased demand of 9 % on its energy
sector. So there is a requirement of utilising renewable source of energy. In the scope of
producing electricity by harnessing solar energy is :
• Potential is 178 billion MW.
• India can receive 5.6kw/m2
.
• Photovoltaic system converts solar energy directly.
• Solar electric power plants ranges from kW to MW.
Comparative Per capita Energy consumption for India :
Country Consumption Population Energy
USA 8000 KWh 7% 32%
INDIA 150KWh 20% 1%
ii
Electricity
Electricity tariffs in India are structured in a relatively simple manner. While high tension
consumers are charged based on both demand (kVA) and energy (kWh), the low-tension (LT)
consumer pays only for the energy consumed (kWh) as per tariff system in most of the
electricity boards. The price per kWh varies significantly across States as well as customer
segments within a State. Tariffs in India have been modified to consider the time of usage and
voltage level of supply. In addition to the base tariffs, some State Electricity Boards have
additional recovery from customers in form of fuel surcharges, electricity duties and taxes. For
example, for an industrial consumer the demand charges may vary from Rs. 150 to Rs. 300 per
kVA, whereas the energy charges may vary anywhere between Rs. 2 to Rs. 5 per kWh. As for the
tariff adjustment mechanism, even when some States have regulatory commissions for tariff
review, the decisions to effect changes are still political and there is no automatic adjustment
mechanism, which can ensure recovery of costs for the electricity boards.

ELECTRICAL TARIFFS
Electricity Billing in Depth
The electricity billing by utilities for medium & large enterprises, in High Tension (HT) category,
is often done on two-part tariff structure, i.e. one part for capacity (or demand) drawn and the
second part for actual energy drawn during the billing cycle. Capacity or demand is in kVA
(apparent power) or kW terms. The reactive energy (i.e.) kVArh drawn by the service is also
recorded and billed for in some utilities, because this would affect the load on the utility.
Accordingly, utility charges for maximum demand, active energy and reactive power drawn (as
reflected by the power factor) in its billing structure. In addition, other fixed and variable expenses
are also levied.
The tariff structure generally includes the following components:
a) Maximum demand Charges
These charges relate to maximum demand registered during month/billing period and
corresponding rate of utility.
b) Energy Charges
These charges relate to energy (kilowatt hours) consumed during month / billing period and
corresponding rates, often levied in slabs of use rates. Some utilities now charge on the basis
of apparent energy (kVAh), which is a vector sum of kWh and kVArh.
c) Power factor penalty or bonus rates, as levied by most utilities, are to contain reactive power
drawn from grid.
d) Fuel cost adjustment charges as levied by some utilities are to adjust the increasing fuel expenses
over a base reference value.
e) Electricity duty charges levied w.r.t units consumed.
f) Meter rentals
g) Lighting and fan power consumption is often at higher rates, levied sometimes on slab basis or on
actual metering basis.
h) Time Of Day (TOD) rates like peak and non-peak hours are also prevalent in tariff structure
provisions of some utilities.
i) Penalty for exceeding contract demand
j) Surcharge if metering is at LT side in some of the utilities

Analysis of utility bill data and monitoring its trends helps energy manager to identify ways for
electricity bill reduction through available provisions in tariff framework, apart from energy
budgeting.
The utility employs an electromagnetic or electronic trivector meter, for billing purposes. The minimum
outputs from the electromagnetic meters are
• Maximum demand registered during the month, which is measured in preset time intervals (say of
30 minute duration) and this is reset at the end of every billing cycle.
• Active energy in kWh during billing cycle
• Reactive energy in kVArh during billing cycle and
• Apparent energy in kVAh during billing cycle
It is important to note that while maximum demand is recorded, it is not the instantaneous
demand drawn, as is often misunderstood, but the time integrated demand over the predefined
recording cycle.
For Calculation of Power, 3 of the pre-requisites are as below:-
• Unit Rate
• Maximum Demand Constraint
• Power Factor Penalty
Tariff in TATA BP Solar India Ltd., Bangalore :-
i) Contract Demand : 7500KVA
ii) 75% of Contract Demand : 56250KVA
iii) Demand Charges Per Unit(KVA) : 180 INR
iv) 1st
Slab Energy Charges(KWH) : 3.80 INR per Unit till 100,000 Units.
v) 2nd
Slab Energy Charges(KWH) : 4.30 INR per Unit > 100,000 Units.
Power Factor Penalty :
(1) If p.f. = 0.9 then no penalty.
(2) If 0.6<p.f.<0.9 then 2% of total bill Penalty.
(3) If p.f.>0.97 then incentive of 2% on total bill.
Step wise approach for controlling the Maximum Demand

1. Load Curve Generation
Presenting the load demand of a consumer against time of the day is known as a ‘load curve’. If
it is plotted for the 24 hours of a single day, it is known as a ‘hourly load curve’ and if daily
demands plotted over a month, it is called ‘daily load curve’.
2. Rescheduling of Loads
Rescheduling of large electric loads and equipment operations, in different shifts can be planned and
implemented to minimize the simultaneous maximum demand. For this purpose, it is advisable to
prepare an operation flow chart and a process chart. Analyzing these charts and with an integrated
approach, it would be possible to reschedule the operations and running equipment in such a way as
to improve the load factor which in turn reduces the maximum demand.
3.Storage of Products/in process material/ process utilities like refrigeration
It is possible to reduce the maximum demand by building up storage capacity of products/ materials,
water, chilled water / hot water, using electricity during off peak periods. Off peak hour operations
also help to save energy due to favorable conditions such as lower ambient temperature etc.
4. Shedding of Non-Essential Loads
When the maximum demand tends to reach preset limit, shedding some of non-essential loads
temporarily can help to reduce it. It is possible to install direct demand monitoring systems, which
will switch off non-essential loads when a preset demand is reached. Simple systems give an alarm,
and the loads are shed manually.
5.Operation of Captive Generation and Diesel Generation Sets
When diesel generation sets are used to supplement the power supplied by the electric utilities, it is
advisable to connect the D.G. sets for durations when demand reaches the peak value. This would
reduce the load demand to a considerable extent and minimize the demand charges.
6. Reactive Power Compensation
The maximum demand can also be reduced at the plant level by using capacitor banks and
maintaining the optimum power factor. Capacitor banks are available with microprocessor based
control systems. These systems switch on and off the capacitor banks to maintain the desired Power
factor of system and optimize maximum demand thereby.
Power Factor Improvement and Benefits
The advantages of PF improvement by capacitor addition
a) Reactive component of the network is reduced and so also the total current in the system
from the source end.
b) I
2
R power losses are reduced in the system because of reduction in current.
c) Voltage level at the load end is increased.

d) kVA loading on the source generators as also on the transformers and lines upto the
capacitors reduces giving capacity relief. A high power factor can help in utilising the full
capacity of your electrical system.
Cost benefits of PF improvement
While costs of PF improvement are in terms of investment needs for capacitor addition the
benefits to be quantified for feasibility analysis are:
a) Reduced kVA (Maximum demand) charges in utility bill
b) Reduced distribution losses (KWH) within the plant network
c) Better voltage at motor terminals and improved performance of motors
d) A high power factor eliminates penalty charges imposed when operating with a low power
factor
e) Investment on system facilities such as transformers, cables, switchgears etc for delivering
load is reduced.
Selection and location of capacitors
Direct relation for capacitor sizing.
kVAr Rating = kW [tan φ1 – tan φ2]
where kVAr rating is the size of the capacitor needed, kW is the average power drawn, tan φ1 is
the trigonometric ratio for the present power factor, and tan φ
2
is the trigonometric ratio for the
desired PF.
φ
1
= Existing (Cos
-1
PF
1
) and φ
2
= Improved (Cos
-1
PF
2
)
Location of Capacitors
Maximum benefit of capacitors is derived by locating them as
close as possible to the load. At this location, its kilovars are
confined to the smallest possible segment, decreasing the load
current.
This, in turn, will reduce power losses of the system substantially. Power losses are proportional
to the square of the current. When power losses are reduced, voltage at the motor increases;
thus, motor performance also increases.
It should be noted that the rating of the capacitor should not be greater than the no-
load magnetizing kVAr of the motor.

Electrical Equipment Description
Transformer
Location of Transformer
Transformers should be placed close to the load centre, considering other features like
optimisation needs for centralised control, operational flexibility, etc. This will bring down the
distribution loss in cables.
Transformer Losses and Efficiency
The efficiency varies anywhere between 96 to 99 percent. The efficiency of the transformers not
only depends on the design, but also, on the effective operating load.
Transformer losses consist of two parts: No-load loss and Load loss
1. No-load loss (also called core loss) is the power consumed to sustain the magnetic field in
the transformer's steel core. Core loss occurs whenever the transformer is energized; core
loss does not vary with load. Core losses are caused by two factors: hysteresis and eddy
current losses. Hysteresis loss is that energy lost by reversing the magnetic field in the core
as the magnetizing AC rises and falls and reverses direction. Eddy current loss is a result of
induced currents circulating in the core.
2. Load loss (also called copper loss) is associated with full-load current flow in the
transformer windings. Copper loss is power lost in the primary and secondary windings of a
transformer due to the ohmic resistance of the windings. Copper loss varies with the
square of the load current. (P=I
2
R).
Voltage Fluctuation Control
A control of voltage in a transformer is important due to frequent changes in supply voltage
level. Whenever the supply voltage is less than the optimal value, there is a chance of nuisance
tripping of voltage sensitive devices. The voltage regulation in transformers is done by altering
the voltage transformation ratio with the help of tapping.
There are two methods of tap changing facility available: Off-circuit tap changer and On-load
tap changer.
Off-circuit tap changer
It is a device fitted in the transformer, which is used to vary the voltage transformation ratio.
Here the voltage levels can be varied only after isolating the primary voltage of the transformer.
On load tap changer (OLTC)

The voltage levels can be varied without isolating the connected load to the transformer. To
minimise the magnetisation losses and to reduce the nuisance tripping of the plant, the main
transformer (the transformer that receives supply from the grid) should be provided with On
Load Tap Changing facility at design stage. The down stream distribution transformers can be
provided with off-circuit tap changer.
The On-load gear can be put in auto mode or manually depending on the requirement. OLTC can
be arranged for transformers of size 250 kVA onwards. However, the necessity of OLTC below
1000 kVA can be considered after calculating the cost economics.
Parallel Operation of Transformers
The design of Power Control Centre (PCC) and Motor Control Centre (MCC) of any new plant
should have the provision of operating two or more transformers in parallel. Additional
switchgears and bus couplers should be provided at design stage.
Whenever two transformers are operating in parallel, both should be technically identical in all
aspects and more importantly should have the same impedance level. This will minimise the
circulating current between transformers.
Where the load is fluctuating in nature, it is preferable to have more than one transformer
running in parallel, so that the load can be optimised by sharing the load between transformers.
The transformers can be operated close to the maximum efficiency range by this operation.
them.
Transformers used in TATA BP Solar India Ltd.
1 nos. Of 16/20MVA Transformer.
5 nos. Of 2MVA Transformer.
Transformer setting values used :
Oil Temperature Indicator :
The temp. for alarm & trip contact setting are as follows :
• Alarm : 85 deg.C

• Trip : 90 deg.C
Winding Temperature Indicator :
The temp. for alarm & trip contact setting setting shall be as under :
• Alarm : 90 deg.C
• Trip : 100 deg.C
• Fans ON : 60 deg.C
• Pump ON : 75 deg.C
Differential Protection for Transformer provided :
Current restraint tripping characteristics.
Stabilized against in-rush currents using the 2nd
harmonics.
Stabilized against transient and steady state fault currents caused e.g. by over-excitation
of transformers, using a further harmonic : optionally the third or fifth harmonics . Here
in TATA BP solar third harmonics is used.
High earth fault sensitivity by detection of the star point current of an earthed
transformer winding.
Integrated matching of the transformer connection group.
Harmonics
In any alternating current network, flow of current depends upon the voltage applied and the
impedance (resistance to AC) provided by elements like resistances, reactances of inductive and
capacitive nature. As the value of impedance in above devices is constant, they are called linear
whereby the voltage and current relation is of linear nature.
However in real life situation, various devices like diodes, silicon controlled rectifiers, PWM
systems, thyristors, voltage & current chopping saturable core reactors, induction & arc
furnaces are also deployed for various requirements and due to their varying impedance
characteristic, these NON LINEAR devices cause distortion in voltage and current waveforms
which is of increasing concern in recent times. Harmonics occurs as spikes at intervals which are
multiples of the mains (supply) frequency and these distort the pure sine wave form of the
supply voltage & current.
Harmonics are multiples of the fundamental frequency of an electrical power system. If, for
example, the fundamental frequency is 50 Hz, then the 5th harmonic is five times that
frequency, or 250 Hz. Likewise, the 7th harmonic is seven times the fundamental or 350 Hz, and
so on for higher order harmonics.
Harmonics can be discussed in terms of current or voltage. A 5th harmonic current is simply a
current flowing at 250 Hz on a 50 Hz system. The 5th harmonic current flowing through the

system impedance creates a 5th harmonic voltage. Total Harmonic Distortion (THD) expresses
the amount of harmonics. The following is the formula for calculating the THD for current:
Concept of dealing with harmonics in TATA BP Solar India Ltd. :
When switching unloaded transformers on a live bus bar , high magnetising (inrush) currents may
occur . These inrush currents produce differential quantities as they seem like single end fed fault
currents.
Also during paralleling of transformers or an over-excitation of a power transformer , differential
quantities may occur due to magnetising currents caused by increased voltage and/or decreased
frequency. The inrush current can amount to a multiple of a rated current and is characterized by a
considerable 2nd
harmonic content (double rated frequency) which is practically absent in the case of
a s.c. if the 2nd
harmonic content exceeds a selectable threshold , trip is blocked.
Thus , the third or fifth harmonics are suitable to detect such phenomena . But, as the third
harmonic is often eliminated in power transformers (e.g. by the delta winding) , the use of the fifth is
more common.
Major Causes Of Harmonics
Devices that draw non-sinusoidal currents when a sinusoidal voltage is applied create
harmonics. Frequently these are devices that convert AC to DC. Some of these devices are listed
below:
Electronic Switching Power Converters
Computers, Uninterruptible power supplies (UPS), Solid-state rectifiers
Electronic process control equipment, PLC’s, etc
Electronic lighting ballasts, including light dimmer

Reduced voltage motor controllers
Arcing Devices
Discharge lighting, e.g. Fluorescent, Sodium and Mercury vapor
Arc furnaces, Welding equipment, Electrical traction system
Ferromagnetic Devices
Transformers operating near saturation level
Magnetic ballasts (Saturated Iron core)
Induction heating equipment, Chokes, Motors
These devices use power electronics like SCRs, diodes, and thyristors, which are a growing
percentage of the load in industrial power systems. The majority use a 6-pulse converter. Most
loads which produce harmonics, do so as a steady-state phenomenon. A snapshot reading of an
operating load that is suspected to be non-linear can determine if it is producing harmonics.
Normally each load would manifest a specific harmonic spectrum.
Many problems can arise from harmonic currents in a power system. Some problems are easy
to detect; others exist and persist because harmonics are not suspected. Higher RMS current
and voltage in the system are caused by harmonic currents, which can result in any of the
problems listed below:
3. Blinking of Incandescent Lights - Transformer Saturation
4. Capacitor Failure - Harmonic Resonance
5. Circuit Breakers Tripping - Inductive Heating and Overload
6. Conductor Failure - Inductive Heating
7. Electronic Equipment Shutting down - Voltage Distortion
8. Flickering of Fluorescent Lights - Transformer Saturation
9. Fuses Blowing for No Apparent Reason - Inductive Heating and Overload
10. Motor Failures (overheating) - Voltage Drop
11. Neutral Conductor and Terminal Failures - Additive Triplen Currents
12. Electromagnetic Load Failures - Inductive Heating
13. Overheating of Metal Enclosures - Inductive Heating
14. Power Interference on Voice Communication - Harmonic Noise
15. Transformer Failures - Inductive Heating
Overcoming Harmonics

Tuned Harmonic filters consisting of a capacitor bank and reactor in series are designed and
adopted for suppressing harmonics, by providing low impedance path for harmonic component.
The Harmonic filters connected suitably near the equipment generating harmonics help to
reduce THD to acceptable limits. In present Indian context where no Electro Magnetic
Compatibility regulations exist as a application of Harmonic filters is very relevant for industries
having diesel power generation sets and co-generation units.
Electric Motors
Motor Selection
The primary technical consideration defining the motor choice for any particular application is
the torque required by the load, especially the relationship between the maximum torque
generated by the motor (break-down torque) and the torque requirements for start-up (locked
rotor torque) and during acceleration periods.
The duty / load cycle determines the thermal loading on the motor. One consideration with
totally enclosed fan cooled (TEFC) motors is that the cooling may be insufficient when the motor
is operated at speeds below its rated value.
Few of salient selection issues are given below:
Reactive power drawn (kVAR) by the motor.
Indian Standard 325 for standard motors allows 15 % tolerance on efficiency for motors
upto 50 kW rating and 10 % for motors over 50 kW rating.
The Indian Standard IS 8789 addresses technical performance of Standard Motors while
IS 12615 addresses the efficiency criteria of High Efficiency Motors. Both follow IEC 34-2
test methodology wherein, stray losses are assumed as 0.5 % of input power. By the IEC
test method, the losses are understated and if one goes by IEEE test methodology, the
motor efficiency values would be further lowered.
It would be prudent for buyers to procure motors based on test certificates rather than
labeled values.
The energy savings by motor replacement can be worked out by the simple relation : kW
savings = kW output × [ 1/η
old
- 1/ η
new
] where η
old
and η
new
are the existing and
proposed motor efficiency values.
The cost benefits can be worked out on the basis of premium required for high efficiency
vs. worth of annual savings.
In the selection process, the power drawn at 75 % of loading can be a meaningful
indicator of energy efficiency.

Different Losses for Motors :
Stator and Rotor I
2
R Losses
These losses are major losses and typically account for 55% to 60% of the total losses. I
2
R losses
are heating losses resulting from current passing through stator and rotor conductors. I
2
R losses
are the function of a conductor resistance, the square of current. Resistance of conductor is a
function of conductor material, length and cross sectional area. The suitable selection of copper
conductor size will reduce the resistance. Reducing the motor current is most readily
accomplished by decreasing the magnetizing component of current. This involves lowering the
operating flux density and possible shortening of air gap. Rotor I
2
R losses are a function of the
rotor conductors (usually aluminium) and the rotor slip. Utilisation of copper conductors will
reduce the winding resistance. Motor operation closer to synchronous speed will also reduce
rotor I
2
R losses.
Core Losses
Core losses are those found in the stator-rotor magnetic steel and are due to hysterisis effect
and eddy current effect during 50 Hz magnetization of the core material. These losses are
independent of load and account for 20 – 25 % of the total losses.
The hysterisis losses which are a function of flux density, are be reduced by utilizing low-loss
grade of silicon steel laminations. The reduction of flux density is achieved by suitable increase
in the core length of stator and rotor. Eddy current losses are generated by circulating current
within the core steel laminations. These are reduced by using thinner laminations.
Friction and Windage Losses
Friction and windage losses results from bearing friction, windage and circulating air through the
motor and account for 8 – 12 % of total losses. These losses are independent of load. The
reduction in heat generated by stator and rotor losses permit the use of smaller fan. The
windage losses also reduce with the diameter of fan leading to reduction in windage losses.
Stray Load-Losses
These losses vary according to square of the load current and are caused by leakage flux induced
by load currents in the laminations and account for 4 to 5 % of total losses. These losses are
reduced by careful selection of slot numbers, tooth/slot geometry and air gap.

Factors Affecting Energy Efficiency & Minimising Motor Losses in Operation
Power Supply Quality
Motor performance is affected considerably by the quality of input power, that is the actual
volts and frequency available at motor terminals vis-à-vis rated values as well as voltage and
frequency variations and voltage unbalance across the three phases. Motors in India must
comply with standards set by the Bureau of Indian Standards (BIS) for tolerance to variations in
input power quality. The BIS standards specify that a motor should be capable of delivering its
rated output with a voltage variation of +/- 6 % and frequency variation of +/- 3 %. Fluctuations
much larger than these are quite common in utility-supplied electricity in India. Voltage
fluctuations can have detrimental impacts on motor performance. Voltage unbalance, the
condition where the voltages in the three phases are not equal, can be still more detrimental to
motor performance and motor life. Unbalance typically occurs as a result of supplying single-
phase loads disproportionately from one of the phases. It can also result from the use of
different sizes of cables in the distribution system.
The options available for an energy manager to ensure near to rated voltage at motor
terminals include:
i) Load end power factor improvement by providing matching PF capacitors
ii) Minimizing line / cable voltage drops from sub-station to motor terminals
iii) Transformer tap changing as required in case of consistent and continuous low voltage
situations.
The options that can be exercised to minimize voltage unbalance include:
i) Balancing any single phase loads equally among all the three phases
ii) Segregating any single phase loads which disturb the load balance and feed them
from a separate line / transformer
Motor Loading

Measuring Load
Reducing Under-loading
The most common practice contributing to sub-optimal motor efficiency is that of under-
loading. Under-loading results in lower efficiency and power factor, and higher-than-necessary
first cost for the motor and related control equipment.
Several reason for Under Loading are :
Original equipment manufacturers tend to use a large safety factor in motors they
select. Under-loading of the motor may also occur from under-utilisation of the
equipment. For example, machine tool equipment manufacturers provide for a motor
rated for the full capacity load of the equipment ex. depth of cut in a lathe machine. The
user may need this full capacity rarely, resulting in under-loaded operation most of the
time.
Another common reason for under-loading is selection of a larger motor to enable the
output to be maintained at the desired level even when input voltages are abnormally
low.
Under-loading also results from selecting a large motor for an application requiring high
starting torque where a special motor, designed for high torque, would have been
suitable.
Larger motors have inherently higher rated efficiencies than smaller motors. Therefore,
the replacement of motors operating at 60 – 70 % of capacity or higher is generally not
recommended
Steps to reduce Under loading :
For motors, which operate at loads below 40 % of rated capacity, might be operated in star
mode .
eason to operate in Star Mode:R

Operating in the star mode leads to a voltage reduction by a factor of ‘√3’. Motor is
electrically downsized by star mode operation, but performance characteristics as a
function of load remain unchanged.
Thus, full-load operation in star mode gives higher efficiency and power factor than
partial load operation in the delta mode.
Motor operation in the star mode is possible only for applications where the torque-to-speed requirement is
lower at reduced load. As speed of the motor reduces in star mode this option may be avoided in case the
motor is connected to a production facility whose output is related to the motor speed.
For applications with high initial torque and low running torque needs, Del-Star starters are used
which helps in avoiding de-rating of electric motors after initial start-up.
Sizing to Variable Load
Industrial motors frequently operate under varying load conditions due to process
requirements.
Steps that can be taken while sizing of motors are :
Select a motor based on the highest anticipated load.
Motor is selected on the basis of the load duration curve for the particular application.
Thus, rather than selecting a motor of high rating that would operate at full capacity for only a short period,
a motor would be selected with a rating slightly lower than the peak anticipated load and would operate at
overload for a short period of time. Since operating within the thermal capacity of the motor insulation is of
greatest concern in a motor operating at higher than its rated load, the motor rating is selected as that
which would result in the same temperature rise under continuous full-load operation as the weighted
average temperature rise over the actual operating cycle. Under extreme load changes, e.g. frequent starts /
stops, or high inertial loads, this method of calculating the motor rating is unsuitable since it would
underestimate the heating that would occur.
Power Factor Correction
Induction motors are characterized by power factors less than unity, leading to lower overall
efficiency (and higher overall operating cost) associated with a plant’s electrical system.
Capacitors connected in parallel (shunted) with the motor are typically used to improve the
power factor.
Benefits of Power Factor Correction :
Reduced kVA demand (and hence reduced utility demand charges), reduced I
2
R losses in cables
upstream of the capacitor (and hence reduced energy charges), reduced voltage drop in the
cables (leading to improved voltage regulation), and an increase in the overall efficiency of the
plant electrical system.

It should be noted that PF capacitor improves power factor from the point of installation back to
the generating side. It means that, if a PF capacitor is installed at the starter terminals of the
motor, it won’t improve the operating PF of the motor, but the PF from starter terminals to the
power generating side will improve, i.e., the benefits of PF would be only on upstream side. The
size of capacitor required for a particular motor depends upon the no-load reactive kVA (kVAR)
drawn by the motor, which can be determined only from no-load testing of the motor. In
general, the capacitor is then selected to not exceed 90 % of the no-load kVAR of the motor.
(Higher capacitors could result in over-voltages and motor burn-outs). Alternatively, typical
power factors of standard motors can provide the basis for conservative estimates of capacitor
ratings to use for different size motors.
Maintenance
Inadequate maintenance of motors can significantly increase losses and lead to unreliable
operation. For example, improper lubrication can cause increased friction in both the motor and
associated drive transmission equipment. Resistance losses in the motor, which rise with
temperature, would increase. Providing adequate ventilation and keeping motor cooling ducts
clean can help dissipate heat to reduce excessive losses. The life of the insulation in the motor
would also be longer : for every 10
0
C increase in motor operating temperature over the
recommended peak, the time before rewinding would be needed is estimated to be halved.
A checklist of good maintenance practices to help insure proper motor operation would include:
Inspecting motors regularly for wear in bearings and housings (to reduce frictional
losses) and for dirt/dust in motor ventilating ducts (to ensure proper heat dissipation).
Checking load conditions to ensure that the motor is not over or under loaded. A change
in motor load from the last test indicates a change in the driven load, the cause of which
should be understood.
Lubricating appropriately. Manufacturers generally give recommendations for how and
when to lubricate their motors. Inadequate lubrication can cause problems, as noted
above. Over-lubrication can also create problems, e.g. excess oil or grease from the
motor bearings can enter the motor and saturate the motor insulation, causing
premature failure or creating a fire risk.
Checking periodically for proper alignment of the motor and the driven equipment.
Improper alignment can cause shafts and bearings to wear quickly, resulting in damage
to both the motor and the driven equipment.
Ensuring that supply wiring and terminal box are properly sized and installed. Inspect
regularly the connections at the motor and starter to be sure that they are clean and
tight.

Life
Most motor cores in India are manufactured from silicon steel or de-carbonized cold-rolled
steel, the electrical properties of which do not change measurably with age. However, poor
maintenance (inadequate lubrication of bearings, insufficient cleaning of air cooling passages,
etc.) can cause a deterioration in motor efficiency over time. Ambient conditions can also have a
detrimental effect on motor performance. For example, excessively high temperatures, high
dust loading, corrosive atmosphere, and humidity can impair insulation properties; mechanical
stresses due to load cycling can lead to misalignment. However, with adequate care, motor
performance can be maintained.
Rewinding Effects on Energy Efficiency
It is common practice in industry to rewind burnt-out motors. The population of rewound
motors in some industries exceed 50 % of the total population. Careful rewinding can
sometimes maintain motor efficiency at previous levels, but in most cases, losses in efficiency
result. Rewinding can affect a number of factors that contribute to deteriorated motor
efficiency : winding and slot design, winding material, insulation performance, and operating
temperature. For example, a common problem occurs when heat is applied to strip old windings
: the insulation between laminations can be damaged, thereby increasing eddy current losses. A
change in the air gap may affect power factor and output torque.
However, if proper measures are taken, motor efficiency can be maintained, and in some cases
increased, after rewinding. Efficiency can be improved by changing the winding design, though
the power factor could be affected in the process. Using wires of greater cross section, slot size
permitting, would reduce stator losses thereby increasing efficiency. However, it is generally
recommended that the original design of the motor be preserved during the rewind, unless
there are specific, load-related reasons for redesign.
Starting Current required for Electrical Motors :
LV MOTORS - 6 times + 20% positive tolerance
HV MOTORS UPTO 1500 kW - 6 times inclusive of tolerance
HV MOTORS above 1500 kW - 4.50 times

Problems Caused by Instability
Whenever the machines operating in synchronism go out of step, there are high mechanical torque
and currents in the machines, which may cause mechanical and thermal damage to the system if the
protection does not act to isolate the two machines. Out-of-step operation also causes large
oscillatory flows of real and reactive power over the circuits connecting the out-of-step machines.
Most Common Disturbances Producing Instability
Short circuits
Loss of a tie circuit to a public utility
Loss of a portion of on-site generation.
Starting a high rating motor.
Switching operations
Impact loading on motors
Abrupt decrease in electrical load on generators.
Motors consists of 70% of Electrical Loads.
Starting of Induction Motors
When started on line, without any special equipment an Induction Motor draws about 5-6
times the full load current during starting condition, till it attains almost full speed. This current
is mostly reactive in nature and the power factor during starting is in the range of 0.2 to 0.3 for
squirrel cage motors.
Due to this high starting current, the voltage at the terminal of motors dips. The voltage dip
depends upon fault level of the bus on which motor is started, starting current and the length &
size of the cable between the switchgear and motor terminal.
The motor draws an almost constant current till it attains full speed. The voltage at the bus also
dips during this period and it recovers as soon as motor current reduces to its full load value.
For Extreme downstream protection the following settings are recommended to be followed :
• The co-ordination interval for the relay immediately above the fuse is decided by the fuse
positive tolerance, relay negative tolerance, relay overshoot and a safety margin. A
minimum co-ordination interval of 0.2 sec. is to be maintained between the relay and the
fuse.

• As for as possible, a co-ordination interval of 0.3 sec. is to be maintained between two relays
to ensure proper discrimination. The time includes the breaker opening time, relay errors,
relay overshoot and a safety margin.
• For industrial plants, the operating time of the extreme upstream relay in the plant,
considered along with its breaker opening time, at the incoming power supply fault
level, is governed by the maximum time permitted by the Electricity Board and equipment
ratings at that fault level. The co-ordination starting from the extreme downstream relays
shall ensure that this requirement is met.
TATA BP Load Description :
Total load on UPS :
CONNECTED LOAD IN UPS TO OPERATE LINE-3
LOAD IN KW
DESCRIPTION UPS
TOOLS LOAD 867
LIGHTING DB's 6.81
POWER DB's 34.8
DG PDB 0
CDA 0
WWT PANEL 0
UPW-PLC-1 0
UPW-PLC-2 87.3
PROCESS CHILLED WATER 180
SCRUBBER & EXHAUST 230.26
PURE AIR 0
HVAC HIGH SIDE 0
HVAC LOW SIDE 0
SPECIAL GASES 13.96
CHEMICAL SUPPLY 12
CHEMICAL DISTRIBUTION MODULE 9.32
SECURITY & WEIGH BRIDGE 0
BMS SYSTEM 3
EXTERNAL POWER SUPPLY 1.5
LEV-00 UPS VENTILATION PANEL 45.5
LEV-00 UPS LIGHTING&POWER 2.6
TOTAL CONNECTED LOAD 1494.05iii

Total load required including grid & UPS.
SL.NO DESCRIPTION UPS GRID
A TOOLS
1 Wafer Inspection tool 20 0
2 Automation, load InTex (wet chem 1 ) 15 0
3 Automatic Wet Bench, Texturing Acid wet chem 1 21 0
4 Automation unloader for wet chem 1 20 0
5 Tube dope Diffusion (5 Tube) 168 0
6 Automation, wafer resistivity and casseting tool 17 0
7 Automation, load InOx (wet chem 2) 15 0
8 InOx Wetbench (oxide etch only) (wet chem 2) 6 0
9 Automation, unload InOx (wet chem2) 15 0
10 Tube PECVD (4 Tube) 173 0
11 Vaccum pump 12 0
12 PECVD Purge panel (part of pecvd) 0 0
13 Boat etching for PECVD tubes 1.5 0
14 Pre deposition tool 39 0
15 Pump for predep 3 0
16 Drying oven 4.5 0
17 Front Printer 30 0
18 Dryer 36 0
19 Back Printer #1 30 0
20 CO - Fire 191 0
21 Laser Edge Isolation 15 0
22 Cell Tester and Sorter 35 0
TOTAL 867 0
B LIGHTING DB's LOAD
1 ELDB-UTILITY 3.11
2 ELDB-2 3.7 0
3 LDB-1 0 6
4 LDB-2 0 3.7
5 LDB-3 0 3.7
6 LDB-6 0 5.5
TOTAL 6.81 18.9
C POWER DB's LOAD
1 UPDB-3 (Shifted to raw power) 21.6 0
2 UPDB-4 13.2 0
3 PDB-5 0 12
TOTAL 34.8 12
D DG PDB @ DG BUILDING

1 CDA LDB (GF+FF) 0 1.76
2 CDA PDB (GF+FF) 0 2.2
3 DG LPDB (GF) 0 6.72
4 DG LPDB (FF) 0 2.08
5 UPW LDB 0 3.75
6 UPW PDB 0 31.02
7
WEIGH BRIDGE 0 8
8 32A,TP SOCKET OUTLET-2NO @ GF 0 6
TOTAL 0 61.53
E CDA BUILDING
1 CDA-1 0 90.8
2 CDA-2 0 90.8
3 CDA-3 0 0
4 CDA-4(S) 0 0
TOTAL 0 181.6
F WASTE WATER TREATMENT PANEL
1 HF&HNO3 TRANSFER PUMP 0 3.7
2 HF&HNO3 TRANSFER PUMP 0 3.7
3 HF&HCL TRANSFER PUMP 0 3.7
4 HF&HCL TRANSFER PUMP 0 3.7
5 H3PO4 TRANSFER PUMP 0 3.7
6 H3PO4 TRANSFER PUMP 0 3.7
7 H2 SO4 TRANSFER PUMP 0 3.7
8 H2 SO4 TRANSFER PUMP 0 3.7
9 NAOH TRANSFER PUMP 0 3.7
10 NAOH TRANSFER PUMP 0 3.7
11 RINSE WASTE WATER TRANSFER PUMP 0 7.5
12 RINSE WASTE WATER TRANSFER PUMP 0 7.5
13 UPW MAKE-UP SYSTEM TRANSFER PUMP 0 7.5
14 UPW MAKE-UP SYSTEM TRANSFER PUMP 0 7.5
15 PLC PANEL LOAD 0 0.5
WITH STAND-BY LOAD 0 67.5
WITHOUT STAND-BY LOAD 0 34
TOTAL 0 34
G ULTRA PURE WATER PLANT
G1 PLC PANEL-1
1 MMF FEED PUMP-P-001A 0 5.5
2 MMF FEED PUMP-P-001B 0 4
3 MMF BACKWASH PUMP 0 4
4 ACF FEED PUMP 0 7.5

5 ACF FEED PUMP 0 7.5
6 ACF BACKWASH SF REGENERATION PUMP 0 7.5
7 RO1 HIGH PR.PUMP 0 15
11 RO CIP PUMP/EDI CIP PUMP(Mobile)-SPARE 0 4
12 PORTABLE PUMP 0 5.5
13 UV-001 0 3.5
14 FLECK VALVE-MMF-001 0 4
15 FLECK VALVE-ACF-001 0 4
16 FLECK VALVE-SF-001 0 4
17 NAOCI DOSING PUMP 0 0.017
18 FeCI3 DOSING PUMP 0 0.017
19 NAOH DOSING PUMP 0 0.017
20 PANEL LIGHT,HEATER FAN,etc 0 0.5
21 PLC LOAD 0 0.5
22 AC/DC CONVERTER POWER SUPPLY-1 0 0.15
23 AC/DC CONVERTER POWER SUPPLY-2 0 0.15
24 SENSORS AND OTHER LOADS 0 0.5
WITH STAND-BY LOADS 114.851
WITH OUT STAND-BY LOAD 69.851
TOTAL 0 69.851
G2 PLC PANEL-2
1 RECTIFIER 36 0
2 EDI FEED PUMP 5.5 0
3 EDI FEED PUMP 5.5 0
4 UPW TR.PUMP 11 0
5 UPW TR.PUMP 11 0
6 REGENERATION PUMP 4 0
7 PORTABLE PUMP 5.5 0
8 UV-002 3.5 0
9 UV-003 3.5 0
10 PANEL LIGHT,HEATER etc 0.5 0
11 PLC LOADS 0.5 0
12 AC/DC CONVERTER POWER SUPPLY-1 0.15 0
13 AC/DC CONVERTER POWER SUPPLY-2 0.15 0
14 SENSORS AND OTHER LOADS 0.5 0
WITH STAND-BY LOAD 87.3
WITHOUT STAND-BY LOAD 70.65
TOTAL 70.65 0

H PROCESS COOLING WATER
1 CHILLER-1 - 310
2 CHILLER-2 - 0
3 CHILLER-3 - 345
4 CHILLER-4 - 0
5 CHILLER-5(S) - 0
6 BOOSTER PUMP-1(W) 90 0
7 BOOSTER PUMP-2(S) 90 0
8 HOT WATER GENERATOR - 150
9
FAN FILTER UNITS(FFU's)-55NO's(EACH-.55KW FOR LINE
3) 30.25
WITH STAND-BY LOAD 180
WITHOUT STAND-BY LOAD 90
TOTAL 90 835.25
I SCRUBBER AND EXHAUST SYSTEM
I1 NOX-SCRUBBER
1 REC.PUMP-1 2.24 0
2 REC.PUMP-2 2.24 0
3 ED PUMP 0.52 0
4 DAMPER-1 0.37 0
5 DAMPER-2 0.37 0
6 BLOWER-1 7.46 0
7 BLOWER-2 7.46 0
8 INSTRUMENT PANEL 0.55 0
I2 ACID SCRUBBER
1 ED PUMP-1 0.52 0
2 ED PUMP-2 0.52 0
3 ED PUMP-3 0.52 0
4 REC PUMP-1 2.24 0
5 REC PUMP-2 2.24 0
6 REC PUMP-3 2.24 0
7 REC PUMP-4 2.24 0
8 REC PUMP-5 2.24 0
9 REC PUMP-6 2.24 0
10 BLOWER-1 22.38 0
11 BLOWER-2 22.38 0
12 BLOWER-3 22.38 0
13 DAMPER-1 0.37 0
14 DAMPER-2 0.37 0

15 DAMPER-3 0.37 0
I3 AMMONIA SCRUBBER
1 REC PUMP-1 2.24 0
2 REC PUMP-2 2.24 0
3 DAMPER -1 0.37 0
4 DAMPER -2 0.37 0
5 BLOWER-1 9.33 0
6 BLOWER-2 9.33 0
7 ED PUMP 0.52 0
0
I4 SOLVENT SCRUBBER 0
1 BLOWER-1 11.19 0
2 BLOWER-2 11.19 0
3 DAMPER-1 0.37 0
4 DAMPER-2 0.37 0
0
I5 GENERAL SCRUBBER
1 BLOWER-1 18.65 0
2 BLOWER-2 18.65 0
3 BLOWER-3 18.65 0
4 BLOWER-4 18.65 0
5 DAMPER-1 0.37 0
6 DAMPER-2 0.37 0
7 DAMPER-3 0.37 0
8 DAMPER-4 0.37 0
16 PCS SYSTEM AT TERRACE(5NOs-EACH.3.0KW) 15
TOTAL 144.28 0

J PURE AIR SYSTEM
1 AIR COMPRESSOR-1 0 74.6
2 AIR COMPRESSOR-2(S) 0 0
3 HEATER FOR CATALYTIC CONVERTER 0 29.84
4 HEATER-1 FOR AIR DRYER 0 4.54
5 HEATER-2 FOR AIR DRYER(S) 0 0
6 HOT AIR BLOWER FAN-1 0 0.22
7 HOT AIR BLOWER FAN-2 0 0
8 CONTROL PANEL CIRCUITS 0 0.5
WITH STAND-BY LOAD
WITHOUT STAND-BY LOAD
0 109.7
K HVAC HIGH SIDE
1 PRIMARY PUMP(6/11C)-1 22
3 PRIMARY PUMP(6/11C)-3 (standby) 22
6 PRIMARY PUMP(14/19C)-3 (standby) 22
7 HOT WATER PUMP-1 3
8 HOT WATER PUMP-2 (standby) 3
9 PROCESS COOLING PUMP-1 22
10 PROCESS COOLING PUMP-2 (standby) 22
11 EXPANSION TANK PUMP-1 0.63
12 EXPANSION TANK PUMP-2 0.63
13 EXPANSION TANK PUMP-3 (standby) 0.63
14 EXPANSION TANK PUMP-4 (standby) 0.63
15 MAKE-UP WATER PR.PUMP-1(W) 4
16 MAKE-UP WATER PR.PUMP-2(S) 4
17 LDB-12 FOR TERRACE LIGHTING 8.22
118.26
L HVAC LOW SIDE
1 PRODUCTION AREA MAU-1 15
2 PRODUCTION AREA MAU-2 15
3 SPARE 7.5
6 L1 SUPPORT AREA(AHU-9B) 2.2
7 L1 SUPPORT AREA(AHU-9A) 2.2
8 VENTILATION SUPPLY FOR CHEMICAL STORE 1.1

11 PDB 0
12 L-1 SERVER ROOM(AHU-06) 22
13 SPARE 3.7
14 L-1 STORES(AHU-07) 3.7
15 SERVICE AREA(AHU-10) 0.75
16 WASH ROOM(AHU-11) 0.37
17 SPARE 4.5
18 SPARE 4.5
19 SPARE 4.5
20 CDA BUILDING(AHU-18B) 1.1
21
CLEAN GOWNING+AIRLOCK+CLEAN
CONSUMABLES+WAFER INSPECTION ROOM(AHU-2) 15
22 SPARE 7.5
23 PRODUCTION AREA(MAU-3) 15
24 PRODUCTION AREA(MAU-4) 15
25 L-1 SERVER ROOM(AHU-06) 22
26 SPARE 4.2
27 SPARE 4.5
28 CDA (AHU-18C) 1.1
32 SERVICE AREA(AHU-10) 0.75
34
PACKING MATERIALS+WAFER INSP.+COSUMABLES(AHU-
4) 3.7
35 LABORATORY ROOM(AHU-5A) 2.2
36 RECIRCULATION AHU FOR FMCS(AHU-5B) 0.75
37
DOCUMENT ROOM+MEETINGROOM+ENGG.OFF(AHU-
08) 7.5
38 LDB 0
39 SPARE 1.5
41 AREA FEEDER-4 15.6
42 SPARE 15
TOTAL LOAD 222.72
FINAL LOAD FOR LINE-3 75.34
ADDITIONAL LOADS REQUIRED
1 TRAINING ROOM-AHU12a 1.5
2 TRAINING ROOM-AHU12b 1.5
3 TRAINING ROOM-AHU12c 1.5
4 TRAINING ROOM-AHU12d 1.5

5 UPW / WWT LAB AHU-15a 4.5
6 UPW / WWT LAB AHU-15b 4.5
7 EMERGENCY CONTROL ROOM AHU-17a 4.5
8 EMERGENCY CONTROL ROOM AHU-17b 4.5
9 NEW SECURITY BLDG AHU-20a 4.5
10 NEW SECURITY BLDG AHU-20b 4.5
11 UPW / WWT ROOM AHU-14a 2.2
12 UPW / WWT ROOM AHU-14b 2.2
13 UPW / WWT ROOM AHU-14c 2.2
14 FIRE DAMPER(16 Nos)-EACH-0.008KW TERRACE 0.128
15 B.FLY VALVE WITH ACTUATOR(12nos)-0.24kw CHILLER 2.88
16
3-WAY MIXING VALVE(17nos)-0.004kw each AHU
OUTLET 0.06
17 SOLENOID VALVE(7nos)-EACH-0.0083kw FCU OUTLET 0.0412
TOTAL LOAD 42.7092
M SPECIAL GASES
1 EQUIPMENT LOAD 8 0
2 LIGHTING LOAD 0.96 0
3 POWER LOAD 5 0
4 OTHER LOADS
13.96
N CHEMICAL SUPPLY
2 POWER LOAD 0 0
3 OTHER LOADS 0 0
0
O CHEMICAL DISTRIBUTION MODULE
1 EQUIPMENT LOAD(CONTROL CABINET) 5 0
2 LIGHTING LOAD 0.32 0
3 POWER LOAD 4 0
4 OTHER LOADS 0 0
9.32
P SECURITY&WEIGH BRIDGE
2 LIGHTING LOAD 0 0.32
3 POWER LOAD 0 0.8
9.12
Q BMS SYSTEM
2 LIGHTING LOAD 0 0

3 POWER LOAD 0 0
3
R EXTERNAL POWER SUPPLY
1 HT SWITCH YARD 1.5 0
3 FIRE HYDRANT SYSTEM 275
4 LIFT A & B 30
Total power requirement by considering diversity factor of 0.7 for utilities &
0.4 for tools.
CONNECTED/REQUIRED
LOAD TO OPERATE
LINE-3
LOAD IN KW
W/O.
S/BY
LOAD IN
KW
W/O.
S/BY
DESCRIPTION UPS UPS
DIRECT
GRID
DIRECT GRID
A TOOLS LOAD 867 867 0 0
B LIGHTING DB's 6.81 6.81 18.9 18.9
C POWER DB's 34.8 34.8 12 12
D DG PDB 0 0 61.53 61.53
E CDA 0 0 181.6 90.8
F WWT PANEL 0 0 67.5 34
G(G1) UPW-PLC-1 0 0 114.85 69.85
G(G2) UPW-PLC-2 87.3 70.65 0 0
H PROCESS CHILLED WATER 180 90 835.25 835.25
I SCRUBBER & EXHAUST 230.26 144.28 0 0
J PURE AIR 0 0 109.7 109.7
K HVAC HIGH SIDE 0 0 200.74 118.26
L HVAC LOW SIDE 0 0 222.72 75.34
M SPECIAL GASES 13.96 13.96 0 0
N CHEMICAL SUPPLY 12 5 0 0
O
CHEMICAL DISTRIBUTION
MODULE 9.32 9.32 0 0
P
SECURITY & WEIGH
BRIDGE 0 0 9.12 9.12
Q BMS SYSTEM 3 3 0 0
R EXTERNAL POWER SUPPLY 1.5 1.5 305 305
S
LEV-00 UPS VENTILATION
PANEL 45.5 22.75 0 0
T
LEV-00 UPS
LIGHTING&POWER 2.6 2.6 0 0
TOTAL CONNECTED LOAD 1494.05 1271.67 2138.91 1739.75

Diversity
Factor
UtIlity Loads 2139.42 0.7 1497.594
Line 3 Tools Loads 867 0.4 346.8
TOTAL Load with
diversity factor
considered
1844.394 KW
Lighting
Basic Terms in Lighting System and Features
Lamps
Lamp is equipment, which produces light. The most commonly used lamps are described briefly
as follows:
• Incandescent lamps:
Incandescent lamps produce light by means of a filament heated to incandescence by the flow
of electric current through it. The principal parts of an incandescent lamp, also known as GLS
(General Lighting Service) lamp include the filament, the bulb, the fill gas and the cap.
• Reflector lamps:
Reflector lamps are basically incandescent, provided with a high quality internal mirror, which
follows exactly the parabolic shape of the lamp. The reflector is resistant to corrosion, thus
making the lamp maintenance free and output efficient.
• Gas discharge lamps:
The light from a gas discharge lamp is produced by the excitation of gas contained in either a
tubular or elliptical outer bulb.
The most commonly used discharge lamps are as follows:
• Fluorescent tube lamps (FTL)
• Compact Fluorescent Lamps (CFL)
• Mercury Vapour Lamps
• Sodium Vapour Lamps
• Metal Halide Lamps
Luminaire
Luminaire is a device that distributes, filters or transforms the light emitted from one or more lamps.
The luminaire includes, all the parts necessary for fixing and protecting the lamps, except the lamps

themselves. In some cases, luminaires also include the necessary circuit auxiliaries, together with the
means for connecting them to the electric supply. The basic physical principles used in optical
luminaire are reflection, absorption, transmission and refraction.
Control Gear
The gears used in the lighting equipment are as follows:
Ballast:
A current limiting device, to counter negative resistance characteristics of any discharge lamps. In
case of fluorescent lamps, it aids the initial voltage build-up, required for starting.
Ignitors:
These are used for starting high intensity Metal Halide and Sodium vapour lamps.
Illuminance
This is the quotient of the illuminous flux incident on an element of the surface at a point of surface
containing the point, by the area of that element.
The lighting level produced by a lighting installation is usually qualified by the illuminance produced
on a specified plane. In most cases, this plane is the major plane of the tasks in the interior and is
commonly called the working plane. The illuminance provided by an installation affects both the
performance of the tasks and the appearance of the space.
Lux (lx)
This is the illuminance produced by a luminous flux of one lumen, uniformly distributed over a
surface area of one square metre. One lux is equal to one lumen per square meter.
Luminous Efficacy (lm/W)
This is the ratio of luminous flux emitted by a lamp to the power consumed by the lamp. It is a
reflection of efficiency of energy conversion from electricity to light form.
Colour Rendering Index (RI)
Is a measure of the degree to which the colours of surfaces illuminated by a given light source
confirm to those of the same surfaces under a reference illuminent; suitable allowance having been
made for the state of Chromatic adaptation.
Lamp Types and their Features
Recommended Illuminance Levels for Various Tasks / Activities / Locations
Recommendations on Illuminance : The minimum illuminance for all non-
working interiors, has been mentioned as
20 Lux (as per IS 3646). A factor of
approximately 1.5 represents the smallest
significant difference in subjective effect of

illuminance. Therefore, the following scale
of illuminances is recommended.
Scale of Illuminance: The higher value (H) of the range should
be used at exceptional cases where low reflectances or contrasts are present in the task,
errors are costly to rectify, visual work is critical, accuracy or higher productivity is of great
importance and the visual capacity of the worker makes it necessary.
Similarly, lower value (L) of the range may be used when reflectances or contrasts are unusually
high, speed & accuracy is not important and the task is executed only occasionally.
Recommended Illumination :
The following Table gives the recommended illuminance range for different tasks and activities
for chemical sector. The values are related to the visual requirements of the task, to user's
satisfaction, to practical experience and to the need for cost effective use of energy.(Source IS
3646 (Part I) : 1992).
Chemicals Petroleum, Chemical and Petrochemical works
Exterior walkways, platforms, stairs and
ladders
30-50-100
Exterior pump and valve areas 50-100-150
Pump and compressor houses 100-150-200
Process plant with remote control 30-50-100
Process plant requiring occasional manual
intervention
50-100-150
Permanently occupied work stations in
process plant
150-200-300
Control rooms for process plant 200-300-500
Pharmaceuticals Manufacturer and Fine chemicals manufacturer
Pharmaceutical manufacturer
Grinding, granulating, mixing, drying,
tableting, sterilising, washing, preparation
of solutions, filling, capping, wrapping,
hardening
300-500-750
Fine chemical manufacturers
Exterior walkways, platforms, stairs and
ladders
30-50-100

Process plant 50-100-150
Fine chemical finishing 300-500-750
Inspection 300-500-750
Soap manufacture
General area 200-300-500
Automatic processes 100-200-300
Control panels 200-300-500
Machines 200-300-500
Paint works
General 200-300-500
Automatic processes 150-200-300
Control panels 200-300-500
Special batch mixing 500-750-1000
Colour matching 750-100-1500
Design LUX level for TATA BP Solar :
LUMINAIRE AREA RECOMMENDE
D LUX.LEV
Expecte
d Lux
level
with
the
availabl
e
fittings
TYPE OF
FITTING
NUMBER
OF FITTINGS
TOTAL LOAD
IN WATTS
CABLE SIZE
STREET LIGHT
(EXTERNAL
LIGHTING) 50
80
HPMV 11 Nos 8375W
4Cx10mm
2
Arm Cu
Cable
TERRACE
LIGHTING 50 73 HPVC 44 Nos 8220W
4Cx25mm2
Arm Cu
Cable
SECURITY
&WEIGHBRIDGE 300 400 deco FIL 4Nos 320W
3Cx4mm2 Arm Cu
Cable
DG-GF 300 330 Indl FIL 8Nos 576W
4Cx16mm2
Arm Cu
Cable

DG-FF 200 210 Indl FIL 28 Nos
2080W+560
W
4Cx16mm
2
Arm Cu
Cable
UPW/WWT 200 210 HPMV
16 Nos+3
Nos
4000W+750
W
(RP+UPS)
4Cx10mm2 Arm Cu
Cable
CHEMICAL
SUPPLY ROOM 200 280 FP, F/L 4 Nos 320W
4Cx4mm2 Arm Cu
Cable
SP GAS ROOM 300 380 FP FIL 12 Nos 960W
4Cx16mm
2
Arm Cu
Cable
CDA GF 150 200 Indl FIL 10+4 1120W
4Cx16mm2 Arm Cu
Cable
CDA FF 150 200 Indl FIL 10+4 1280W
4Cx16mm2 Arm Cu
Cable
SWITCHYARD
LIGHTING
(OUTDOOR) 50 87.3 Flood Light 8 Nos 3200W
4Cx6mm2 Arm Cu
Cable
HT ROOM
LIGHTING 300 328 Ind FIL 9 Nos 720W
LT ROOM
LIGHTING 300 516 Ind FIL 6 Nos 480W
BATTERY ROOM
LIGHTING 100 243 Ind FIL 2Nos 160W
CLEAN ROOM
AREA 500 550
Teardrop
FTL 465 Nos 16740W
4Cx10mm2 Arm Cu
Cable
PRODUCTION
SUPPORT AREAS 300-350 360 CFL 435 Nos 42060W As per Load
TRANSFORMER
AREA (
OUTDOOR) 50 90.5
WELL
LUMINAIRE
18 Nos 1280W
3Cx4mm2 Arm Cu
Cable
Upw level1
building 300 Ind FIL iv
For TATA BP the lux level required will be equivalent to that of a pharmaceutical industry.
BUILDING MANAGEMENT SYSTEM
Building Management System is for the integration of all utilities for effective management &
operation of utilities . It provides us a single podium where in we can control & observe the total
plant.
BMS Details for HVAC in TBPS
As per Drg.

Sl.N
o. BMS work description
Unit
description
No. of
Motoriz
ed
valves
No.of
pressu
re
switch
No. of
Temperatu
re sensor
N
o
of
T
&
R
H
1 Chiller Unit :
3 nos.
325TR
Chiller , 2
nos. 267TR
chillers
12 10 10
Cable Laying
Fixing of pressure switch
Fixing of temperature sensor
Fixing of motorized valves
Motorized valves
Tagging at site
Termination of cables
2 Primary pump:
3 nos.
200CMH , 3
nos.
170CMH
12
Cable Laying
Fixing of pressure switch
Fixing of temperature sensor
Tagging at site
Termination of cables.
3 Hot water pumps
2 nos.
20CMH
4 4
4
MAU & AHU supply line in chiller
foundation 6 deg C
1
MAU & AHU return line in chiller
foundation 11 deg C
1
Cable Laying
Tagging
Cable Termination
5
PCW supply pipeline in chiller
foundation 14 deg C
1
PCW return pipeline in chiller
foundation 19 deg C
1
Cable Laying
Tagging
Cable Termination
6
PCW supply pipeline near heat
exchanger. 14 deg C
1
PCW return pipeline near heat
exchanger 19 deg C
1
Cable Laying

Tagging
Cable Termination
7 MAU & AHU
Fixing of Motorized valves. 8
Fixing of T & RH sensors 4
Cable Laying
Tagging at site
Termination of cable
8 Panel-4 nos.
Panel Installation
Cable Termination
Power supply for panel
Software download
Total Qty. 20 26 20 4
BMS details for Non-HVAC in TBPS :
Building Management System - Excluding HVAC - As per I/p ,O/p Summary
Sl.
No
. Utilities
Mo
d
bus
Anal
og
I/p
Digit
al
I/p
Commu
nicatio
n
MSTP
Controll
er
Master
Controll
er
Expansio
n
module
1
Chemical Dispensing
Module
CDM Microprocessor
Supply Panel
RS-
485 1
CDM Microprocessor
Main Panel
RS-
485 1
2 Compressed Dry Air
CDA Microprocessor
Panel
RS-
485 1
3 66KV Substation
66KV HT Yard
RS-
485 1

4 11KV System
HT Yard 11KV
RS-
485 1
5 LT
LV Panel 415 V
RS-
485 1
6
16/20 MVA
Transformer
1 1
Winding Temperature 1
Oil Temerature 1
7 2MVA Transformer
Winding Temperature 1
Oil Temerature 1
8
Life safety & Security-
HT Yard
1 1Fire HYD Press Switch 1
Gas Press Switch 1
Water Level Switch 1
9
Un-interrupted Power
Supply
Hydrogen Detector
RS-
485 1
Earth Leak Sensor
RS-
485 1
Instantaneous over
current
RS-
485 1
Battery fault relay
RS-
485 1
Exhaust failure
RS-
485 1
Earth leakage in DC
power side
RS-
485 1
Over Voltage relay
RS-
485 1
10 Waste Water System
WWT Panel
RS-
485 1
11 Gas abatement
Gas abatement panel
RS-
485 1

12 Ultra Pure Water
UPW Panel
RS-
485 1
13 Diesel Storage
High level Switch 1
Low level Switch 1
14
Foam Suppression
System 6
15
Pure air Dew Point
Indicator 1
16 Chiller Soft Interface
Ch1
RS-
485 1
Ch2
RS-
485 1
Ch3
RS-
485 1
Ch4
RS-
485 1
Ch5
RS-
485 1
17 Acid Exhaust
PH Sensor 1
1 1
Flow Switch 1
Diff. Pressure Switch 1
Low level tank 1
Temp. Transmitter 1
18 Exhaust System
18.
1 Nox Scrubbing System
1 1
Power 'ON' status 1
A/M Status 1
ON/OFF Status 1
ON/OFF CMD 1
Inlet damper Status 1
Inlet damper control 1
Outlet daper status 1

Outlet damper control 1
18.
2 Acid Exhaust System
1
Power 'ON' status 1
A/M Status 1
ON/OFF Status 1
ON/OFF CMD 1
Outlet damper status 1
18.
3
Ammonia Scrubber
System
1
Power 'ON' status 1
A/M Status 1
ON/OFF Status 1
ON/OFF CMD 1
18.
4
General Exhaust
System
1
Power 'ON' status 1
A/M Status 1
ON/OFF Status 1
ON/OFF CMD 1
18.
5
Solvent Exhaust
System
1
Power 'ON' status 1
A/M Status 1
ON/OFF Status 1

ON/OFF CMD 1
18.
6 Silane Exhaust System
1
Power 'ON' status 1
A/M Status 1
ON/OFF Status 1
ON/OFF CMD 1
19 Fire Alarm System
Data Converter
RS-
485 1
20 Process Tools
Wafer Inspection Tools
RS-
485
Automation,Load
Intex(WC-1)
RS-
485 1
Automation Wet
Bench,Tex. Acid WC-1
RS-
485 1
Automation unloader
for WC-1
RS-
485 1
Tube dope diffusion(5
Tube)
RS-
485 1
Automation , wafer
resistivity & casseting
tool
RS-
485
Automation,load InOx
(WC-2)
RS-
485 1
InOx Wetbench(oxide
etch only) WC-2
RS-
485 1
Automation , unload
InOx(WC-2)
RS-
485 1
Tube PECVD(4 Tube)
RS-
485 1

Vaccum pump
RS-
485
PECVD purge panel
RS-
485 1
Boat etching for PECVD
tubes
RS-
485 1
Pre-deposition tools
RS-
485
Pump for predep
RS-
485
Drying oven
RS-
485 1
Dryer
RS-
485 1
Co-fire
RS-
485
Laser Edge Islation
RS-
485
Cell Tester & Sorter
RS-
485 1
Total Qty : 7 62 35 3 4 6

Fire Alarm System

Chillers
Operation & Control Philosophy of Chillers
Variable Flow System

The chilled water system provides low (6/11°C) and medium (14/19°C) temperature chilled
water as the cooling agent for the plant cooling water system .
Total nos. Of chillers :
3nos. Of 325 Tr chillers
2 nos. Of 267 Tr chillers
2 nos. 325 Tr chillers is used for AHU(Air Handling Unit) & MAU(Make-up Air Unit).
2 nos. 267 Tr chillers is used for Process Cooling Water.
1 nos. 325 Tr chillers is used for Stand-by .
Start-up sequence of Chillers
Chiller System Startup Sequence
o Start secondary water pump with the lowest
accumulated run hours based on the Low or Medium temperature chiller
starting
o Start Cooling tower with the lowest
accumulated run hours
Start Cooling tower Fan
Open cooling tower outlet valve
Open cooling tower inlet valve
o If first chiller is starting irrespective of Low
or medium temperature , condenser inlet valve of the respective chiller opens
and then condenser water pump with the lowest accumulated run hours start ,

otherwise condenser pump starts and then after a delay condenser inlet valve
opens.
o If first chiller is starting Low or medium
temperature ,evaporator inlet valve of the respective chiller opens and then
primary chilled water pump with the lowest accumulated run hours start ,
otherwise primary chilled water pump starts and then after a delay evaporator
inlet valve opens.
o After a five second time delay start Chiller unit.
Heat Exchanger Operation for Medium Temperature Chillers.
If at any time the Medium Temperature Chillers capacity is not sufficient, LTCHW
(low temp Chilled water) can be used to supplement the Medium Temperature
system via the MTCHW(medium temp chilled water) Heat Exchanger and
circulation pump.
During start sequence , Open modulating valve 100% with PID in freeze mode for
the purpose of cooling the primary side of heat exchanger
Open isolation valve located on secondary side of Heat Exchanger and confirm
open
After confirm open of valve Start pump
After confirm Start pump , place PID in Auto mode
During stop sequence, pump is stopped , valve is closed , PID is placed in freeze
mode with TCV close.
During confirm valve failure , valve is closed , pump is stopped , PID is placed in
freeze mode with TCV close.

Process Cooling Water
Instrumentation & Control of Process Cooling Water System
General Description
Closed loop(usually), variable flow cooling system for Fab tools
Pumps, AFDs, filters, heat exchangers, distribution system, chemical treatment and makeup
UPW provides for makeup (leakage, blowdown) & minimum pressure
PCW area frequently a wet area (filters, heat exchangers)
Pumps on standby power, at least one
Pumps fitted with VFD’s
Common suction return and common discharge piping.
75KW motor with VFD.
2 nos 10-micron cartridge filters in parallel .
Resistivity (conductivity) and temperature commonly monitored on filter PCWS outlet.
Typically 2 exchangers, normally one exchanger sized full load with the other 100%
redundant (manual switch)
Temperature: PCWR Inlet 18 deg C, PCWS outlet 14 deg C.
Pressure control by Central header (in Subfab) PID loop setpoint reset by sub header lowest
delta P.
Standby pump starts if a pump fails.
Automatic temperature controller via chiller which get the input via temperature sensors.
Standby CHW pump starts on low CHW delta P & stops on sustained high CHW delta P or
manual reset
Standby CHW pump piped in parallel with normal line/check valve

NETWORKING :
Basics :
Transport Control Protocol/Internet Protocol is the default wide area network protocol that provides
communication across diverse interconnected networks.
An IP address is assigned to each node connected to the TCP/IP network.
It connects up Server/Client PCs which is used for the process data interface.
The network is operated on Glass fiber-optic cable.
VSD devices and Remote IOs communicate with PLC through Profibus communication
Typical PLC Communication
ETHERNET TCP/IP
FOR PLC ETHERNET TCP/IP
ETHERNET TCP / IP
ETHERNET TCP / IP
ETHERNET TCP /ETHERNET TCP /
#1 #2 #3 #4 #5 #6 #7 #8 #9 #10 #11 #12 #13 #14 #15 #16 #17 #18 #19 #20
IO SERVERS
REDUNDANT AOS
#1A #1B #2A #2B #3A #3B #4A #4B #10A #10B#5A #5B #6A #6B #7A #7B #8A #8B #9A #9B
GR
HISTORIAN
INF.SRVR
TAPE BKUP
ENGG STN 3rd
PARTY
ENGG
STATION
(PLC) CLI CLI CLI#3 CLI #4
ENGG
STATION
(SCADA)
UPW /
WWT
CNTL
ROOM
UPW /
WWT
CNTL
UPW /
WWT
CNTL
ROOM
UPW /
WWT
CNTL
ROOM
UPW /
WWT
ELECT
ROOM
UPW /
MAKEUP
CNTL
ROOM
CU /
SLURRY
CUB LVL 2 CUB LVL 2 CUB LVL 2 CUB LVL 2 CUB LVL 2 CUB LVL 1 CUBLVL 1 FAB LVL 1
TOOLS
UPW WWT
LIFT
STN
SPEC
GAS
CHEMICAL
SLURRY
GAS
DETECTION TOOLS
REDUNDANT AOS REDUNDANT AOS REDUNDANT AOS REDUNDANT AOS
INF.CLIENT

Typical PLC Communication
OLM(Optical Link Module)
Profibus OLMs are Designed to be used in optical PROFIBUS field bus networks.
It will convert the electrical PROFIBUS interfaces into optical PROFIBUS interfaces
and vice-versa
Each Module has Two or Three mutually independent ports, which in turn consist of
a transmitting and a receiving component.
Complete PROFIBUS field bus network with modules in Line, Star or ring Topology
The 4 basic Input/Output modules used are as follows:
• 16 points digital input module
• 16 points digital output module
• 8 channel analog input module

• 8 channel analog output module
Basic communication module is as follow:
• RS485 communication module
MODBUS Communication
This Driver enables you to establish a communications link between communication module and “
Modbus capable “ control systems.
Process Device Management (PDM)
PDM is a software package for configuring, parameterizing, commissioning and maintaining Analog
devices which have HART (Highway Accessible Remote Transducers) compatibility.
The basis for device integration is the EDDL (Electronic Device Description Language).
HARDWARE SYSTEM MAINTANCE
Ensure proper ventilation at all control panel.
Check for loose connection at all interface points.
Ensure blown fuse are replaced immediately with the correct size.
Know the reason why a MCB tripped.
SOFTWARE SYSTEM MAINTENANCE
Backup of daily runtime database.
Backup of any program changes.
Ensure both backup programs and operation programs are the same
Maintain all documents related to the plant operation.
Maintain all system software (including updates) so that the operating system and
application program can be reinstalled with ease.

Integrate network security for the complete system.
NB : The Server PCs and Client PCs should be solely used for the purpose for process
visualisation and plant operation.
Do not use it for other purpose like internet access, email access, software not meant for plant
operation and etc.
Failure to do so can lead to system corruption or virus attack.
Uninterrupted Power Supply
Basics
An UPS system is an alternate or backup source of power with the electric utility company being
the primary source. The UPS provides protection of load against line frequency variations,
elimination of power line noise and voltage transients, voltage regulation, and uninterruptible
power for critical loads during failures of normal utility source. An UPS can be considered a
source of standby power or emergency power depending on the nature of the critical loads.
UPS Can be of Two types :
1. Static type.
2. Rotary type.
Static type is the most common type of UPS System used .

Static Type UPS
Description of UPS System Installed in TATA BP Solar
UPS Data Sheet
Capacity 500KVA/450KW
RectifierInput
Rated Voltage 415V
AC Power Input Mode 3 Ph. 3 Wire
Power Factor 0.83 to 0.95 lag or better using 12 Pulse rectifier.
THD <5%
Frequency Range 47 to 53 HZ
Rectifier Efficiency 97%
UPSOutput
Voltage Regulation 415+/-1%
Voltage Transient response 5%
Linear voltage distortion <2%
Non-Linear voltage distortion <5%
Power Factor 0.9
Frequency Sync. Range 50+/-2.5Hz
Phase Displacement(3 Ph) 120+/-1 deg.
Type of UPS System used in TATA BP :
Double Conversion- 12 Pulse Rectifier

Modes of Operation Considered for the UPS in TBPS :
1. AC I/p Mode.
2. Bypass Mode.
3. Maintenance Mode.
Distortion of Power Supply

Following Alarm Indication is provided for the UPS System :
a) I/p & bypass A/C under voltage , over voltage , under frequency & over frequency .
b) Input / bypass input & inverter out of Synchronization .
c) Input & bypass single phasing .
d) Input & bypass reverse phase sequence .
e) Battery system alarm .
f) Control power failure .
g) Fan failure .
h) UPS overload .
i) Battery Operation end .
j) Battery under voltage shot down .
k) Battery charging control fault .
l) Isolation t/f over heat .
m) Inverter fuse blow .
n) Inverter power supply fault .
o) Inverter o/p under voltage / over voltage .
p) Inverter contactor open .
q) Inverter sensor fault .
Air Exchange Calculation for the UPS

Batteries
Basics
Battery is a device that converts chemical energy into electrical energy.
Battery is a collection of cells.
Cells can be classified into two types:
1. Primary Cells : These cannot be recharged.
2. Secondary Cells : These can be recharged.
In TATA BP we use OPzS 2V , 1300Ah Battery .
Each battery bank has 240 nos. Of cells .
The above batteries have the following components :
1. Container :- Styrene Acrylo Nitrile(SAN) Polymer.

2. Anode Plate :- Lead peroxide .
3. Cathode Plate :- Sponge lead .
4. Electrolyte :- Solution of sulphuric acid & water .
Benefit of OPzS Batteries :
1. Maintenance need : These batteries have very low antimony positive plate and lead
calcium negative plate minimizes electrolysis & therefore the water loss will be less.
2. Internal Short Circuit : OPzS batteries have much thicker phenolic resin based rigid
synthetic separators compared to normal tubular batteries & hence the probability of
internal short circuit is much less compared to other batteries.
Diesel Generator

Auto Change over sequence :

Waste Heat Recovery in DG Sets
A typical energy balance in a DG set indicates following break-up:
Input : 100% Thermal Energy
Outputs : 35% Electrical Output
4% Alternator Losses
33% Stack Loss through Flue Gases
24% Coolant Losses
4% Radiation Losses
Among these, stack losses through flue gases or the exhaust flue gas losses on account of
existing flue gas temperature of 350
o
C to 550
o
C, constitute the major area of concern towards
operational economy. It would be realistic to assess the Waste Heat Recovery (WHR) potential
in relation to quantity, temperature margin, in kcals/Hour as:
Potential WHR = (kWh Output/Hour) × (8 kg Gases / kWh Output)
× 0.25 kcal/kg
o
C × (t
g
– 180
o
C)
Where, t
g
is the gas temperature after Turbocharger, (the criteria being that limiting exit gas
temperature cannot be less than 180
o
C, to avoid acid dew point corrosion), 0.25 being the
specific heat of flue gases and kWh output being the actual average unit generation from the set
per hour. For a 1100 KVA set, at 800 KW loading, and with 480
o
C exhaust gas temperature, the
waste heat potential works out to:
800 kWh × 8 kg gas generation / kWh output × 0.25 kCal/kg
o
C
× (480 – 180), i.e., 4,80,000 kCal/hr
While the above method yields only the potential for heat recovery, the actual realisable
potential depends upon various factors and if applied judiciously, a well configured waste heat
recovery system can tremendously boost the economics of captive DG power generation.
The factors affecting Waste Heat Recovery from flue Gases are:
a) DG Set loading, temperature of exhaust gases
b) Hours of operation and
c) Back pressure on the DG set
* Consistent DG set loading (to over 60% of rating) would ensure a reasonable exit flue gas
quantity and temperature. Fluctuations and gross under loading of DG set results in erratic
flue gas quantity and temperature profile at entry to heat recovery unit, thereby leading to
possible cold end corrosion and other problems.
For TATABP the waste heat potential (WHP) works out to be 1,200,000kCal/hr.
Considering 2000KW as the KVA rating of the DG is 2150KVA

Fire Protection System

Utilities requirement for the Solar Power
Plant
ULTRA PURE WATER SYSTEM

PURE AIR PLANT

COMPRESSED DRY AIR

Dew point at
atmospheric
pressure
Moisture Content
0 deg. C 3800 ppm
(-)5 deg. C 2500 ppm
(-)10 deg. C 1600 ppm
(-)20 deg. C 685 ppm
(-)30 deg. C 234 ppm
(-)40 deg. C 80 ppm
(-60) deg. C
(-80) deg. C
6.5 ppm
0.3 ppm

SCRUBBING SYSTEM

v
Description of Solar cell Manufacturing Process :
INTRODUCTION
Solar PV (Photovoltaic) Cells for Power Generation
A solar cell, or photovoltaic cell, is a semiconductor device that converts photons (light) into
electricity. Fundamentally, the device needs to fulfill only two functions:
1. Photogeneration of charger carriers (electrons and holes) in a light-absorbing material, and
2. Separation of the charge carriers, preferably to a conductive contact that will transmit the
electricity.
This conversion is called the photovoltaic effect, and the field of research related to solar
cells is known as photovoltaics.
BASIC CONCEPT BEHIND SOLAR POWER GENERATION
The solar cells that you see on calculators and satellites are photovoltaic cells or modules
(modules are simply a group of cells electrically connected and packaged in one frame).
Photovoltaic, as the word implies (photo = light, voltaic = electricity), convert sunlight directly into
electricity. Once used almost exclusively in space, photovoltaic are used more and more in less
exotic ways. They could even power your house. How do these devices work?
Photovoltaic (PV) cells are made of special materials called semiconductors such as silicon,
which is currently the most commonly used. Basically, when light strikes the cell, a certain portion of
it is absorbed within the semiconductor material. This means that the energy of the absorbed light is
transferred to the semiconductor. The energy knocks electrons loose, allowing them to flow freely.
PV cells also all have one or more electric fields that act to force electrons freed by light absorption
to flow in a certain direction. This flow of electrons is a current, and by placing metal contacts on the
top and bottom of the PV cell, we can draw that current off to use externally. For example, the
current can power a calculator. This current, together with the cell's voltage (which is a result of its
built-in electric field or fields), defines the power (or wattage) that the solar cell can produce.

That's the basic process, but there's really much more to it. Let's take a deeper look into one
example of a PV cell: the single crystal silicon cell.
SILICON AS PHOTOVOLTAIC MATERIAL
SILICON
Silicon has some special chemical properties, especially in its crystalline form. An atom of
silicon has 14 electrons, arranged in three different shells. The first two shells, those closest to the
center, are completely full. The outer shell, however, is only half full, having only four electrons. A
silicon atom will always look for ways to fill up its last shell (which would like to have eight
electrons). To do this, it will share electrons with four of its neighbor silicon atoms. It's like every
atom holds hands with its neighbors, except that in this case, each atom has four hands joined to
four neighbors. That's what forms the crystalline structure, and that structure turns out to be
important to this type of PV cell.
We've now described pure, crystalline silicon. Pure silicon is a poor conductor of electricity
because none of its electrons are free to move about, as electrons are in good conductors such as
copper. Instead, the electrons are all locked in the crystalline structure. The silicon in a solar cell is
modified slightly so that it will work as a solar cell
SILICON IN SOLAR CELLS
A solar cell has silicon with impurities -- other atoms mixed in with the silicon atoms,
changing the way things work a bit. We usually think of impurities as something undesirable, but in
our case, our cell wouldn't work without them. These impurities are actually put there on purpose.
Consider silicon with an atom of phosphorous here and there, maybe one for every million silicon
atoms. Phosphorous has five electrons in its outer shell, not four. It still bonds with its silicon
neighbor atoms, but in a sense, the phosphorous has one electron that doesn't have anyone to hold
hands with. It doesn't form part of a bond, but there is a positive proton in the phosphorous nucleus
holding it in place.

When energy is added to pure silicon, for example in the form of heat, it can cause a few
electrons to break free of their bonds and leave their atoms. A hole is left behind in each case. These
electrons then wander randomly around the crystalline lattice looking for another hole to fall into.
These electrons are called free carriers, and can carry electrical current. There are so few of them in
pure silicon, however, that they aren't very useful. Our impure silicon with phosphorous atoms
mixed in is a different story. It turns out that it takes a lot less energy to knock loose one of our
"extra" phosphorous electrons because they aren't tied up in a bond -- their neighbors aren't holding
them back. As a result, most of these electrons do break free, and we have a lot more free carriers
than we would have in pure silicon. The process of adding impurities on purpose is called doping,
and when doped with phosphorous, the resulting silicon is called N-type ("n" for negative) because
of the prevalence of free electrons. N-type doped silicon is a much better conductor than pure
silicon is.
Actually, only part of our solar cell is N-type. The other part is doped with boron, which has
only three electrons in its outer shell instead of four, to become P-type silicon. Instead of having free
electrons, P-type silicon ("p" for positive) has free holes. Holes really are just the absence of
electrons, so they carry the opposite (positive) charge. They move around just like electrons do.
N-TYPE PLUS P-TYPE SILICON
The interesting part starts when you put N-type silicon together with P-type silicon.
Remember that every PV cell has at least one electric field. Without an electric field, the cell
wouldn't work, and this field forms when the N-type and P-type silicon are in contact. Suddenly, the
free electrons in the N side, which have been looking all over for holes to fall into, see all the free
holes on the P side, and there's a mad rush to fill them in.
Before now, our silicon was all electrically neutral. Our extra electrons were balanced out by
the extra protons in the phosphorous. Our missing electrons (holes) were balanced out by the
missing protons in the boron. When the holes and electrons mix at the junction between N-type and
P-type silicon, however, that neutrality is disrupted. Do all the free electrons fill all the free holes?
No. If they did, then the whole arrangement wouldn't be very useful. Right at the junction, however,
they do mix and form a barrier, making it harder and harder for electrons on the N side to cross to
the P side. Eventually, equilibrium is reached, and we have an electric field separating the two sides.

The effect of the electric field in a PV cell
This electric field acts as a diode, allowing (and even pushing) electrons to flow from the P
side to the N side, but not the other way around. It's like a hill -- electrons can easily go down the hill
(to the N side), but can't climb it (to the P side).
So we've got an electric field acting as a diode in which electrons can only move in one
direction. Let's see what happens when light hits the cell.
MANUFACTURING OF SOLAR CELLS
Now we all know that the silicon is the material used for the production of the Solar Cells. In
fact, Solar cells are nothing but properly processed Silicon wafers. The Wafers will be normally
having the dimension of 125 Sq.mm.
PRODUCTION PROCESS
The Solar Cell manufacturing process will be having following major Steps.
1. Wafer Preparation
2. Wet Chemistry 1

3. Diffusion
4. Plasma
5. Wet Chemistry 2
6. PECVD (Plasma Etch by Chemical Vapor Deposition)
7. Front Contact Printing
8. Drying
9. Back Contact Printing
10. Co-Firing
11. Quality Testing and Electrical Sorting of Cells
Wafer Preparation
The wafers are normally got from wire-sawing the Silicon extrusion with a thickness of an
average of 250 microns. Then the wafers are slightly P-type doped using Boron. This process of
wire-sawing and P-type doping are normally done by Customer Company for the cell
manufacturing company.
In the cell manufacturing company, first the wafers are subjected to visual inspection using a
digital microscope to identify the following defects,
• Saw Damage
• Edge chip
• Edge Broke
• Thick Wafer
• Thin Wafer
After this inspection, the wafers are ready to the processing.

Wet Chemistry 1
The purpose behind subjecting wafers for wet chemistry 1 is saw Damage removal, Texturisation,
and Oxide removal.
1. Saw Damage Removal – This is to remove the Damage done by the Wire-saw on the
wafer surface at micro-level. The wafers are dipped in NaOH solution with controlled
condition to remove Damages.
2. Texturisation – The Silicon Wafers will be initially having very high surface smoothness.
This is undesired in case of Solar cells since it will deflect max. amount of light rays
falling on it. So some amount of irregularity in the wafer surface is provided using again
NaOH with different Concentration.
3. Oxide removal – Oxides if present in the solar cell surface will reduce the amount of
current passing to the storage by conducting it back to the cell surface. So if oxides are
there in the surface of the wafer, the efficiency of the solar cell decreases. Therefore, It
is suitably removed using Hydrofluoric Acid.
Manz – Loader.
The purpose of this equipment
is to load the raw cells for
further process.i.e WC -1 in this
context.

Diffusion
Diffusion is the heart of the Manufacturing Process of Solar cells. This is the time where the
wafer turns out to be a photovoltaic cell.
In Diffusion, the wafers are loaded inside a diffusion furnace. Two wafers at a time are made
back-to-back contact before loading so that one side of each wafer is not available for diffusion.
Then the wafers are heated up to 8800
C and at the same time phosphorus gas is exposed to the
wafer surface. So, one side of each wafers are hence doped with phosphorous resulting in N-type
doping on one side of the wafer.

Edge Isolation
During diffusion process edges of the wafers get diffused which provide shunt path between p and
n+
regions. To eliminate this shunt effect we have to etch some part of the silicon at the edges. For
this etching we are using plasma etching process.
Wet Chemistry 2

Wet chemistry-2 is used to remove the phosphorous silicate glass (PSG) which is deposited
during diffusion process. 4% concentration HF (Hydrofluoric Acid) is used for this process.
Plasma Enhanced Chemical Vapor Deposition (PECVD)
This is the process where Silicon Nitride is made to deposit on the surface of the Wafer using
the Chemical reactor machine called PECVD.
The SiN Coating is provided to the Wafer surface as Anti-Reflection Coating. Since it is
undesired to allow the light incident on the cell to get reflected, the wafers are coated with SiN in
order to trap some amount of the light inside the wafer or to make wafer absorb some amount of
light.
Front Contact Printing

The Wafer Surface is now provided with metallic Grid lines which are required for the conduction of
generated electric power to the Storage area. The Metal used to form grid lines is Pure Silver. Here
Front contact is done to the N-type doped region.
Drying
The wafers after Front contact printing, are now heated in a Drying furnace in order to solidify the
Contact gridlines.
Back Contact Printing

The Back side of the wafers, i.e, P-type doped surface is also printed with silver gridlines in
another fashion and also Aluminum paste is applied on the back surface excluding the surface with
silver contacts.
Co-Firing
The Cell is now suitably passed through different zones of temp. in a Furnace so as to make
the printed contacts solid.
Quality Testing and Electrical sorting of cells

The cells are now tested for Efficiency, Electrical Contact and other characteristics. Then the cells are
properly arranged inside a frame and electrically connected to a single source to collect all the
power generated to a single Region.
Below shown are the Front and Back side of the Solar cells after finishing all the processes.
FRONT SIDE BACK SIDE

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