WELCOME

GETs / MTs – 2008 Batch

POWER DISTRIBUTION
OF SMELTER PLANT

D.C. SAMAL
CHIEF MANAGER
(ELECTRICAL)
 INTRODUCTION
• Power is received from CPP at SMELTER at
an voltage level of 220KV
• The Power requirement of SMELTER can be
broadly classified into two categories:

1. DC power required for Aluminium Smelting in

Potlines
2. AC power required for the Auxiliary loads
catering to the Potlines. (e.g. cast house,
carbon area, utilities, etc.)
 SINGLE LINE DIAGRAM OF SMELTER SWITCHYARD

INCOMER- INCOMER- INCOMER- INCOMER- INCOMER-1

5 4 3 2 RPU

Aux. Aux. Aux. Aux.

Trf. 5 Trf. 4 Trf. 2 Trf. 1

11 KV 11 KV 11 KV
Switchgea Switchgea Switchgea
r r R R R R r
Room - 3 R R R R R R R R Room - 1 G G G G Room - 2
G G G G G G G G 4 3 2 1
4 3 2 1 4 3 2 1

POTLINE – 1 DC
POTLINE – 3 DC POTLINE – 2 DC
 POWER REQUIREMENT
• Total average power requirement of
Smelter Plant – 620 MW

• Power requirement of Potlines – 580 MW

• Power requirement of Smelter plant

auxiliaries – 37 MW

• Power requirement of Township – 3 MW

 11 KV NETWORK

220KV Inc-5 220KV 220KV 220KV 220KV

from CPP INC-4 INC-3 INC-2 INC-1

220KV BUS SECTION

DOUBLE BUS ISOLATOR
AUX. TR-5
220/11
AUX. TR-4 AUX. TR-2 AUX. TR-1 AUX. TR-3
37.5 MVA

11KV SWITCHGEAR-1
11KV SWITCHGEAR-3 11KV SWITCHGEAR-2

Potline-3 related Aux. loads Potline-1 & 2 related Aux. loads

-Township
-FTP 1, 2, 3 & 4
-FTP 5 & 6 -Strip Casting
-Compressor (Old)
-Compressor (New) -Cast House-1
-Cast House-2
-GAP-1
-GAP-2
-Bake Oven-1
-Roddingshop-2 -Roddingshop-1

-Bake Oven-2 -Duplex

-Water Block
 1A06 ( 11KV INCOMER-2 ) ( 11KV INCOMER-1 ) 1A10

VT
VT
11KV √3/ 110V √3
11KV √3/ 110V √3
CT CT

2500 / 1A CL - 0.5 2500 / 1A CL - 0.5

2500 / 1A CL – 5P10 2500 / 1A CL – 5P10
2500 / 1A CL - PS 2500 / 1A CL - PS
VCB 2500A
VCB 2500A
FRONT BUS 1AF
REAR BUS 1AR

VCB 800A
CT
400 / 1A
CL-0.5
400/1A
CL-5P10
1A01 1A02 1A03 1A04 1A05 1A07 1A08 1A09 1A11 1A12 1A13 1A14
WIRE POT SPARE POT CAP. POT TIE COMP. CARBON WATER STN.AUX STN.
HOUSE ROOM ROOM BANK LINE FEEDER HOUSE PLANT BLOCK TRF-1 AUX
S/S-19 AB S/S- CD S/S- 15 ANNEXE WITH 2ND S/S-14, S/S-16, S/S-22, TRF-2
10,11 12, 13 MVAR S/S-20, SWGR 15 17, 18 23
21 2A10

SINGLE LINE DIAGRAM OF 11KV SWITCHGEAR - 1

11KV CELLULAR SWITCHGEAR ROOM
 Load Centers
• The various load centers of Smelter plant constitute mainly the
following types of loads:
1. 11KV rated Motors
2. 6.6KV rated Motors
3. 415 Volt rated Motors and other equipments
4. 230 Volt rated Equipments

• A remote 11KV sub-station is provided for each load center.

• Power is stepped down from 220 KV level to 11KV level at the
Main Conversion Substation and distributed to the various 11KV
Remote substations.
• At the remote substations the Power distribution to the various
equipments of the load centers is done.
 11KV Remote Substations
Substation10 – Pot line1 FTP-1 Substation30 – Pot line3 FTP-5
Substation11 – Pot line1 FTP-2 Substation31 – Pot line3 FTP-6
Substation12 – Pot line2 FTP-3 Substation32 – PCRS-2
Substation13 – Pot line2 FTP-4 Substation33 – LPCS-2
Substation14 – Cast House - A Substation34 – GAP-2
Substation15 – Compressor House (old) Substation35 – Bake Oven – 2
Substation16 – GAP-1 Substation36 – Rodding shop-2
Substation17 – Bake Oven – 1 Substation37 – Comp. House new extn.
Substation18 – Rodding shop-1 Substation38 – Cast House-B
Substation19 – Ware House
Substation20 – PCRS-1
Substation21 – LPCS-1
Substation22 – Water Block
Substation23 – Billet Casting
Substation24 – Compressor House (new)
Substation25 – Strip Casting
Substation26 – HTF Boiler
 TYPICAL 11KV REMOTE SUBSTATION SLD

11KV 11KV
Incomer A Incomer B
11KV Double bus switchboard

11/ 6.6KV 11/.433KV

Transformers transforme
rs

11KV
Motor 415V LT
Switchboard
6.6KV
M M M M
Motor
To 415V rated Loads
415V LT SWITCHGEAR ROOM
 SINGLE LINE DIAGRAM OF 11KV DISTRIBUTION SYSTEM IN NALCO TOWNSHIP
T/S FDR-1 T/S FDR-2 Project Side
2A06 2A11 CISF
MC Room MC Room 4Pole CISF
500KVA
500 KVA Strip Casting
Pump House 7.5MVA, 11/11KV 7.5MVA, 11/11KV CISF
4 Pole
4 Pole ISOL.. TRF ISOL. TRF. 500KVA
Construction Pump S/S-11
House S/S
300MVA

INCOMING FDR-1 S/S-5 INCOMING FDR-2

CB WATER Control CB STRIP
BLOCK SIDE Room CASTING SIDE
Tel. Exchange
4 Pole 500 KVA
S/S - 0
Load Break
S/S - 5 4 POLE
Isolator S/S - 0
300 KVA
S/S – 3 S/S – 5
4 POLE S/S – 3, 630 KVA 500 KVA Horticulture 4 Pole

S/S – 6 500 KVA 630 KVA

S/S – 2, 630 KVA
S/S – 7
S/S – 4, 630 KVA S/S – 7 500KVA
S/S – 6 4 POLE NORMAL CUT POINT
4 POLE
S/S – 4, 4 POLE
S/S – 1
630 KVA S/S – 1
Proposed 500KVA
S/S – 9 S/S – 10 PROJECT
ring S/S-1, 4 POLE
4 POLE 4 POLE 4 POLE S/S – 8, 4 POLE

S/S – 10 11KV XLPE CABLE

PUMP HOUSE S/S – 9
630KVA
4 POLE 630KVA S/S – 8 11KV / 415V TRANSFORMER
500 KVA
11KV OVER HEAD LINE
 Fixed VAR Compensation
• Smelter Plant consumes about 360 MVAR of Reactive
power at full load, very often CPP is not able to supply
this and imports from GRID, in order to reduce the load
on CPP a Fixed VAR compensation system is installed in
Smelter at 11 KV level.
• The compensation provided is 15 MVAR, which is
obtained by 3 nos. of tuned Capacitor banks of 2.5
MVAR, 5 MVAR and 7.5 MVAR ratings.
• The capacitor banks are tuned at 4.5th, 5th and 7th
harmonics to filter the harmonics present in Smelter
power network
THANK YOU