POWER SUPPLY SYSTEM

A systematic planning of power supply requirement of any particular broadcasting station of AIR/DD is carried out in the beginning. Loads to be added in future, as per extension program of station are also taken into consideration. Major stations of AIR/DD has the following types of loads: 1) 2) 3) 4) 5) 6) Equipment loads Air conditioning and associated loads Lighting and fans load Workshop load Loads relating to mast light and aerial hut Future provision

The total demand of the station is worked out and then decision is taken whether H/T or L/T supply would meet the requirement. H.T supply is required in case the maximum demand of station exceeds 30 kVA.

AC POWER SUPPLY
The electric power at 11 kV is received in the H.T. substation through underground feeders from the power supply of the P/S authority. The H.T substation is located nearby the studio/transmitter and generally houses metering facilities for reading maximum demand, power factor and the energy consumed. It also houses the H.T OCB. Separate feeder is provided from the P/S station to our centres whose total demand exceeds 50 kV. Standby feeder from the same or other P/S station is invariably provided. A typical P/S schematic is shown in fig. 1.

Induction Course (General) Fig. 1 P/S Schematic of a Typical Station Ref. Drg.No.STI (T)850,(DC602) The incoming power through metering system and H.T OCB is fed to the step-down transformer where voltage is reduced from 11 kV to 400 V, 3 phase 4-wire system. This supply is now called L.T supply. The step down transformer is housed normally in a separate enclosure at a suitable distance from the bus bar and switchgear room. In some stations two nos. of L.T transformers are provided (fig.2). One is used with normal and the other one with the standby feeder. In such cases Isolators, ACB, mechanical and electrical interlocks are provided to prevent earthing and back feed. Power from the secondary of the transformer is fed to the bus bar (sometimes through L.T OCB) for distribution through switchgears. This bus bar is called the main bus bar. The main bus bar feeds power to the auxiliary bus bar, located in the vicinity of the studio/transmitters.

Fig. 2 Arrangement for Preventing back feed in case of feeders Ref. Drg.No.:-STI(T)850,(DC602) Normally one auxiliary bus bar feeds supply to loads like A/C plants and lighting. The other one is used to meet the requirement of the main studio/transmitting equipments. A tie line if provided between two auxiliary bus bars proves beneficial in case of trouble with one of the feeders. From the bus bars, the power is distributed to the loads or sub-distributors (for redistribution) through medium voltage switchers. The main switchgear may comprise full circuit breaker units; oils or air breaks type. Basically a hand operated (Iron clad) switch gear is required for each separate circuit system and it should be capable of interrupting load current at some degree of over current which is normally three times the normal rating of the switch at a power factor of 0.8. The switchgears can be mounted above or below the bus bar. This type of switch is of double break type and with the switch, open fuse links are completely isolated so that the same can be removed and replaced in safety. The fixed contacts are completely enclosed within the insulating shrouds. A protective gear (interlock) ensures that switch must be opened before the cover can be opened and the switch cannot be closed with the cover opened.

Load distribution - Essential and Non-essential loads Load should be distributed in such a manner that each phase shares equal load as far as possible. Total load should be divided into two groups (I) the essential load and (ii) Non-essential load. The essential loads (equipment load) are those minimum loads, which are necessary to maintain the continuity of the service.
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Continuous P/S to these loads should be ensured by connecting them to the standby generator in case of power failure. Therefore, P/S to these loads are required to be arranged accordingly to meet this requirement. Earthing
Earthing is very important in power supply system. The purpose of earthing is to ensure safety of the equipment from damage due to earth fault and prevent operating personnel from getting electric shock. Earthing means making a connection to the general mass of the earth. Earthing associated with the current carrying equipment (switchgears, transformer body etc) is normally essential for the safety of the system and is generally known as system earthing. All L.T/H.T. switchgears are provided with double earth. H.T/L.T transformer neutral is normally connected to earth for safety of transformer. Earthing of non-current carrying metal work and conductor is essential to the safety of human life and is known as equipment earth. System and equipment earths are provided separately. Water may be required to be put into earth pits at regular intervals in case the land is very dry.

AVR
Automatic voltage regulator is a very vital part of the P/S system. Power to most of the loads in studio/transmitter equipment is supplied through AVR, as they require constant voltage all the time. Notable exceptions are the loads relating to A/C plants and lighting etc. Input to the AVR is provided through ACB/MCB, depending upon the load rating of AVR from the switchgear incorporating h.r.c. fuse. The output of AVR is brought to a distribution panel from where the power is distributed to different loads through respective ACBs.The principle and working of an AVR is described below: Electrical equipments are designed to operate at certain supply voltage. If the supply voltage is fluctuating from the rated voltage, the performance of the equipment is bound to suffer. Both under and over voltages are determintal to the load and effectiveness of the equipment. Present state of art to control the fluctuation is with the help of servo stabilizers. A servo stabilizer has four basic components. 1) 2) 3) 4) Stepless toriodally wound autotransformer. Instantaneous start-stop reversible sync motor. Solid state sensing circuit. Series transformer.

Fig. 3 Servo Stablizer Ref. Drg.No.:-STI(T)857,(DC609) STI(T) Publication 87 002/IC(G)/2006

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The secondary of the series transformer is connected in series to the input and the primary is fed through the stepless toriodally wound auto transformer. The tapping of this transformer, which is coupled with the shaft of the servomotor, is automatically adjusted by its movement. The movement of the motor is controlled by the solid state comparator, which continuously compares the output voltage with a fixed reference voltage. In case of error, motor moves in such a direction so as to correct the error. With the movement of the motor, the voltage supplied to the primary of the series transformer changes. Thus the voltage of the series transformer is added or subtracted to the input voltage. The circuit is arranged in such a way that if the output is more than the set voltage the motor tends to reduce the voltage applied to the primary of the series transformer and vice versa. The single-phase stabilizer employs only one variable autotransformer driven by a motor and one sensing circuit. This type of AVR is suitable for single-phase loads. A balanced type 3-phase servo stabilizer employs a single control circuit. These variable autotransformers are mechanically coupled and driven by single-phase motor. The sensing is done in one of the three phases and the other two are corrected correspondingly. This type is suitable for use with balanced loads. However, these can be used with some unbalanced loads if less accuracy in output voltage is acceptable.

H.R.C. fuse
In low and medium voltage range H.R.C (high rupturing capacity) fuse is the most commonly used interrupting device. It is relatively cheap and occupies less space. It is used as a complementary to the other circuit breaker. The fuse has a disadvantage that it is required to be replaced after each operation. Basically, the H.R.C. fuse has a ceramic body that contains specially designed fuse element. Fuse element is connected to metal caps. The caps also serve the purpose of sealing the body after it has been filled up with pure granulated quartz. Vaporization of the metalic elements occurs on melting and then there is a fusion which leads to rapid are extinction. The chemical reaction produces a substance of high resistance, which becomes insulator and therefore the current is interrupted.

Circuit Breakers
The devices used for making and breaking an electrical circuit under some predetermined condition are called circuit breakers. The functions of a circuit breaker are as follows: It must close on and carry full load currents for long period. It must open automatically to disconnect the load, on over load under pre-determined condition. It must rapidly interrupt the heavy current, which may flow under a short circuit condition in any part of the system. The circuit breaker must be capable of withstanding the effect of arcing at its contact and the thermal conditions, which arise due to flow of current. Breaking current capacity is more important than making current capacity. 88 002/IC(G)/2006

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All circuit breakers consist essentially of pairs of matting contacts, each pair comprising fixed and moving elements. Under normal conditions, these elements are in contact and carrying full load current; but on receipt of a tripping signal initiated by hand or protective gear, the circuit will be interrupted. At the start of the separation, an arc will be established which is required to be extinguished as early as possible. Generally, we come across two types of circuit breakers at medium and high voltage, for indoor application. They are called Oil Circuit Breaker (OCB) and Air Circuit Breaker (ACB). In oil circuit breaker, oil insulates the live contact from the earthen metal tank and provides insulation between the open contacts when the arc is extinguished. Hydrogen is produced during arcing period, which in turn interrupts the arc. In air circuit breakers, the arc exists in the mixture of nitrogen, oxygen and metalic vapor and the successful arc interruption takes place due to cooling by diffusion. The OCB and ACBs require yearly maintenance. Contacts are required to be cleaned and oil is replaced if needed, after carrying out oil test for its electric strength and acidity. Before test, oil is subjected to filtering process for removal of sludge and other foreign material.

3-Phase AC Power and Power Factor

The actual power consumed in three phase balanced system is given by W =3VI Cos , the apparent power is expressed by 3 VI. The power factor, Cos = W/3 VI = kW/(3 kVA)

Where is the phase angle between voltage and current. Similarly I = W/(3 V Cos ).

It can be seen from this equation that current required to be supplied by P/S system is higher when power factor is lower. The higher current (low power factor) has the following disadvantages:

1)
2)

The line losses are proportional to I. Typical case when Cos = 0.8, the line loss would be 1.57 times to that which would occur with unity power factor. Rating of transformer, generators, feeders are proportional to current. Therefore low power factor leads to higher cost for the generator, switch gear, transformer and cables. P/S authorities have to maintain voltage within the prescribed limits by incurring additional expenditure to compensate the losses. Therefore P/S authorities penalize the consumers, for their low power factor, charging extra tariff. It is therefore advantageous to increase the power factor by installing power factor correction capacitors and the same would be necessary in many centers.

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Maintenance
The power supply authority is generally responsible for the maintenance of the service line carrying H.T or L.T. supplies to installation. This may include the supply transformer. The sub station equipment, when provided by the station should be maintained departmentally. i) Weekly maintenance General cleaning of transformer, bus bar etc. ii) Check oil level and colour. Check oil leakage. Check breather and reactive and change the moisture absorbing compound if necessary. Check temperature of oil after longest transmission period. Carry out oil test. Filter oil and change if necessary. Paint the body of the transformer if necessary.

Annual maintenance

Precaution
While carrying out test and maintenance on the transformer, care should be taken to isolate it completely from the supply so that the accident may not occur.

DC POWER SUPPLY
Every electronic equipment and operating system need regulated power supply specially at lower voltages. This constant voltages were earlier provided by the Linear regulated power supplies and recently by switch mode power supplies(SMPS). Without doubt the SMPS has become very popular with the equipment manufacturers and users because of its various advantages. It is also being said that at last the power supply is also catching up with the technical advancement of the other devices. We shall analyse merits and demerits of both the Power Supply Units.

The Linear Power Supply System

The block diagram of a Linear regulated Power Supply is shown in the fig. 4. 230 V AC supply is fed to an isolation transformer which steps down the voltage to the required low level. Here the rating of the transformer depends on the current requirement of the load. Therefore, the transformer is normally bulky.

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AC

Isolation Power TR.

Rectifiers and Filters

Series Pass Element

Vout

Vref.

Feedback and Control

Fig. 4 the Linear Power Supply System The stepped down voltage is rectified and filtered by full wave or bridge rectifiers and electrolytic capacitors. The series pass element, normally a Power transistor or FET, gets input from the filter. The output voltage is fed back to a comparator, which compares it with a standard reference and gives an error to the base of the transistor such that its conduction is increased or decreased. In short we can say that the series pass element works like a variable resistor giving constant voltage output. The merits and demerits of this system are as follows

Merits
1. 2. Very low output noise. Very low ripple.

Demerits
1. 2. 3. 4. 5. Because of the bulky transformer the power supply unit is usually bulky. Relatively narrow input voltage range. Normally + 10%. Very low output hold up time about 1 milli sec. Low efficiency about 40 to 50%. Heat dissipation is more.

The Switch Mode Power Supply System (SMPS)

The block diagram of a SMPS is given in Fig. 5.

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AC

RF I Filter

Rectifiers And Filters

Switching Element

Isolation Power TR.

Output Rectifier And Filters

Vout

Feedback and Control Vref.

Fig. 5 The Switch Mode Power Supply We know from the transformer theory that Or Where E E = 4.44 x f x B x A x N fxBxA

E = Voltage f = Frequency BxA = Flux density N = No. of turns. Because of the inherent limitations, the flux density cannot be increased in power transformer above 0.97 wb/m so if the frequency is increased the transformer size can be brought down and hence the weight. This is what has been done in SMPS. The 230 V AC is fed directly to the rectifier and filter through Radio Frequency interference/electromagnetic interference filter. This dc voltage then chopped by a switching transistor or FET. This chopped high frequency AC is then applied to a power transformer for stepping it down. This stepped down voltage is further rectified and filtered and given to the load. A sample of the output voltage is taken and compared with a reference voltage. The error voltage is then given to the base of the switching transistor for increased or decreased switching action. Normally, the frequency of operation is between 10 kHz to 60 kHz from no load to full load. Even frequencies up to 1 MHz are now available in market.

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Fig. 6 Principle of SMPS Ref. Drg.No.:-STI(T)317,(DC78) Because of higher frequencies and to reduce the core loss ferrite is normally used as the core. It can also be seen that the switching element is acting like switch (ON and OFF) and hence the heat dissipation will be low. The merits and demerits of a SMPS is as follows:

Merits
Because of less transformer weight the power supply is light and compact. Very wide input voltage range between 90 to 260 V AC. Very good hold up time, typically 25-milli sec. Efficiency is quite high 70 to 80%.

Demerits
Higher output noise. Higher ripple content. EMI/RFI generation. Higher design complexity.

We see that SMPS is having many advantages compared to the Linear Power Supplies. The system designers as well as electronic manufacturers consider size and weight as important features.

28 V 52 A SMPS Unit Used In GCEL/BEL Transmitters

The circuit is built around a pulse width modulator IC (PWM) 3524 which drives a full bridge inverter. It is also having over temperature control, output over voltage/under voltage sense or input under voltage sense and current limit adjustment and output voltage adjustment. For this two quad Op- Amp LM 324 ICs are being used. It is having additional facility that it can be switched by remote control.

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Induction Course (General) The main supply is passed through a double section LC filter for suppressing voltage spikes on the AC input voltage as well as RF interferences. Then the AC is applied to the bridge rectifier which rectifies the AC. This rectified DC is filtered by capacitor filters. Before applying to the filter 4 Nos. of thermistors are connected in series (Negative temperature coefficient) to limit the current during starting when the capacitors are having zero charge. After the output voltage has settled the thermistors are shorted by a SCR (thermistor during operation 0.9 at the time of start around 2.5 ). The thermistors remain in circuit during the working also in GCEL Power Supply Unit. After the filter the 300 V DC is applied to the inverters which consists of 8 nos. of switching transistors in full bridge configuration. This chopped voltage is applied to a step down transformer and the stepped down voltage is rectified and filtered. A sample of the output is taken and compared with a standard reference in pulse width modulator chip 3524 and the width of the driving pulses of the full bridge is increased or decreased depending on the requirement. The block diagram of the chip is also given. A second power transformer is used to provide power supply to the remote switching PCB and the LCD front panel. Remote ON/OFF can be done by giving TTL remote input. An opto-coupler has been used to provide complete isolation. Thermal over load protection, over voltage protection, current limit, output under voltage/ short circuit protection, have been provided by LM 324 quad Operational amplifiers. [Please refer fig. 7 to fig. 12].
Inrush Current Control

Mains Input

LC Filter RFI/EMI

Inrush Current Limiter

Filter

Full Bridge Inverter

Isolation TransFormer

Rectifier And Filter

Vout

Led Indicator

Power TransFormer

Remote Switching PCB

Remote Switching Pulse

PWM & Control Circuit Output O/V,U/V & C/L,O/T

Output Voltage Sample

Remote Input

Fig. 7 Block Diagram of 28V/52V SMPS Unit

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Fig. 8 Ref. Drg.No.:-STI(T)319,(DC80) STI(T) Publication 95 002/IC(G)/2006

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Fig. 9 Ref. Drg.No.:-STI(T)320,(DC81)

Fig. 10 In Rush Current Control Ref. Drg.No.:-STI(T)321,(DC82)

Fig. 11 Remote ON/OFF Ref. Drg.No.:-STI(T)321,(DC82) STI(T) Publication 96 002/IC(G)/2006

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Fig. 12 Full Bridge Convertor Circuit Ref. Drg.No.:-STI(T)321,(DC82)

Bibliography
1. 2. 3. High frequency switching power supplies Theory and design by George C. Chryssis. Switch mode power supply Handbook by Keith billings. Operation & Maintenance manual for 28 V, 52 A SMPS Unit.

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