i

PREFACE

This presents the experiences and knowledge I have gathered during my training period

starting from 8th February 2010 to 23rd July 2010 at Loadstar (Private) Limited, Ceylon

Electricity Board and Lanka Electricity Company (Private) Limited. In detail, problems I

encountered and techniques used to overcome these problems are included.

The Introduction, Training Experiences and Conclusion are the three sections discussed in

this Report.

Chapter one reviews information about the training organizations, their main functions,

organizational structure and hierarchy. I also mention present performance, profitability and

usefulness to Sri Lankan Society. And also discussed is about how to improve its

performance.

My experience and knowledge gained are presented in the second Chapter onwards.

Information about the work place where I visited, duties and functions during training period,

Problems encountered during the training and solutions found are also discussed.

The ability of the three training establishments I visited to provide useful industrial training

and suggestions to improve the training practices in house are discussed in the Conclusion.

The contribution of Loadstar is described first in each chapter as this was the first

establishment I was trained at. This company manufactures solid and pneumatic tires, wheels

and tracks under the Solideal brand and is an ISO 9000 certified company.

The Ceylon Electricity Board (also abbreviated as CEB), is the largest electricity company in

Sri Lanka. With a market share of nearly 100%, it controls all major functions such as

electricity generation, transmission, distribution and retailing in Sri Lanka. I spent 2 months

of the highest quality training at CEB.

Lanka Electricity Company (Private) Limited (also abbreviated as LECO) was my next

destination. I spent a highly eventful and busy 1 month at LECO. This company was

ii

incorporated in 1983 for the electricity distribution in Sri Lanka. Lanka Electricity Company

(Private) Limited being the only company behind Ceylon Electricity Board to be involved in

electricity distribution in Sri Lanka is continuing its work with the mission to be the best in

the Electricity Distribution Industry and to actively contribute to develop a Competitive

Electricity Industry in Sri Lanka for the Benefit of Electricity Consumers. 

I have tried my best to reflect on all the important information gathered during my training

period.

M. Lalintha Gayan Polpitiya

Department of Electrical Engineering,

Faculty of Engineering,

University of Moratuwa.

August 2010

iii

ACKNOWLEDGEMENTS

The training program having three destinations was a lot more useful than staying at one

place throughout the whole six months. I wish to extend my deep gratitude towards all the

people who arranged this valuable opportunity to obtain a successful Industrial Training

through three different training places.

I’m thanking to the Training Department of University of Moratuwa and National Apprentice

& Industrial Training Authority (NAITA) for giving me this valuable opportunity to be

exposed to the industry. And also I should be grateful for the Loadstar (PVT) Ltd, Ceylon

Electricity Board, Lanka Electricity Company (Pvt) Ltd for having me as an industrial

trainee.

My special acknowledgement goes to Mr. N.A.Wijeyewickrama, the Director of Industrial

training of the training division of the faculty of engineering for his devotion towards making

this training program a success.

I also like to thank,

Mr. Amitha Kumara, Training Manager (Loadstar (Pvt) Ltd)

Mr. W.D.Buddhadasa, Electrical Engineer of Internal Training(CEB)

Dr. Narendra De Silva, Head of Engineering (LECO)

for arranging and facilitating us with a good internal training program.

I also like to thank my training supervisors during the training,

Mr. Aravinda Gamage (Electrical Engineer, Loadstar)

Mr. Sheron Wickramasighe (Electrical Engineer, Loadstar)

Mr. T.M.S.K. Thilakarathna (Chief Engineer, Kothmale Power Station, CEB)

Mr. Hendahewa (Chief Engineer, Kalanithissa Power Station, CEB)

Mr. N.A.F.G. Jayamaha (Chief Engineer, Kelanithissa Combined Cycle Power Station, CEB)

Mr. Lakshitha Weerasinghe (Chief Engineer, System Control Center, CEB)

Mr. S.H. Midigaspe (Chief Engineer, Generation Planning & Design, CEB)

Mr. Hettiwatta (Chief Engineer, Tr. O. & M. - Anuradhapura Region, CEB)

Mr. Jayasundara (Branch Engineer, Kelaniya, LECO)

iv

Mr. C.S. Unagolla (Chief System Development Engineer, LECO)

for supervising me to get knowledge & valuable experience.

My deep gratitude goes to all the employees of the Loadstar (Pvt) Limited, Ceylon Electricity

Board & Lanka Electricity Company (Pvt) Ltd for all the help they provided.

My special thank go to Ms. Medhani Bandara, Undergraduate, Faculty of Medicine and allied

sciences, Rajarata University who help me to finalize the training report by proof reading &

review.

Thank you again to all the stated & non-stated people who helped me to finish my industrial

training program very successfully.

M. Lalintha Gayan Polpitiya

Department of Electrical Engineering

Faculty of Engineering

University of Moratuwa

Sri Lanka.

v

CONTENTS

Topic Page No

Preface…………………………………………………………………………………………i

Acknowledgements……………………………………………………………….………….iii

Contents……………………………………………………………………………………….v

List of Figures………………………………………………………………………………...ix

List of Tables…………………………………………………………………………………..x

1. Introduction to the Training Establishment……………………………………………...01

1.1. Introduction to Loadstar (Private) Limited………………………………………....01

1.1.1. Vision if Loadstar……………………………………………………………01

1.1.2. Mission of Loadstar……………………………………………………….....01

1.1.3. Main functions of plants and offices…………………………..…………….01

1.1.4. Organizational Structure and Hierarchical levels……………………...……..02

1.1.5. Strengths and Weaknesses…………………………………………………...02

1.1.6. Profitability…………………………………………………………………..03

1.1.7. Usefulness to Sri Lankan Society……………………………………………03

1.2. Introduction to Ceylon Electricity Board (CEB)……………………………………04

1.2.1. Vision of CEB………………………………………………………………..04

1.2.2. Mission of CEB………………………………………………………………04

1.2.3. Main functions of CEB………………………………………………………04

1.2.3.1. Generation……………………………………………………………04

1.2.3.2. Transmission…………………………………………………………05

1.2.3.3. Distribution…………………………………………………………..05

1.2.4. Organizational Structure and Hierarchy of CEB…………………………….05

1.2.5. Present Performance, Weaknesses and Problems……………………………05

1.2.6. Future of CEB………………………………………………………………..06

1.3. Introduction to Lanka Electrical Company (Private) Limited………………………07

1.3.1. Introduction…………………………………………………………………..07

1.3.2. Vision of LECO………………………………………………………………

07

1.3.3. Mission of LECO…………………………………………………………….07

1.3.4. Organizational Structure and Hierarchy of LECO…………………………...08

vi

1.3.5. Present Performance and New Trends……………………………………….08

1.3.6. Weaknesses…………………………………………………………………..09

1.3.7. Profitability and Usefulness to the society………………………………….09

2. Training Experience……………………………………………………………………..10

2.1. Training at Loadstar (Private) Limited……………………………………………...10

2.1.1. My work sites………………………………………………………………...10

2.1.2. Duties and functions…………………………………………………………10

2.1.2.1. Projects……………………………………………………………….10

2.1.2.2. Electrically operated machine maintenance………………………….10

2.1.2.3. Preventive and Electrical breakdown maintenance of a factory……..11

2.1.2.4. Single-phase and Three-phase motor winding and motor selecting for

various applications……………………………………………………….11

2.1.2.5. Capacitor bank designing for Industrial Environments………………13

2.1.2.6. Panel Board Designing……………………………………………….13

2.1.2.7. PLC Programming for Siemens and Hitachi…………………………13

2.1.2.8. Experience with ANDON Board project……………………………..15

2.1.3. Problems and Difficulties.……………………………………………………15

2.1.4. Information of Production processes of JIP and CPD………………………..16

2.1.5. Safety Procedure……………………………………………………………...16

2.1.5.1. Industrial Safety……………………………………………………...17

2.1.5.2. Notification and recording of an accident……………………………17

2.1.5.3. General Statement of safety at Loadstar……………………………...17

2.1.6. Maintenance Management…………………………………………………...18

2.1.6.1. Introduction………………………………………………………….18

2.1.6.2. Organization of Maintenance………………………………………...19

2.1.6.3. Types of Maintenance………………………………………………..19

2.1.6.3.1.1. Improved Maintenance……………………………….19

2.1.6.3.1.2. Corrective Maintenance……………………………...20

2.1.6.3.1.3. Preventive Maintenance……………………………...20

2.2. Training at Ceylon Electricity Board……………………………………………….21

2.2.1. My work sites………………………………………………………………...21

2.2.2. Kotmale Hydro power station………………………………………………..22

2.2.2.1. Introduction………………………………………………………….22

vii

2.2.2.2. Surge Chamber……………………………………………………….22

2.2.2.3. Turbines………………………………………………………………23

2.2.2.4. Generators……………………………………………………………24

2.2.2.5. Transformer Yard…………………………………………………….24

2.2.2.6. The Switchyard……………………………………………………….25

2.2.2.7. MW/Mvar control…………………………………………………….26

2.2.2.8. Maintenance of the Power station……………………………………26

2.2.2.9. Synchronization………………………………………………………26

2.2.3. Mini Hydro power station at Nillambe……………………………………….27

2.2.4. Kelanithissa Power Station…………………………………………………...27

2.2.4.1. Kelanithissa Combined Cycle Power Station………………………...28

2.2.5. System Control Center……………………………………………………….28

2.2.5.1. Operations Planning section………………………………………….31

2.2.5.2. Maintenance………………………………………………………….31

2.2.6. Generation Planning and Designing………………………………………….32

2.2.6.1. Introduction…………………………………………………………..32

2.2.6.2. Main objectives of Generation Planning……………………………..32

2.2.6.3. Demand Forecast…………………………………………………….33

2.2.6.4. Load Forecast Scenarios……………………………………………..33

2.2.6.5. WASP Package……………………………………………………....33

2.2.7. Transmission Planning..……………………………………………………...34

2.2.7.1. Introduction………………………………………………………….34

2.2.7.2. Objectives of Transmission Planning………………………………..34

2.2.7.3. The Importance of Transmission Planning……..……………………34

2.2.7.4. Planning Criteria……………………………………………………..35

2.2.7.5. Voltage Criteria……………………………………………………...35

2.2.7.6. Thermal Criteria……………………………………………………...35

2.2.7.7. Security Criteria……………………………………………………...35

2.2.7.8. Stability Criteria……………………………………………………..36

2.2.7.9. Short Circuit Criteria…………………………………………………36

2.2.7.10. PSS/E Software (Power System Stimulation for Engineers)………...36

2.2.8. Transmission Operation and Maintenance (Anuradhapura Region)…………37

2.2.8.1. Introduction………………………………………………………….37

2.2.8.2. Grid Substation………………………………………………………37

viii

2.2.8.3. Circuit Breakers……………………………….……………………..37

2.2.8.4. Isolator………………………………………………………………38

2.2.8.5. Autotransformer……………………………………………………..38

2.2.8.6. Surge arresters………………………………………………………..39

2.2.8.7. Current Transformers ………………………………………………..39

2.2.8.8. Voltage Transformers………………………………………………...39

2.2.8.9. Protection……………………………………………………………..3

9

2.2.8.9.1.1. Transformer Protection……………………………….40

2.2.8.9.1.2. Bus bar Protection……………………………………40

2.3. Training at Lanka Electricity Company (Private) Limited………………………….41

2.3.1. My Work sites………………………………………………………………..41

2.3.2. Customer Service Center – Wattala………………………………………….41

2.3.3. Branch Office Kelaniya………………………………………………………42

2.3.3.1. Branch Administration……………………………………………….43

2.3.4. System Development Department……………………………………………44

2.3.5. Distribution Control Center…………………………………………………..45

2.3.5.1. Transformer oil testing……………………………………………….45

2.3.5.2. Meter repair and Calibration…………………………………………46

3. Conclusion……………………………………………………………………………….48

3.1. Loadstar (Private) Limited………………………………………………………….48

3.2. Ceylon Electricity Board……………………………………………………………49

3.3. Lanka Electricity Company (Private) Limited………………………………………50

Annex A Organizational Structure & Hierarchical levels of Loadstar (Pvt) Ltd……….xi

Annex B Organizational Structure & Hierarchical levels of Ceylon Electricity

Board................................................................................................................xii

Annex C Organizational Structure & Hierarchical levels of Lanka Electricity

Company (Pvt) Ltd………………………………………………………..…xiv

Annex D Analysis for further improvement of CNC machines efficiency in the

factory and investigation to any breakdown occur in CNC machines……….xv

Annex E Mahaweli Complex…………………………………………………………..xx

Annex F Laxapana Complex…………………………………………………………..xxi

ix

Annex G Copy of the Certificate obtained by Loadstar (Pvt) Ltd …..……………….xxii

Abbreviations………………………………………………………………………………xxiii

List of Figures

Figure Page No

Figure. 1.1. – Areas governed by LECO..............................................................................07

Figure. 2.1. – Preparing fan motor winding.........................................................................11

Figure. 2.2. – Finished Fan Motor........................................................................................11

Figure. 2.3. – Preparing 3-phase motor to wind...................................................................11

Figure. 2.4. – Preparing 3-phase motor to wind...................................................................11

Figure. 2.5. – Panel Board Designing...................................................................................13

Figure. 2.6. – Panel Board Designing...................................................................................13

Figure. 2.7. – Master PLC.....................................................................................................14

Figure. 2.8. – Tire Press Machine..........................................................................................14

Figure. 2.9. – Heat Treatment plant.......................................................................................14

Figure. 2.10. – Control panel of the Heat Treatment plant......................................................14

Figure. 2.11. – Sample Code....................................................................................................14

Figure. 2.12. – Configuration Settings.....................................................................................14

Figure. 2.13. – Power house, Kotmale. The arrangement of basic components of the Power

Station. It consists of three generators 67 MW each…………………...……22

Figure. 2.14. – Surge

Chamber.................................................................................................23

Figure. 2.15. – Turbine.............................................................................................................23

Figure. 2.16. – The transformer yard.......................................................................................25

Figure. 2.17. –The Switchyard................................................................................................25

Figure. 2.18. – The Nilambe Power Station............................................................................27

Figure. 2.19. – At the breakdown site......................................................................................42

Figure. 2.20. – At the breakdown site......................................................................................42

Figure. 2.21. – Cable preparing. This person is preparing the underground cable joint……..43

Figure. 2.22. – Digging the ground to repair underground cables...........................................43

Figure. 2.23. – Transformer oil tester......................................................................................46

Figure. 2.24. – Test bench for meter calibration......................................................................46

x

List of Tables

Table 2.1 – Information on worksites…………………………..............................................21

Table 2.2 – Comparison between Static and Brushless Exciters.............................................24

Table 2.3 – Hydropower plants and Capacities.......................................................................29

Table 2.4 – Thermal power plants and owned by CEB...........................................................30

Table 2.5 – Private Thermal power plants...............................................................................31

Table 2.6 – Voltage Criteria.....................................................................................................35

Table 2.7 – Short circuit Criteria..............................................................................................36

Table 2.8 – Circuit Breakers.....................................................................................................38

Table 2.9 – Information on worksites in LECO…………………….......................................41