1

LARJI HYDROPOWER PROJECT (3*42MW)

SUBMITTED BY
GAURAV& NISHANT VERMA



DEPARTMENT OF MECHANICALENGINEERING
JUNE, 2013



2

LARJI HYDROPOWER PROJECT (3*42MW)

A Industrial seminar report submitted
in partial fulfillment of the requirements
for the award of the degree of


BACHELOUR OF TECHNOLOGY
in
(MECHANICAL ENGINEERING)
by
(Roll No.46015& 46033)

DEPARTMENT OF MECHANICALENGINEERING

JUNE, 2013



3

CONTENT

Sr. No. Particulars Pg. No.
1

Certificate 4
2 Acknowledgement 5
3 Detail of contents 6-8
4 Chapter 1: Introduction about Hydro Plant 9-17
5 Chapter 2: Plant Location 18-29
6 Chapter 3: Specification of Equipment of hydro Plant 30-44
7 Chapter 4: Operation and Maintenance 44-52
8 Chapter 5: Conclusion 53



4


Certificate




















5


ACKNOWLEDGEMENT

I do express my deepest sense of gratitude and indebtedness towards my training
supervisor J.E. AshishDepartment of HPSEBLarji, thalot, distt. Mandi (H.P.), for their
invaluable guidance, constant encouragement, suggestions, great patience, and continuous
technical support which helped me, survive through crests and troughs of my dissertation work
which got completed successfully. It is a great privilege to work under them, who motivated me
in every course of my work and made me believe in myself.
I also thank Mr. Sunil kumar HOD ME and co-ordinator who have equally given me valuable
guidance and advise to improve quality of my work. I express my sincere thanks for their
suggestions, constant and continuous support throughout this work. I would like to extend my
sincere thanks to my colleagues for their
valuable assistance and co-operation.
I would like to express my heartfelt appreciation for my parents and family members
for their constant encouragement and blessings.
I save the best for my God who destined me to go beyond deliverance into eternal land
of true joyfulness to experience the fullness of his purpose and plan in my life. I thank you God
for all things happened and will be happening to my life; Youre gracious, Your ultimate
sacrifice made my life possible. I will never be tried of thanking You!

NISHANT VERMA
Date:
Place:

ROLL NO 46033
6

CONTENTS
CHAPTER 1
1.1 Introduction
1.2 Historical background of the project
Civil work
Electro mechanical work
Transmission line
Commissioning of the project
1.3 Hydro power plan
Hydro electricity
Hydro power is produced
Cost of hydro electricity
1.4 Generating methods
Conventional dam
Pumped storage
Run of the river
Tide
1.5 Type of plant
1.6 Water turbines
Type of turbine with typical range of heads
1.7 Advantages and disadvantages
Advantages
Disadvantages
CHAPTER 2
2.1 Hydro generator
Stator
Rotor
Bearing
Description of turbine equipment
Spiral casing
Draft tube cone
Draft tube kneeling
Stay ring
Lower ring
Runner
Turbine shaft
Set of guide vanes
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Turbine top cover.
Regulating ring
Guide earthing
Oil pumping unit
Pressure accumulator
Oil leakage unit
Cooling water system
Dewatering and drainage system.
Main inlet valve
Governor
Power transformer
Power equation
CHAPTER 3

3.1 Hydro generator
Specification
3.2 Turbine.
Specification
3.3 Main inlet valve.
Specification.
3.4 Generator transformer
Specification
Function.
3.5 Unit auxiliary transformer
Specification
Function.
3.6 Unit excitation transformer
Specification.
Function
3.7 Station transformer
Specification.
Function.
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3.8 Battery bank
Specification.
Type of cell
3.9 Battery charger
48V DC PLCC Battery charger 1,2
220V DC Distribution board 1,2
3.10 Gas insulated substation type F35
Performance
Characteristics
Customer benefits
Technical data
Main components
Function of GIS
CHAPTER 4
Operation and Maintenance
4.1 Best practice in operation & maintenance of hydro plant
4.2 Maintenance practice
Turbine & its auxiliary
Turbine
Governor
Governor & its auxiliary
Transformer & switchyard.
Emergency D.G. set
Other P.H. equipment
CHAPTER 5
Conclusion
LIST OF FIGURES:-
Figure 1.1- Inside Larji Power House
Figure 2.1- internal view of generator
Figure 2.2- internal view of turbine
Figure 4.1- water conduction system

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CHAPTER 1

1.1 INTRODUCTION:-
INDIA is endowed with economically exploitable and viable hydro potential assessed to be
about 84,000 MW at 60% load factor (1,48,701 MW installed capacity). In addition, 6780 MW
in terms of installed capacity from Small, Mini, and Micro Hydel schemes have been assessed. In
addition, 56 sites for pumped storage schemes with an aggregate installed capacity of 94,000
MW have been identified. However, only 19.9% of the potential has been harnessed so far.
Figure 1.1: Inside Larji Power House
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1.2 BACKGROUND:-
1.2.1 The Himachal Pradesh State Electricity Board Limited (hereinafter referred to as HPSEB
Ltd) is a deemed licensee under the first proviso to section 14 of the Act for distribution
and supply of electricity in the State of Himachal Pradesh as well as a generation
company falling within the definition of section 2 (28) of the Electricity Act, 2003
(hereinafter referred to as the Act).
1.2.2 The HPSEB Ltd has filed Petition No. 171 of 2010 on August 23, 2010 before the
Himachal Pradesh Electricity Regulatory Commission (hereinafter referred to as the
Commission) for determination of Capital Cost of Larji Hydro Electric Project (the
Project) and determination of generation tariff from FY 2007-08 to FY 2010-11 under
sections 62 and 64 of the Electricity Act, 2003, read with the Himachal Pradesh
Electricity Regulatory Commission (Terms and Conditions for Determination of Hydro
Generation Tariff) Regulations, 2007, framed by the Commission, which now stands
repealed by the HPERC(Terms and Conditions for Determination of Hydro Generation
Tariff) Regulation, 2011 with the stipulation that the provisions concerning the tariff for
the Control Period ending on the 31
st
March, 2011 and the provision for conduct of
proceedings for its revocations, variation or alternation, as stood before such repeal, shall
continue to be in-force.
1.2.3 This Order relates to the above mentioned Petition under the Multi Year Tariff regime.
Further, this Order also relates to truing up of ARRs for the period from FY 2007-08 to
FY 2010-11 against the ARRs and tariff provisionally approved by the Commission for
electricity generated from Larji HEP (126 MW) in its Multi Year Tariff Order for FY
2008-09 to FY 2010-11, dated May 30, 2008.
1.3 FUNCTION OF THE COMMISION:-
1.3.1 The Himachal Pradesh Electricity Regulatory Commission was established and
incorporated by the Government of Himachal Pradesh through a notification dated
December 30, 2000, under section 17 of the repealed Electricity Regulatory Commissions
Act, 1998 (14 of 1998), and now covered under the first proviso to section 82 of the
Electricity Act, 2003, with its headquarters located at Shimla.
1.2.4 The Act guides the Commissions approach to regulation. The Act mandates the
Commission to take measures conducive to the development and management of the
electricity industry in an efficient, economic and competitive manner.
1.2.5 The Commission derives its powers under section 86 of the Act, which came into force
with effect from June 10, 2003. The Act repealed the Indian Electricity Act, 1910, the
Electricity (Supply) Act, 1948 and the Electricity Regulatory Commissions Act, 1998.
1.2.6 As part of the tariff related provisions of the Act, the State Electricity Regulatory
Commission (SERC) has to be guided by the Act, the National Electricity Policy (NEP)
and the National Tariff Policy (NTP).
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1.2.7 The functions assigned to the Commission under the Act are as follows:-
The State Commission shall discharge the following functions, namely: -
determine the tariff for generation, supply, transmission and wheeling of electricity,
wholesale, bulk or retail, as the case may be, within the State:
Provided that where open access has been permitted to a category of consumers
under section 42 of the Act, the State Commission shall determine only the wheeling
charges and surcharge thereon, if any, for the said category of consumers;
regulate electricity purchase and procurement process of distribution licensees
including the price at which electricity shall be procured from the generating
companies or licensees or from other sources through agreements for purchase of
power for distribution and supply within the State;
facilitate intra-State transmission and wheeling of electricity;
issue licences to persons seeking to act as transmission licensees, distribution
licensees and electricity traders with respect to their operations within the State;
promote cogeneration and generation of electricity from renewable sources of energy
by providing suitable measures for connectivity with the grid and sale of electricity
to any person, and also specify, for purchase of electricity from such sources, a
percentage of the total consumption of electricity in the area of a distribution
licensee;
adjudicate upon the disputes between the licensees and generating companies and to
refer any dispute for arbitration;
levy fee for the purposes of this Act;
specify State Grid Code consistent with the Grid Code specified under clause (h) of
sub-section (1) of section 79;
specify or enforce standards with respect to quality, continuity and reliability of
service by licensees;
fix the trading margin in the intra-State trading of electricity, if considered,
necessary;
discharge such other functions as may be assigned to it under this Act.
The State Commission shall advise the State Government on all or any of the following
matters, namely: -
promotion of competition, efficiency and economy in activities of the electricity industry;
promotion of investment in electricity industry;
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reorganisation and restructuring of electricity industry in the State;
matters concerning generation, transmission, distribution and trading of electricity or any
other matter referred to the State Commission by that Government.
1.4 HISTORICAL BACKGROUND OF THE PROJECT:-
1.4.1 Larji HEP with an installed capacity of 126 MW (3 Units each of 42 MW), a run- of-river
scheme on river Beas with pondage, with underground power station and static
excitation, situated in District Kullu, was initially taken up for construction in 1987 after
its techno-economic approval was received from Government of India (GOI) on August
04, 1986 and the approval from Planning Commission was received on March 30, 1987 at
a total cost of Rs.168.85 crore. The total cost of Rs.168.85 crore included civil works
consisting of Rs.99.95 crore Electrical works of Rs.54.40 crore and cost of transmission
line of Rs.18.50 crore. In the DPR prepared in 1987, following structures were envisaged
for the project:-
Diversion Tunnel on left bank
30.30 m high concrete Gravity Dam
Desanding arrangements with 4 chambers.
4850 m long, 8.50 m dia circular Power Tunnel.
Two open ended Surge Shafts each of 44m height 28m dia.
Surface Power House with 3 Units each of 42 MW
Rectangular, 29 m long Tail Race channel.

1.4.2 However, despite techno-economic clearance by the Central Electricity Authority (CEA)
on August 4, 1986 and approved by Planning Commission G.O.I. on March 30, 1987 for
an estimated cost of Rs.168.85 crore, the construction of the Larji HEP did not proceed as
planned, primarily due to paucity of funds. From 1987 to March, 1999 only limited
infrastructure was developed and detailed investigations were carried out. Initially, the
State Government decided to take up the project for execution in 1991. Consequent to
findings of Sub-surface geological explorations which were concurrently in progress,
some inherent changes in Project components were found necessary by the erstwhile
HPSEB (the Board) in consultation with the Panel of Experts (P.O.E), which was
constituted by the Board in 1995 for suggesting and firming up the necessary changes in
the DPR. As practically no work had been carried out in respect of main structures
envisaged in 1987 proposal, the Board decided to incorporate following changes in main
project structures:-
Concrete Dam was replaced by a gated diversion barrage.
6 Nos. radial gates in spillway were replaced with 5 Nos. radial gates in the
diversion barrage but of bigger size.
Desanding arrangements of 4 chambers was retained with bigger sizes.
HRT length was reduced to 4119.86 m retaining old dia and type of Power Tunnel.
13

Adit locations were changed which changed their length type of Power Tunnel.
Two numbers Surge Shafts were replaced by one open Surge Shaft after making
changes in height and size.
Surface Power House was replaced by underground Power House
29 m long Tail Race channel was replaced by 258mx10m dia Tail Race Tunnel.
A new provision of TRT chamber was made.
1.4.3 The State Government decided to take up the Project for active construction in 1998.
Accordingly, a revised DPR (March 1999) with the above mentioned changes in scope of
the Project was submitted to the Central Electricity Authority (CEA) for according
Techno Economic Clearance (TEC) and Planning Commissions Approval. The Central
Electricity Authority (CEA) accorded Techno Economic Clearance on January 14, 2000
at revised cost estimate ofRs.796.98 crore including transmission line and IDC. This
included civil works costing Rs.419.03 crore. Electro mechanical works of Rs.221.05
crore, cost of transmission lines as Rs.25.75 crore and estimated IDC at Rs.131.16 crore
with an overall per MW cost of Rs.6.32 crore.
1.4.4 Civil works: Except for HRT works (Package II) for which letter of intent had been
issued in April, 1999, all other Civil/ Mechanical Works for the project were awarded
during April, 2000 to January, 2002.
1.4.5 Electro Mechanical works: the HPSEB Ltd entered into two main contracts for Electro
Mechanical works for the Project. The first contract was for Ex-manufacturing
works/place for main equipment with Alstom make SF6 GIS and mandatory spares and
the second contract was for main Equipment and mandatory spares, unloading and
handling at site, storage, installation, testing and commissioning including performance
testing and insurance covering all activities, which was awarded to M/S BHEL on
February 15, 2001.
1.4.6 Transmission line: The construction of transmission lines was decided to be taken up
internally by the Board. There were two 132 kV D/C lines, one from Larji to Gaggal
which was completed in May, 1993 and commissioned in December, 1998. However, the
line was charged on 33 kV for supplying additional power to Kullu Valley. The second
line from Larji to Kangoo was completed in June, 2006.
1.4.7 Commissioning of the Project: The First Unit (Unit-III) of Larji HEP was
commissioned in September, 2006, Second Unit (Unit-II) was commissioned in October,
2006 and Third Unit (Unit-I) was commissioned in February, 2007.
1.5 HYDRO POWER PLANT:-
1.5.1 Hydroelectricity is the term referring to electricity generated by hydropower; the
production of electrical power through the use of the gravitational force of falling or
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flowing water. It is the most widely used form of renewable energy, accounting for 16
percent of global electricity consumption, and 3,427 terawatt-hours of electricity
production in 2010, which continues the rapid rate of increase experienced between 2003
and 2009.
1.5.2 Hydropower is produced in 150 countries, with the Asia-Pacific region generating 32
percent of global hydropower in 2010. China is the largest hydroelectricity producer, with
721 terawatt-hours of production in 2010, representing around 17 percent of domestic
electricity use. There are now three hydroelectricity plants larger than 10 GW: the Three
Gorges Dam in China, Itaipu Dam in Brazil, and Guri Dam in Venezuela.
1.5.3 The cost of hydroelectricity is relatively low, making it a competitive source of
renewable electricity. The average cost of electricity from a hydro plant larger than 10
megawatts is 3 to 5 U.S. cents per kilowatt-hour.
[1]
Hydro is also a flexible source of
electricity since plants can be ramped up and down very quickly to adapt to changing
energy demands. However, damming interrupts the flow of rivers and can harm local
ecosystems, and building large dams and reservoirs often involves displacing people and
wildlife. Once a hydroelectric complex is constructed, the project produces no direct
waste, and has a considerably lower output level of the greenhouse gas carbon
dioxide (CO
2
) than fossil fuel powered energy plants.

1.6 GENERATING METHODS:-
1.6.1 CONVENTIONAL DAM:-
Most hydroelectric power comes from the potential energy of dammed water driving
a water turbine and generator. The power extracted from the water depends on the volume
and on the difference in height between the source and the water's outflow. This height
difference is called the head. The amount of potential energy in water is proportional to the
head. A large pipe (the "penstock") delivers water to the turbine.
1.6.2 PUMPED STORAGE:-
This method produces electricity to supply high peak demands by moving water
between reservoirs at different elevations. At times of low electrical demand, excess
generation capacity is used to pump water into the higher reservoir. When there is higher
demand, water is released back into the lower reservoir through a turbine. Pumped-storage
schemes currently provide the most commercially important means of large-scale grid
energy storage and improve the daily capacity factor of the generation system.
1.6.3 RUN-OF-THE-RIVER:-
Run-of-the-river hydroelectric stations are those with small or no reservoir capacity, so that
the water coming from upstream must be used for generation at that moment, or must be
allowed to bypass the dam.
1.6.4 TIDE:-
A tidal power plant makes use of the daily rise and fall of ocean water due to tides; such
sources are highly predictable, and if conditions permit construction of reservoirs, can also
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be dispatchable to generate power during high demand periods. Less common types of
hydro schemes use water's kinetic energy or undammed sources such as
undershot waterwheels.
1.7 TYPES OF PLANT:-
1.7.1 SMALL TYPE:-
Small hydro is the development of hydroelectric power on a scale serving a small
community or industrial plant. The definition of a small hydro project varies but a
generating capacity of up to 10 megawatts (MW) is generally accepted as the upper limit
of what can be termed small hydro. This may be stretched to 25 MW and 30 MW
in Canada and the United States. Small-scale hydroelectricity production grew by 28%
during 2008 from 2005, raising the total world small-hydro capacity to 85 GW. Over
70% of this was in China (65 GW), followed by Japan (3.5 GW), the United States (3
GW), and India (2 GW).
Small hydro plants may be connected to conventional electrical distribution networks as a
source of low-cost renewable energy. Alternatively, small hydro projects may be built in
isolated areas that would be uneconomic to serve from a network, or in areas where there
is no national electrical distribution network. Since small hydro projects usually have
minimal reservoirs and civil construction work, they are seen as having a relatively low
environmental impact compared to large hydro. This decreased environmental impact
depends strongly on the balance between stream flow and power production.
1.7.2 MICRO:-
Micro hydro is a term used for hydroelectric power installations that typically produce up
to 100 KW of power. These installations can provide power to an isolated home or small
community, or are sometimes connected to electric power networks. There are many of
these installations around the world, particularly in developing nations as they can provide
an economical source of energy without purchase of fuel.
[12]
Micro hydro systems
complement photovoltaic solar energy systems because in many areas, water flow, and thus
available hydro power, is highest in the winter when solar energy is at a minimum.
1.7.3 PICO:-
Pico hydro is a term used for hydroelectric power generation of under 5 KW. It is useful in
small, remote communities that require only a small amount of electricity. For example, to
power one or two fluorescent light bulbs and a TV or radio for a few homes.
[13]
Even
smaller turbines of 200-300W may power a single home in a developing country with a
drop of only 1 m (3 ft). Pico-hydro setups typically are run-of-the-river, meaning that dams
are not used, but rather pipes divert some of the flow, drop this down a gradient, and
through the turbine before returning it to the stream.




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1.8 WATER TURBINES:-
Water turbines were developed in the 19th century and were widely used for industrial
power prior to electrical grids. Now they are mostly used for electric power generation.
They harness a clean and renewable energy source, but can cause indirect environmental
damage associated with water storage and construction.

1.8.1 TYPES OF TURBINES WITH TYPICAL RANGE OF HEADS:-
Hydraulic wheel turbine0.2 < H < 4
Archimedes' screw turbine 1 < H < 10
Kaplan2 < H < 40
Francis 10 < H < 350
Pelton 50 < H < 1300
Turgo 50 < H < 250
Where (H = head in m)

1.9 ADVANTAGES AND DISADVANTAGES:-
1.9.1 ADVANTAGES:-
A renewable source of energy - saves scarce fuel reserves.
Non polluting and hence environment friendly.
Long life (The first hydro project completed in 1897 is still in operation at Darjeeling is
still in operation)
Cost of generation, operation and maintenance is lower than the other sources of energy.
Ability to start and stop quickly and instantaneous load acceptance/rejection makes it
suitable to meet peak demand and for enhancing system reliability and stability.
Has higher efficiency (over 90%) compared to thermal (35%) and gas (around 50%).
Cost of generation is free from inflationary effects after the initial installation.
Storage based hydro schemes often provide attendant benefits of irrigation, flood control,
drinking water supply, navigation, recreation, tourism, pisciculture etc.
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Being located in remote regions leads to development of interior backward areas
(education, medical, road communication, telecommunication etc.)
1.9.2 DISADVANTAGES:-
Away from Load Centers, Evacuation of power is Big Problem.
Environmental /Ecological & rehabilitation/ Resettlement Problem due to submergence/
Construction activities
Difficulty in Investigation / Implementation due to Remoteness of the area
Long gestation period
Lack of availability of long term finance
Geological surprises resulting in the time and Cost Over-runs.
Hydro Projects suffer from production Risks since the project is planned based on the
Historical data, which may not occur in future.
















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CHAPTER 2
2.1 HYDRO GENERATOR
The hydro generator at larji HEP is a vertically placed generator. The major
mechanical parts of the generator are stator, rotor, shaft and turbine. Since the rotor and stator are
enclosed, these are not visible. Main content are explained as follow.
2.1.1 STATOR :-
STATOR FRAME:-
It is made of wieldable steel plates and has adequate depth to prevent distortion
during any operation. Joints between the segments are heavily flanged internally and
coupled by number of studs. Water cooled air cooler are fixed on the opening ,
provided on outer casing of the stator frame.
STATOR CORE:-
It is build up of stampings of high ratings, hot rolled silicon alloy steel with varnish
insulation on both sides. Stator core is pressed between steel plate ends through non
magnetic radial fingers welded on them. The core is securely clamped by number of
long studs along the outer periphery of the core, extending over its full height.
STATOR WINDING:-
It is a double layer, bar type wave wound. brazing joins the bar ends and each joints
is tested by ultrasonic wave for perfection. the stator winding is star connected. three
main and three neutral terminals have been brought out side the stator frame. in order
to prevent condensation of winding during period of shut down, low temperatures
heaters are mounted below the lower air baffles.
2.1.2 ROTOR:-
ROTOR:-
The rotor has been design to safety with stand all mechanical stresses imposed by the
maximum run way speed. The dynamic balancing of the rotor shall be carried out to keep
values of rotor vibration within allowable limits.

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FIGURE 2.1 Internal view of generator
ROTOR RIMS:-
the rotor rim is built up from sheet steel laminations each covering two pole pitches and
successive layers of laminations overlapped to give adequate strength to the rim. T
shaped slots in the outer periphery of the ring receive similar shape projection on the pole.
The rim is secured tangentially to the rectangular bars of the spider with sets of five parts
keys having a master key in the middle and a set of taper keys on the each side so as to
allow the rim to float freely during operation.
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SHAFT AND THRUST CUM GUIDE BEARING COLLAR:-
It is made from high quality alloy steel. It has been accurately mechanism and has a hole
bored through the centre for inspection and other purpose. The bottom surface of collar is
polished in fine limits to act as runner surface.
POLES WITH FIELD WINDING:-
poles are of laminated construction consisting of sheet steel poles punching, clamped
between heavy steel and plates by means of studs. The poles core has a number of T
shaped tails to engage with corresponding T shaped tails in the rotor rim. The damper
windings bar are of circular copper section and are embedded in poles face. The ends of
damper bar are short circuit together by copper segments. The field windings are made of
special profile copper strip wound on edge. The coils are electrically heated and
pressurized to heal the turn insulation and thus strengthen the coil.
SLIP RINGS AND BRUSH GEAR:-
slip rings are of mills steel and shall be mounted on extension shaft. The brush gear
collector shall be mounted on insulated studs supported on the upper brackets and is
conveniently accessible for maintenance and inspection. The insulation for slip rings and
their connection is non hygroscopic and oil resistant. Slip rings shall have condition for
reversing their polarity without removing the field poles or its collector rings by
interchanging connection of the field leads at brush gear.
2.1.3 BEARINGS:-
THRUST BEARING:-
It is of pivoted segmented type, in which stationary parts consists of sets of pivoted
segmented pads supported on circular pad supports. Bearing shall be self lubricated type
with plug in type oil coolers located in oil reservoir. Each pad rests on pad supports
which work like spring plates and provided cushioning effect to whole assembly. Radial
movements are prevented by the mean of stoppers.Thrust bearing collar is accurately
perpendicular to the axis of the shaft. Thrust bearing pads are completely immersed in
the oil and would be cooled by mean of oil cooler units. Oil used in the trust bearing is of
46 no. of the prime oil. The edge pads are tapered to allow the oil to enter in the gaps
between pads and runner. Pads are designed so that tilting is possible, thus enabling the
automatic adjustment of required lubrication gap for actual speed and load.
GUIDE BEARINGS:-
the guide bearing is of pivoted pad type consisting of a raw of white metal pads arranged
in a support ring. A pivoted bar is bolted to the back of each guide pad to enable the pad
to move up and down slightly to take up stable position and facilitates formation of the
21

oil film while running. Guide bearing pads are immersed in oil of 68 prime oil.
Resistance and dial thermometer are provided in pads, and oil bath for temperature
measurement and protection against over heating.
UPPER BRACKET:-
The upper bracket supports the weight of the stationary parts of brush gear. Upper gear
generator cover and mechanical over speed devices etc. It is to be placed on the stator
frame.
LOWER BRACKET:-
The lower bracket houses is the lower guide bearing. The bracket is designed to carry the
weight of the rotating parts of the generator and turbine as well as hydraulic thrust. It is
designed in such a way that it is possible to lift it through the stator core.
BREAKING AND JACKETING SYSTEM:-
To apply the brakes, air at 4.0-5.0 atmospheric pressure shall be fed in to the cylinder
from the station compressed air system. Brakes shall be automatically applied, when the
speed of the rotor reduced to a present value and shall remain applied continuously, so
that the unit stop completely. However, it shall be possible to apply the brakes manually.
The brakes shall automatically reset after complete stopping of the generator. Limit
switches have been provided for each brake to prevent the machine from starting, if any
brake be in the raised position and provide ON and OFF indication on the unit control
room.

CARBON DUST COLLECTION EQUIPMENT:-
Carbon dust is produced due to continuous rubbing of carbon brushes on slip rings. To
prevent deposition of this dust on slip ring, a chamber has been provided to enclosed the
slip rings area and the air from this chamber is extracted by an exhaust fan through a
sheet metal duet.
BRAKE DUST COLLECTION EQUIPMENT:-
The brake dust collection equipment consists of an extraction unit, hoppers around brake
assembly for trapping the brake dust and flexible hoses for connecting hoppers to
extraction unit. Provision has been made in the control schematic to the unit for its
ON/OFF operating in auto mode.
VENTILATION:-
The generator has closed circuit type ventilation. Twelve air cooler units have been
installed in the outer periphery of the stator frame and the cooled air is discharged into
22

the space surrounding the stator. Part of this air is then returned to fan below rotor
through ducts in the foundation and remainder cooled air returns to the fan above rotor.
FANS:-
fans of suitable design are fixed at each end of the rotor rim at top and bottom. Suitable
air guides have been provided to ensure proper distribution of air in the machine.
AIR COOLERS:-
A number of the air cooler are fixed on the stator frame for dissipating the heat in the
form of losses in the generator. Each air cooler consists of a rectangular nest of tube
between two water chambers, arranged for the air to flow over water through the tubes.
The tubes are of cuprous nickel alloy and have coiled coil tinned copper wire around its
periphery to increase cooling surface.
2.1.4 DESCRIPTION OF TURBINE EQUIPMENTS:-

FIGURE 2.2 Internalview of turbine
23

SPIRAL CASING:-
It is logarithmic form and substantially circular in the cross-section, designed to
withstand maximum water hammer pressure. The diameter at the inlet is 4200 mm. It is
made from boiler steel plates in minimum number of section of different thickness and
shall be welded to straying at site.
DRAFT TUBE CONE:-
It is fabricated from plates and made in three parts to facilitate runner removal from
bottom at valve floor. The upper draft tube cone is fabricated from stainless steel plates.
On the upper side it is connected to bottom flange of the lower ring of the guide
apparatus and on the lower side it is bolted to the intermediate draft tube cone. The
intermediate draft cone is fabricated from structural steel and on the upper side it is
connected to the upper cone and end is kept in position with the help of the lower draft
tube cone. The lower draft cone is also fabricated from carbon steel plates and fixed to
the top ring of draft tube knee lining. To prevent leakage of water, all the joints have
been provided with rubber sealing cords.
DRAFT TUBE KNEE LINING:-
It is fabricated from steel plates and is ribbed on its outer surface to give rigidity. It is
also manufactured in number of parts. A drainage box has been provided at the side of
the liner for dewatering turbine water path into dewatering gallery through a pipe and
gate valve.
STAY RING:-
It is designed to withstand the hydraulic forces and is of cast fabricated construction. It
consists of cast upper and lower belts connected together by steam lined cast steel stay
vanes for drainage the top cover leakage water by gravity. This is designed to give
hydraulic losses, to conform to the flow formed by spiral casting, to guide the water to
vanes and meeting the strength requirements.
LOWER RING:-
The lower ring of guide apparatus (bottom ring) is fabricated from steel plates. The
cups, which house the lower brushes of guide vanes are rigidly to the lower ring so that
they can be taken out and replaced without dismantling either lower ring or turbine top
cover. The lower ring is fixed to stay ring.
RUNNER:-
The runner shall be Francis type having inlet diameter of 3450 mm. It is made from
stainless steel. The runner cone is also of stainless steel. The design is such that the
velocity of the water at the skirt is relatively low to minimize silt erosion. All the surface
of the runner is ground smooth and is free from hollow, cracks or projections.
24

TURBINE SHAFT:-
The turbine shaft of external diameter 750 mm and internal diameter 400 mm is forged
from high quality manganese steel. The shaft has flanges at both its ends. The upper
flanged of the turbine shaft is connected to the flanged of the generator shaft and its
lower flange, the turbine shaft is connected with the runner. The connection at both the
ends is made with the help of fitted bolts. The axial load as well as the torque is
transmitted through these bolts. The shaft is provided with a bearing skirt for guide
bearing and stainless steel rotating sleeve for turbine sealing.
SET OF GUIDE VANES:-
The guide vanes, 24 in number are made of cast stainless steel and have a smooth
hydraulic profile. The guide vanes are housed between the turbine top cover and lower
ring. The turning of the guide of the guide vane is carried by two servomotors. Safety
share pins set shared off, in the event of a foreign body getting wedged between the
vanes, thus protecting the guide vanes and turning mechanism against any damage.
Contacts have been provided for signalling in case of shear pin failure. The limit
switches are provided to give the alarm signal when any of the shear pin gets broken due
to jamming of guide vanes. The limit switches are oil/water tight and special glands are
used to prevent entry of water in the limit switches through the cables. Stoppers are
provided to prevent movement of guide vanes beyond the fully opened and closed
position.
TURBINE TOP COVER:-
The turbine top cover is fabricated from steel plates and is made in two parts. It is rigidly
connected to the upper belt of stay ring. provision for gravity drainage of top cover has
been made. In its internal vertical cylinder, windows have been provided to have access
to turbine sealing for repairs. Renewable stainless steel upper stationary labyrinth
sealing has been fixed with top cover.
REGULATING RING:-
The regulating ring is made of welded construction. It is supported and guided on the
support for regulating ring. Which is also fabricated on the turbine top cover. The
regulating ring is provided with bronze pads on the surfaces, rubbing against the support
and these pads are immerged in an oil bath to minimize friction. Oil is poured in the bath
through a special funnel provided for the purpose. The regulating ring is connected with
servomotors.
GUIDE BEARING:-
Oil lubricating turbine guide bearing of segment type has been adopted in the design. It
consists of eight Babbitt line segment arranged along the outer circumference of bearing
belt of the shaft. The bearing body is made of mild steel plates and is fixed to the top
turbine top cover with the help of studs. The guide bearing oil cooler are located inside
25

guide bearing. under stationary condition, the Babbitt line segments are kept immerged
in the oil bath. Radial holes have been provided in the skirt of the shaft to act as a
centrifugal pumps, when the shaft rotates, thus forcing the oil under pressure to pass
through the gap between the segment and shaft and take a wedge form and a oil film is
formed ensuring lubrication of guide bearing. The oil flow over the cylinder to guide
bearing oil cooler.The oil, after passing through the cooler, flow to the inner tank. Thus
the complete circulation of oil is achieved. Cooling water is fed to the oil cooler at a
pressure of 3 to 4 kg/cm2. Level relay and flow relay with the alarm are providing for
indicating low oil level and less flow of cooling water respectively. For temperature
control thermo signalizes and resistance thermometers are provided in the bearing
segments as well as in oil bath.
OIL PUMPING UNIT:-
Each unit is provided with its own pressure system. The pumping unit is equipment with
two screw pumps driven by electric motors through flexible coupling and of sufficient
capacity, to meet all the oil requirement of turbine. The pump with the turbine is
mounted on the top of oil sump tank. Pumping of the oil is mainly carried out by the
main pump under the control of idler cum safety valve to maintain the pressure in the
pressure accumulator. When the oil pressure drops to a present value in the pressure
accumulator, the pressure switch aculates the standby pump to start. When the pressure
build up again, the pressure switch operates to stop the pump.
PRESSURE ACCUMULATOR:-
It is a fabricated pressure vessel. It is an oil accumulator filled with oil and compressed
air, and serves as the source of energy for driving the power organs of the system by
means of oil under pressure.
OIL LEAKAGE UNIT:-
the oil leakage unit is intended for the collection of oil leakage from the servomotor of
guide apparatus and periodic pumping from the tank of leakage unit into the sump tank
of oil pressure unit. The O.L.U. consists of tank and mounted on its pump motor set.
COOLING WATER SYSTEM:-
water shall be taken from the individual penstock of each unit through self cleaning strainer
and cyclonic and will be supplied to serve the following requirement of respective unit:-
Cooling water for generating air cooler.
Cooling water for heat exchanger of generator guide and thrust bearing.
Cooling water for turbine sealing, turbine guide bearing etc.
Cooling water for transformer,
26

Cooling water for supply to compressor.
The water after passing through the self cleaning strainer and cyclonic strainer will
be feed to the various equipments. Water from the various equipments will be
directly discharged into the tailrace.
DEWATERING AND DRAINAGE SYSTEM:-
this is common for all units the water of draft tube is collected in sump. The bottom of
sump is at an elevation of 880m. Two vertical turbine pumps each of capacity 750m3/hr
are installed to give maximum dynamic head of 50m, when the working in parallel. The
discharge of both is combined through suitable slide and non-return valves and goes to
tailrace. One pressure gauge is also provided in common discharge line.
AIR AND WATER PIPE LINES:-
air and water pipe line inside the turbine pits are provided serve for:-
Supply of air to the repair seal (inflatable type) provided under turbine sealing.
Cooling water to turbine sealing.
Drainage of leakage water by pump motor set from turbine top cover.
Cooling water to labyrinth sealing during synchronous condenser operation.
Air supply during synchronous condenser operation.
Air supply during part load operation.
Water pressure relieving from upper portion of crown.
Cooling water inlet and outlet for guide bearing.
2.1.5 MAIN INLET VALVE:-
A) The butterfly valve is located on the pen stock before the turbine and serves the
following purposes:-
It stops the water entry to the turbine when the latter leakage is stopped for a longer
period, to decrease the water leakage and to protect the guide apparatus against silt
cavitations.
It stops the water supply to the turbine in case of emergency.
B) Normal closing of valve takes place in still water, but during emergency it is closed
against flow of water.
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C) Butterfly valve is installed in the power house building itself. During operation the
valve should be either completely closed or completely opened. Intermediate
position of disc to allow partial flow is not allowed.
D) Opening of the valve is carried out after equalization is done by supplying water to
the spiral casing through bypass valve, keeping the guide apparatus in closed
position.
E) The valve is operated by means of two oil operated pistons receiving oil from oil
pressure unit.
F) The butterfly valve has got horizontal axis of rotation.
G) A set of limit switches have been mounted on butterfly valve with corresponding set
of levers to operate of B.F. valve.

2.1.6 GOVERNOR
The accuracy and sensitivity of the order of 0.02% is desired so that as to assure that
several regulators behave in the same way for the system disturbances, thus avoiding mutual
hunting and over regulation. To meet above requirements it is, therefore, provided withmicro
processor based on electric hydraulic governor which should be able to perform speed control,
load control, intelligent sequencing a rapid system monitoring of hydro turbine with reliability
and precision. To ensure flexibility in the system there will be provision to change the reference
values like speed setting. Gate limit or position and parameter values of PID controller by
software means in addition to conventional hardware means.









28

2.1.7 POWER TRANSFORMER
For each 42MW unit there are three power transformer of 52MVA, rating.
Transformer has two side HV and LV side, whatever side will be used as input or output. When
an hydro generator is in generating stage output voltage of generator is 11 kv, which is input to
power transformer and output of that transformer will be 132 kv which is feed to power grid
system at that time this transformer is used as step up transformer, but in case of power grid
failure power plants will be totally shut down then to start a unit of plant same transformer is
used to step down voltage from 132 kv to 11 kv. This 11 kv supply is given to UAT, UET of
plant to start machine of plant.


















29

2.1.8 POWER EQUATION:-

Every Power house has different power generating capacity. This is governed by factor
like water head level, discharge rate of water and the efficiency of the system.

Power, P = 9.81*q*h*
Where,
P= is power generated in KW
q= is Discharge of water (m3/sec)
= is overall efficiency of TG units
h= is net head acting on turbine in meters (Net Head=Gross Head-Losses in WCS)
Power calculation for each unit of LARJI power house:-
Given data:-

Rated head = 56 m
Discharged of water = 83.33m3/sec
Efficiency = 0.9% to 0.95%
Power produced by each unit = 0.92*83.33*9.81*56 kw
= 42115.92 kw = 42 MW









30

CHAPTER 3
3.1 HYDROGENERATOR
3.1.1 SPECIFICATIONS:-
Types of generator SV 806/083-36
Capacity (KVA) 46667
Capacity (KW) 42000
Maximum continuous output (KVA) 51334
Maximum continuous output (KW) 46200
Terminal voltage 11000 V
Stator current2450 A
Power factor 0.9 lag/lead
Excitation current 1165 A
Excitation voltage 140V
Speed/no. of rotor poles 166.7 RPM/36
Frequency 50 Hz
Direction of rotation Clock wise
Types of winding Wave wound
No. of slots 270
Height of stator frame 2150 mm
Height of generator shaft 2384 mm
Overall diameter of rotor 7264 mm
Stator core inside diameter 7300 mm
Pressure for cooling water 3-4kg/cm
















31

3.2 TURBINE
3.2.1 SPECIFICATIONS:-
1. Type of turbine francis(vertical)
2. Net head
Maximum 68.25m
Rated 56.84m
Minimum 53.80m
3. Rated output at rated head 43500 kw
4. Maximum output at
Rated net head 47850 kw
Maximum net head 47850 kw
Minimum net head 43500 kw
5. Discharge at rated output 81.86 m3/sec
& rated net head
6. Speed
Rated speed 166.7 rpm
Run away speed 330 rpm
7. Direction of rotation when clockwise
Viewed from top
8. Maximum speed raise 45%
9. Maximum pressure raise 45% of max. static head
10. Runner inlet diameter 3450 mm
11. Guide apparatus
Elv. Of centre line 894.7 m
P.C.D. of guide vane 4140 m
Height\of guide vane 1092 m
No. of guide vane 24
12. No. of blades 13
13. Type of spiral casing metallic
14. Elevation of lowest point in the draft tube 883.7 m









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3.3 MAIN INLET VALVE (MIV)
3.3.1 SPECIFICATIONS:-

Type double seal lattice valve

Diameter 4200 mm

Design pressure 11 kg/cm2

Opening / closing time 60 sec

Number and diameter of servo motor 2/450

Diameter of bypass valve 300 mm

Diameter of air valve 200 mm





















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3.4 GENERATORTRANSFORMER(132/11kv)
3.4.1 SPECIFICATIONS:-
Type of transformer core type

Rating HV(MVA) 52

Rating LV(MVA) 52

No load voltage HV (KV) 132

No load voltage LV (KV) 11

Line current HV (amp) 227.71

Line current LV (amp) 2732.53

Type of cooling OFWF

Core/ winding (kg) 35000

Weight of oil (kg) 12500

Total weight (kg) 62000

3.4.2 GENERATOR TRANSFORMERS

Generator transformers of 52 MVA, 11/132 kv, 3 Phases, 50Hz rating is provided
and is place in different niches on has been providing. The transformer on 11KV side has
been connected to the generator through bus duct and on 132 KV side to SF6 GIS. The
transformer shall be equipped with protection equipments.








34

3.5 UAT:- UNIT AUXILARY TRANSFORMER
3.5.1 SPECIFICATIONS:-
Type of transformer dry type

Capacity (KVA) 500

Rating HV (KV) 11

Rating LV (KV) 0.415

Rated current HV (amp) 26.24

Rated current LV (amp) 695.6

No. of phases 3

Frequency (Hz) 50

Ambient temperature 50

Temp. rise over ambient 90

Insulation class F

Weight (Kg) 3400

3.5.2 FUNCTION OF UAT:-
These transformers are not oil type transformer, they are of dry type. Dry type
transformer is a step down and has rating of 5 KVA. All the auxiliary of machine such as carbon
dust collector, breaking system, MIV system, water cooling and oil pumping system have supply
from UAT. The input for UAT is from hydro generator, diesel generator and from power grid
system.



35

3.6 UET:- UNIT EXCITATION TRANSFORMER
3.6.1 SPECIFICATIONS:-
Type of transformer dry type

Capacity (KVA) 610

Rating HV (KV) 11

Rating LV (KV) 0.240

Rated current HV (amp) 32.02

Rated current LV (amp) 1.467

No. of phases 3

Frequency (Hz) 50

Ambient temperature 50

Temp. rise over ambient 90

Insulation class F

Weight (Kg) 3000

3.6.2 FUNCTION OF UET:-
These transformers are not oil type transformer, they are of dry type. Dry type transformer is a
step down and has rating of 610 KVA.UET supply the power to the excitation unit of generator.
UET transformers are take input from generating unit.





36

3.7 STATION TRANSFORMER
3.7.1 SPECIFICATIONS:-
Type of transformer core type

Rating HV (MVA) 6.3

Rating LV (MVA) 6.3

Line current HV (amp) 27.56

Line current LV (amp) 330.66

No. of phases 3

Frequency (Hz) 50

No load voltage HV (KV) 132

No load voltage LV (KV) 11

Type of cooling OFWF

Core/ winding (Kg) 14010

Weight of oil (Kg) 8680

Total Weight (Kg) 3480

3.7.2 FUNCTION:-
At starting time of generating unit when there is no power generated by generator in power
house. To start generating unit, we need power. At first power is taken from grid system through
station transformer, then synchronized the generating unit with grid. Station transformer supply
the power to all auxiliary machines of generating unit, within 3-5 sec. generating unit start
running and generate 11 kv the supply from the grid will cut off and this transformer taken
power from generating unit then all auxiliary machine get power from station transformer.


37

3.8 BATTERY BANK
Battery bank is the main heart of the power house. Battery bank supply the D.C. power to
controlling and protection system of the power house, Liquid type of battery is used and are
connecting in series.
3.8.1 SPECIFICATIONS:-
A) Lead acid cell plante:-
Type YHP-21
Capacity 1070 AH
Temperature 60C
Total no. of cell 110
Each cell voltage 2 V D.C.
Total voltage 220V D.C.

YHP-21 is a lead acid cell plante, which supply DC voltage to all DC panels (metering
panel) and protection relay of generator and transformer, circuit breaker open and closed,
lighting.

B) Lead acid cell tublar:-
Type B-150S
Capacity 150AH-10HR
Temperature 210-270C
Total no. of cell 24
Each cell voltage 10V D.C.
Total voltage 240V D.C.

B-150S is a lead acid cell tublar, which supply DC voltage to remote optical fiber wires,
used in DC panel.

C) Dry cell:-
type Type B-150S
Capacity 760AH
System voltage 26V
Total no. of cell 13
Each cell voltage 2V D.C.
Floating voltage 28.99V
Boast voltage 29.09V
Maximum charging current 152A

This cell supply DC voltage to microprocessor and data chip.
38


D) Lead acid cell tublar:-
Type T600H HDP
Capacity 600AH-10HR
Temperature 210-270C
Total no. of cell 24
Each cell voltage 2V D.C.
Total voltage 48V D.C.

T600H HDP is a lead acid cell tublar, which supply DC voltage to PLCC ( Power Line
Carrier Communication)

E) Dry cell:-
Type T600H HDP
Capacity 100AH
Total no. of cell 120
Each cell voltage 2V D.C.
Total voltage 240V D.C.

It is dry cell, supply DC voltage to computer.






















39

3.9 BATTERY CHARGER

3.9.1 48V DC PLCC Battery charger 1,2:-
A) Serial no. IS-3136
B) Direct voltage
Float voltage 43-53V
Boost voltage 43-64V
C) Direct current
Float current 60A
Boost current 100A
D) Type of load continuous
E) Insulation class F
F) Input voltage 41510%
G) Phase 3
H) Frequency 50 Hz

3.9.2 220 DC Distribution Board 1,2:-

A) Serial no. DB/18811
B) AC input 41510
C) Output voltage
Float voltage 236.5V DC
Boost voltage 2.75V DC
D) Output current
Float current 286A max.
Boost current at starting rate 128A
Boost current at finishing rate 64A
E) Phase 3
F) Frequency 50 Hz
G) Max. operating temperature 50C
H) Battery bank 110 nos. lead acid cell of 1070 AH






40

3.10 GAS INSULATED SUBSTATION TYPE F35

3.10.1 PERFORMANCE:-
Up to 145 kv
Up to 40 kv short circuits
Up to 3150A continuous

3.10.2 CHARACTERSTICS:-
Three phase in one enclosure
Cast aluminium enclosure
Spring mechanism

3.10.3 CUSTOMER BENEFITS:-
flexibility
space spacing, having compactness
increased safety & reliability
modularity and adaptability
easier operation
accessibility of components

3.10.4 TECHNICAL DATA:-
Type 3 phase, common metal enclosed
Location underground/indoor
Rated voltage (KV) 72.5-145
Rated frequency (Hz) 50/60
Rated normal current (Amp) 2500-3150
Rated short ckt current (KA) 31.55-40
Rated lighting impulse withstand
Voltage (peak) (KV) 325-650
Number of phases 3
No. of bus bars 2
Material of bus bar aluminium alloy
Insulation medium SF6





41

3.10.5 MAIN COMPONENTS:-
Main components are made of thermal effect circuit breaker with 3 single phases interrupting
elements contains in the same enclosure are:-
Ckt breaker/disconnector combining the functionality and performance of a ckt breaker
and a disconnector.
High-speed earthing switch: moving contact driven by a spring charged during opening
and closing operation.
Current and voltage transformers.
Surge arresters.
High-voltage interfaces: HV plug in cable connection and direct connection to power
transformer, over head line connection.
Local control cubicle.

3.10.6 FUNCTION OF GIS:-

The GIS type F35 is designed to withstand 40 KA, and the ckt breakers to interrupt the
full 40KA short ckt from 72.5 KV to 145 KV. They protect substation equipment,
transmission lines and power transformer, it acts as isolator between the line connected to
the power transformer. The single phase interrupting elements of thermal type are
contained in the same enclosure. The ckt breaker combined the functionally and
performance of a ckt breaker, a ckt breaker interrupting capability and a
disconnectorsdielectrical insulation with insulation co-ordination across terminal and to
earth.















42


3.11 COMPONENTS

1) Dam / barrage
Spillway, radial / vertical gates, sluice gates
Power dam
Intake
2) Silt flushing arrangement
3) Head race tunnel / Head race channel (Open or Cut & cover)
4) Penstock direct from DAM
5) Surge shaft (Upstream of penstock)
6) Power House
Turbine
Generator
Transformer
7) Tail race tunnel / channel / tail pool
8) Switchyard








43


3.12 MAJOR COMPONENTS OF POWER HOUSE

1) Water path
Inlet valve
Spiral casing and turbine
Draft tube
2) Governor
3) Generator
4) Excitation system
5) Unit auxiliary transformer
6) Bus duct
7) Generator transformer
8) Unit control board
9) Control & protection
10) A.C. Supply System
11) D.C. Supply System
12) Cooling water system
13) Compressed air system
14) EOT crane
15) Ventilation system and air conditioning
16) Drainage and dewatering system
17) Fire protection system

44



3.13 SWITCHYARD COMPONENTS

1) Circuit Breaker
2) Isolator
3) Earthing switch
4) Current transformer
5) Potential transformer
6) Lightning Arrestor
7) Bus Bar
8) Control & relay panel













45


CHAPTER 4
OPERATION AND MAINTENACE
Operation and Maintenance of hydro power stations must aim at reducing failure rate by
ensuring smooth operational levels of the power utility. This can be done by adopting timely
preventive maintenance schedule regarding all vital areas of the power project. Engineers are
well-advised here to follow the well-known dictum
Prevention is better than cure.

4.1Hydro Power Plant Engineering : Major component of hydro electric
power projects:
A typical Hydro electric power project is spread in a vast geographical area. Depending on the
designs of the project, it may be spread over 30 to 50 Km of area. In the vast geographical area,
there are large number of critical component which make a hydro electric project works. In this
blog post I am going to briefly describe each and every part of those component.

Figure 4.1 Water conductor system.
46

4.1 DAMS:-The most important aspect of hydro power generation is to ensure that the plant
continue to function continuously. The main component of hydro power project is dam, which
may be concrete gravity, rock filled, earthen or combination of some of above types. Earthen
dams differ from masonry and concrete dams due to relatively greater deformability and higher
permeability of earth masses (excluding plastic clay hearting). As these dams are big in general,
The safety of the dams is most vital for the unhindered performance of the power plant.
4.2 BARRAGE:-The diversion structure like barrage and weir are generally designed on the
principle governing the percolating of water below the foundation of the structure. The floor of
the structure is suitably designed either as a raft of gravity section to be safe against the uplift
pressures created.
4.3 WATER INTAKE STRUCTURE:-A structure to divert the water to waterway,
which includes trash racks, a gate and an entrance to a canal, penstock directly to turbine
depending on the structure of the project.
4.4 HEAD RACE TUNNEL/POWER CHANNEL:-A canal, tunnel and/or penstock
carries the water to the power house. Sometimes a desilting chamber precedes the head race
tunnel, which remove the larger size sediments from entering into the tunnel.
4.5 SURGE SHAFT:-Surge tank is provided into water conducting system primarily to
reduce the surge pressure to be considered in the designed penstock/ pressure shaft. This
economizes the design of penstock/ pressure shaft justifying the extra cost for the provision of
the surge tank. The provision of the surge tank has following advantages:
The length of the column of water gets reduce by placing a free water surface close to the
turbine.
It act as a pressure relief opening to absorb surplus kinetic energy.
It acts as a balancing reservoir to supply/ store additional water during starting/ closure of the
gates/ valves.A surge tank absorbs the water hammer effects due to rapid start or closure of the
turbine.
4.6 PENSTOCK/PROTECTION VALVE:-The penstock valves are provided after the
surge shaft to facilitate maintenance of the penstock. These valves are butterfly valves. The are
butterfly valves are operated hydraulically with provision of pressure accumulated in case of
power failure.
4.7 PENSTOCK/ PRESSURE SHAFT:-The penstock convey the water to the power
house and can take many configurations, depending upon the project layout. Where the power
house is an integrated part of the dam, the penstock is simply a passage through the upstream
portion of the dam. In case of project having long head race tunnel terminating in the surge tank,
the penstock from the surge tank, where most of drop in elevation occurs, would be a
pressurerized tunnel or pipe. For multi unit installation, it is often desirable to surve several units
with a single penstock, and manifolds or bifurcation structures are provided to direct the flow to
individual units.

47


4.8 MAIN INLET VALVE (MIV):-These are spherical valves just provided before the
water enter into the spiral casing of the turbine. This is provided to stop the water for small
maintenance purpose In turbine hall.
4.9 POWER HOUSE:-Power house contains the electro mechanical equipment i.e. hydro
power turbine, Generator, excitation system, main inlet valves, transformers, Switchyard, DC
systems, governor, bus duct, step up transformers, step down transformers, high voltages switch
gears, control metering the protection systems.
4.10 TAILE RACE (Tunnel/ channel):-The tail race tunnel or channel are provided to
direct the used water coming out of draft tube back to the river. The important criteria of
designing the tail race tunnel/ channel is kind of draft tube, the gross head and geographical
situation of the area. Tail race is designed in such a way that water hammer is minimizes when
water leaves the draft tube.
4.2 BEST PRACTICES IN OPERATION & MAINTENANCE OF HYDRO
POWER STATIONS:-
4.1 Best Practices in Operation & Maintenance of Hydro Power stations shall be such that by
following such procedures, the downtime of individual generating Unit & Plant should be
minimum. The operational reliability of the generating units of the hydro power stations shall
be such that whenever the grid demands, it should be available for generation. Some of the
aspects, which can be taken into consideration, in Operation & Maintenance of Hydro Power
Stations, are given as under :

1) Each failure/tripping occurrence must be questioned with basicminimum three questions :-

a) Why this occurred?
b) How this occurred?
c) What is to be done to avoid its reoccurrence?
This will definitely reduce failure rate to the greater extent.
2) Since It is important to adopt timely preventive MaintenanceSchedules covering all vital
areas and plants, the detailed Daily,Weekly, Monthly, Quarterly, Annually and Capital
MaintenanceSheets should be maintained properly.

3) During replacement of any part or equipment after its full utilization or breakdown, it
should be ensured that the replaced part orequipment should be of improved version & of
latest technologyhaving longer durability to meet all desired requirements so as
to213increase plant efficiency and reliability.

48


4) Operating conditions should continuously be monitored and recorded.Records are very
important to diagnose the causes of fault / failure/replacement & to determine residual
life. Early action can be takenbefore any type of failure.
5) Eventhough Original Equipment Manufacturers recommend max./min. permissible
parameters for their equipment, the records/experience/past history play important role to
set limiting values ofparameters of these equipment, as characteristics of
identicalequipment vary from unit to unit and required to monitor its set values.

6) On the basis of past history/records & recommendations of OEMsmaintenance schedules
can be framed. Breakdowns/forced outagescanbe minimized by proper follow-up of the
maintenance schedulesbased on recommendations of OEMs.etc. Life of the equipment
thuscanbe enhanced.


7) Starting/stopping of the units shall be planned to be minimum toincrease the life.

8) Procurement of the equipment spares should be planned as per therate of the consumption,
based on minimum requirement to optimize the inventory.

9) Optimum utilisation of the men & material to be planned.

10) It would be beneficial to arrange training to O&M staff to refresh theirknowledge and to
give advanced technical information to improvework quality & quantity.


11) Interaction amongst working staff at various power stations in thecountry needs to be
organised to improve performance of plant andequipment in totality so as to implement
good Operation &Maintenance Practices.

12) Provision of On Line Condition Monitoring System on genenrator,214turbine and main
transformers could be considered for installationon all existing power stations.


13) Afforestation in catchment areaCatchment Area Treatment studies for the Stations in
operation could begot carried out and as per recommendations of the studies, the
PowerStation should carry out afforestation work in the catchment area. Thiswould help in
reduction of silt content in the inflow water.



49



4.2 MAINTENANCE PRACTICE:-
Some of the practices to be adopted at hydro power stations for maintenance of certain main
plant are broadly given below.
4.2.1 Water Intake, Water Conduit System and Associated Equipment Water storage
(Reservoir) & water conductor system comprising of intake, head race tunnel, surge
shaft, emergency valves & pressure shafts, penstock, main inlet valves are very vital
organ of a hydro power plant. .Due to negative and positive water hammer during sudden
changes in water flow, it is essential to attend to these plant & equipment very carefully.
It is very important to regularly test operation of conduit isolation system/equipment i.e.
intake gates, butterfly valves, excess flow device, surge equipment etc. Periodic
physical inspection of water conductor system from inside as well as outside to know its
condition, silt deposition, rusting/erosion of conduit system is very much essential to find
out various changes due to aging factor, stresses developed due to water hammer etc. The
records of such physical inspection should be maintained by noting all the details:-

i.e. normal as well as abnormal. These records can be compared withthe installation data.
Any abnormality is to be further investigated bycarrying out hydraulic testing,
measurement of thickness by Ultrasonictesting& tests for measuring and computing
stresses at strategic locationssuch as intake point, bends, besides observing sudden
changes inelevations& sizes of pressure shafts, penstock etc. Leakages, if any,should be
scrupulously noted and records maintained. It should be215ensured whether inside /
outside (wherever possible) painting is carriedout to protect the conduit system. The
valve seals, if deteriorated shouldbe replaced by using new seals with latest materials for
enhancing thelife of this equipment. Purification and frequent testing of hydraulic
systemoil should be carried out as per recommendations of the manufacturers.For oil
purification on-line electrostatic liquid cleaners may give bestresults. Some of the
additional points as mentioned below also need tobe considered:-

Cavitation & erosion at top portion due to rushing of air during fill up.
The inspection schedule for the durability of anticorrosive paints used.
Replacement schedule for various vulnerable parts such as bends,open conduits etc.
Due to humidity open conduit deteriorates from outside. As suchinspection& cleaning to
be carried out from time to time at regularintervals.
Anticorrosive-painting schedules followed.
Timely Operation & Maintenance of the cranes & hoists.
Healthiness of control & protection for isolating gates/valves &forcranes/hoists.
Maintenance of trash-rack/intake gate filter.
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Maintenance of communication systems, availability of power supply,equipment for
emergency operations, approach roads etc.

4.2.2 TURBINE& ITS AUXILIARIES:-
Regular inspection of runners of turbines should be carried out and recordto that effect should be
invariably maintained. Many a times it is notpossible for Francis Turbine being always immersed
in water and needsisolation on either side. For this it is done as recommended bymanufacturer
without any compromise. Due to cavitation there maybehuge damages to turbine wheel causing
adverse effect on performanceand consequently efficiency. Sometimes, it would be necessary
toundertake in-situ repairs of turbine buckets to recoupe/fillup erosions/white pitting by using
various cold compounds viz. Belzonacompound,Loctite, SS Metalset, Throtex compound etc.
This may give satisfactory216results. Low heat input welding can also be tried at some of the
locationsto some extent.
An effective system for monitoring of silt content (quantity and size inPPM) may be installed &
commissioned by each power station and siltcontent may be monitored continuously on the basis
of which action tomitigate the damaging effect to under water parts may be initiatedreducing the
down time of units / station.Best efficiency microprocessor based digital PID speed
governorsprovide fast response. Periodical maintenance of speed governorsalongwith all
associated mechanical, electrical, electronicscomponentshould be carried out. The control circuit
should be neatly dressed withidentification marks. The electronic components and cards should
becarefully maintained at appropriate temperature level to achieve desiredperformance.
Periodical calibration and testing of transducers, metersNew Turbine Runner of Unit No. 3 of
Burla Power House of HirakudPowerSystem being replaced for RIM & U Works.217etc. needs
to be done. Desired purity level of hydraulic oil is to bemaintained to give trouble free
operations. History of each important partshouldbe maintained. Following maintenance works
also need to betaken up:-
TURBINE:-
Periodic NDT viz. Ultrasonic, etc.
Polishing of the various under water parts of the turbines once in a year to minimize the
white pitting.
Inspection & testing of the runners from experts to decide residual life so as to initiate
action for procurement of runners for replacement.
Inspection of labyrinth seals in case of reaction turbines.
Painting of runner housing with anticorrosive I tar based paints.
Applying anti-erosion coating to the runner.
Checking of brake jet operation in power stations having Pelton turbines once in three months.

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GOVERNOR:-
Purification of hydraulic oils by centrifugal as well as electrostatic liquid cleaner.
Periodic maintenance of the servo valves and motors after carrying out inspection of the
pistons & housings of the servo valves and motors for their worn-out parts. Replacement
of the leaking seals.
Survey of the component failure & procurement of the same and maintain minimum
inventory.
4.2.3 GENERATOR & ITS AUXILIARIES:-
Stator & rotor winding, bearings & excitation system are the main partsof a generator. As
regards stator and rotor windings, regular recording ofIR Values of these winding should be
maintained at regular intervals.Tan Delta and DLA tests of stator winding indicates the status I
conditionof stator winding insulation. Likewise impedance test (voltage drop testacross each
pole) indicates condition of the rotor winding. Proper coolingsystem is to be maintained to limit
rise in stator winding temperaturesand consequently increase the life of stator winding.
Inspection of the218stator winding is also required to be carried out to verify its firmness instator
core slots and healthiness of overhang portion with firm end windingcaps& end spacers, slot
wedges checked for healthiness. Windings arerevarnished to enhance their life. Looseness of
stator core or interlamination, core insulation are direct factors affecting winding heatingdue to
eddy current loss. Thus recommended maintenance as perschedule should be carried out its
records maintained and correctiveactionsbe taken if necessary.Another precision and very critical
components of generator are its guideand thrust bearings. The thrust bearing is main bearing
holding completethrustof rotating mass of turbine and generator unit. The generator andturbine
guide bearings act as guides for controlling the vibrations of theunit . If T -G shaft alignment
with accurate shaft level is achieved then thepad clearances are adjusted precisely and the
rotating machine willoperate smoothly without rise in bearing temperature and increase
lifeMachine Hall of Bhabba Power House 3x40 MW219of bearings. Following works also need
to be taken up:-
Periodic checking of the foundations, tightening the bolts. Filling thefoundations with
epoxy.
Checking the vibrations periodically & history of the recordedreadings gives guidelines
for realignment, looseness if any,unbalanced electrical components, increase in bearing
gaps,coupling misalignment, uneven stator -rotor air gap etc.
Periodic cleaning or replacement of the generator air coolers andbearing oil coolers to
improve performance of the generator.
Primary and secondary testing of the protection system for itshealthiness and correct
operation.
Inspection of the CTs, PTs and bus bars for overheating, temperaturerise etc.
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Inspection of circuits for protection & control circuits & mock trials of the fire fighting
system along with evacuation system. Checking weightloss of the CO2 cylinders and
replenish as per recommendations ofOEM.

4.2.4 TRANSFORMER & SWITCHYARD:-
Continuous monitoring of oil & winding temperature.
Periodic oil filtration.
Oil testing for various tests and Dissolved Gas Analysis.
Tandelta& insulation resistance etc. as per schedule.
Cleaning and replacement of oil cooler
Testing protection system for healthiness.
Mock trials of Checking, maintenance and inspection for Fire fighting system, CO2
&mulsifire.
Tests for operation time of the breaker.
Operation & testing of isolator opening & closing.
Checking of control circuit & healthiness of operating system of thebreaker.220
Periodic cleaning of transformer bushings & insulator strings.
Switchyards are to be kept neat & tidy. Minimum area surrounding theyard to be free
from growth of scrubs and bushes to avoid any bushfire damaging the equipment.

4.2.5 EMERGENCY D.G. SET:-
Regular maintenance of the emergency set. Checking control &
Protection system.
Running of DG set at regular intervals.
4.2.6 OTHER P.H. EQUIPMENT:-
Periodic maintenance of unit auxiliary, station auxiliary &stationService transformer.
Checking healthiness of station batteries & battery chargers.TheTwo charges should be
rotated once in a week.
Regular inspection of cable ducts to ensure proper ventilation / heatDissipation.
Checking the healthiness of pressure relief valve, if provided.




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CHAPTER 5
CONCLUSION

HPSEBL is committed to provide adequate, reliable power to all its consumers and in this
direction all out efforts are afoot.
HPSEBL is also committed to ensure Grid discipline & operate with in a frequency band
of 49.5Hz to 50.2 Hz.
To achieve the above aims we seek the support & cooperation of our Industrial brethren.