CHAPTER1

1.0 1.1 INTRODUCTION Power Development under Srisailam Complex The River Krishna is one of the major river systems in peninsular India and its basin has been and continues to be the cradle of civilization since ancient. Srisailam and Nagarjuna Sagar dams constructed one below the other on this river form two of the largest manmade lakes with combined gross storage of over 700 TMC ft. (20,000 million cubic meters). Such a system of two large reservoirs in cascade (one below the other) is unique. This affords development of Hydel Power in the conventional as well as pumped storage mode. Srisailam dam forms the upper reservoir with a gross storage of 308 TMC ft (8700 million cubic meters). This dam has been constructed as a part of Srisailam Hydro Electric Project comprising the dam and a power station on the right bank with installation of 7 Nos., each of 110 MW Hydel units. This power station is presently in operation and contributes about 2300 million units of energy every year. Though originally conceived mainly as a hydroelectric project, irrigation projects have since been formulated and taken up for execution to draw water from Srisailam reservoir and feed parched lands in drought prone districts of Rayalaseema. Nagarjuna Sagar Dam, which is about 100 KM downstream of the river from Srisailam forms the lower reservoir with a gross storage of 400 TMC ft. Taking advantage of the location of two large reservoirs one below the other, another project has been formulated and executed for development of peaking power by the principle of pumped storage operation. Srisailam Left bank Power Station is an underground power station with installation of 6 Nos., of each of 150 MW reversible type pump turbine motor generating units. This power station facilitates mopping up of surplus off peak thermal power in the system to supply it during peak hours. In addition it generates cheap conventional energy with monsoon surplus flows in the river. Stabilization of the grid and improving voltage are the additional advantages. Brief details of the power Project are given in the following pages.

1.2

Srisailam Right Bank Power House (7 X 110 MW)

1. Project Works A masonry concrete dam at Sunnipenta, (6 Km downstream from Srisailam Temple) to a height of 145 meters (470 ft) and length 512 meters (1680 ft.) was constructed. 12 Nos., 65 ft x 55 ft., flood discharge radial gates are provided at the crest of the spillway. Maximum capacity of flood discharge through these gates is 13, 00, 000 cusecs. Water to the Hydro Power House is taken through a tunnel of diameter, 15M & Length 720M in the Right Flank at EL 219 M (718.54 ft). 7 Nos., 110 MW each Hydro Turbine generators are connected to this system. During peak flood season about 18.0 MU of energy per day will be available through this power house to Andhra Pradesh State Power Grid. 2. Project Programme The Project works were inaugurated by our late Prime Minister Sri. Jawaharlal Nehru in July 1963. All the seven generating units were erected and commissioned during the period August 1982 to March 1987. The Power House was dedicated to Nation by our late Prime Minister Smt. Indira Gandhi in October, 1982. 3. Project Cost The Civil and Electrical works of the project (1st and 2nd stage works) is estimated at Rs.567.27 Crores, as per revised estimated submitted to Government in 04/1991. Out of this estimates cost, an amount of Rs. 120.362 Crores pertains to Power House. 4. Salient Features of Project a) Location State District River Latitude Longitude b) Hydrology Catchment Area Max. Flood Discharge Mean Annual Rain Fall Max. Min.

: Andhra Pradesh : Between Kurnool & Mahaboob Nagar : Krishna : 16 - 5 N : 78 - 54 E : 2,06,030 km2 (7950 Sq. Miles) : 10,60,830 Cusecs : 101.6 cm (40 Inches) : 63.5 cm (25 Inches)

c) Reservoir Full Reservoir Level Max. Water Level Gross Storage Capacity Live Storage Capacity Water spread area at FRL d) Dam Top of Dam Height above deepest Foundation Length at top Crest Level e) Spillway Max. Designed discharge No. of spill way gates and size No. of River Sluices and size Max. Discharge through River Sluice Deep bed level of River Minimum tailrace level f) Power Tunnel Diameter Length Height of Trash Rack Width at Bell mouth entrance Discharge (Max.) Invert Level at Entrance No. of Penstocks Diameter of surge shaft g) Power House No. of Units Unit Capacity Max. Tail Water Level h) Head Maximum (Net) Minimum (Net) Rated (Net) Discharge for full generation per machine at rated head MDDL for generation

: EL +269.75 m (885 ft) : EL +271.88 m (892 ft) : 8.722 MCM (308 TMC) : 5.975 MCM (211 TMC) : 616.42 km2 (238 sq. miles) : EL 275.54 m (904 ft) : 145.10 M (470 ft) : 512 m (1680ft) : 253 m (830 ft) : 13,20,000 Cusecs : 12 Nos. 18.3 m x 16.8 m (60' x 30') each : 2 Nos. 12 ft x 30 ft each : 35,680 cusecs : EL +152 m (500 ft) : EL +163 M (535 ft) : 15 m (50 ft) : 740 m (2428 ft) : 38 m : 18.45 m : 1000 Cumecs (35000 Cusecs) : EL +219 m (718.54 ft) : 7 Nos. of 6.10 m ( 20 ft ) dia each. : 28 m (92 ft) : 4 Nos. under Stage I : 3 No.s under Stage - II : 110 MW each : EL +194 m (635 ft) for max. flood Condition : 103 m ( 344 ft ) : 73 m ( 234 ft ) : 90 m ( 300 ft ) : 147.3 Cumecs ( 5200 Cusecs ) : 240 m (800 ft )

i) Tail Race System Width of DT Tunnel No.& dia. of Surge Shaft 5. Power Complex Works

: 14.5 m : 2 Nos., 8 m each

The Power Complex works comprise the following 1. Intake structure with an approach channel 2. Power Tunnel 3. Surge Shaft 4. Penstock Tunnels 5. Draft Tube Gates 6. Tail Race System 6. Switchgear and Feeder Bays The Switchgear and the feeder bays are located on the top of the hill where the ground elevation is EL 365.75 M. This Sub-station at Srisailam Dam is connected to the Power Grid through 220KV and 132 KV transmission lines. There are 10 Nos., 220KV feeder bays and 2 Nos., 132 KV feeder bays, which have been connected to various stations in the power grid and contribute to the stability of grid and reliability of power supply. The Generation of Power at Srisailam Project has saved to a major extent, low voltage problems and contributed to system stability. 7. Benefits Srisailam Power House has been the most reliable source of dependable Hydro Power Generating about 3,000 Million Units on an average annually representing about 35% of Andhra Pradesh's Total Hydro generation of about 8,000 Million Units per year. Since commissioning of this power house, a total of 53,906.23 MU were generated till 31st March, 2009. The Dates of Commissioning of Generating Units are as follows. Unit No. 1 2 3 4 5 6 7 Commissioning Date 30-08-1982 14-12-1982 19-11-1983 27-08-1984 31-03-1986 30-10-1986 15-03-1987

1.3

Working Process in Srisailam Right Bank Power House The Main requirement for hydro-electric power plant is the availability of water in huge

quantity at sufficient head and this requirement can be met by constructing a dam across a river. The schematic arrangement of a typical hydro-electric plant is shown in the following figure.

In Srisailam, an artificial storage reservoir is formed by constructing a dam across Krishna River. Near the bottom of the dam, there is a water intake. Trash Racks of 38meteis long are provided at the water intake to prevent the ingress of floating and other materials to the turbine. A Power tunnel of 720m long and diameter of 50 feet is taken off from the reservoir to the valve house at the start of Penstock. The valve house contains Bulk Head Gate for controlling water flow to the power station and automatic isolating valves for cutting off water supply in case the penstock bursts. A small storage reservoir called Surge tank (open at the top) is provided just before the valve house for better regulation of water pressure in the system to avoid the water hammer phenomenon. From the reservoir the water is carried to valve house through power tunnel and from valve house to the water Turbine through pipes of large diameter 6.10m made of steel or reinforced concrete, called the Penstock. Gravity causes water to fall through the penstock inside the dam. At the end of the penstock there is a Francis reaction turbine which is turned by the moving water, converts Hydraulic Energy into Mechanical energy. The shaft from the turbine goes up into the 3phase Alternator of capacity 122000KVA, which produces the power. The water after having done its useful work in the turbine is discharged to the tail race which may lead it to the river.
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Each 11 kV phase of Alternator is fed to the primary of single phase 11/220 kV Step-Up transformer. The secondaries of the Transformers are connected to the 220 kV SWITCH YARD from where it is distributed as ten 220 kV feeders, two 132 kV feeders and five 11 kV feeders. 1.4 Main Control Room (MCR) The Control Room (or the operating room) is the NERVE CENTER of the power station. The various controls performed here are Voltage adjustment, load control, emergency tripping of turbines.etc. and the equipment and instruments housed in Control Room are Synchronizing equipment (Synchroscope), Voltage regulators, Ammeters, Voltmeters, Watt meters, Kwh meters, Kvarh meters, Temperature Gauges and other appliances, as well as Mimic diagram and suitable indicating equipment to show the opened and closed position of Circuit Breakers, Isolators..etc.,

CHAPTER2
2.0 2.1 TURBINE Hydro Turbine
A hydro turbine converts the energy of flowing water into mechanical energy into electricity. The turbine is designed for direct coupling with three phase 50 Hz suspended type generator. energy. A hydroelectric generator converts this mechanical

Type of turbine Diameter of runner Speed of rotation Runaway speed Maximum (H Max) Design (HD) Minimum (H min) Rated output of turbine (at design head) Maximum output of turbine (at head 99 m and above) Discharge through the turbine at design head and rated output Optimum efficiency of the turbine Direction of rotation (when viewed from generator end) Maximum axial load transferred from on generator thrust bearing from turbine Speed rise of the set at 100% load throw drop Maximum pressure rise Type of governor Type of inlet valve

Francis 3600 mm 187.5 rpm 375 rpm 104.85 m 91.44 m 71.32 m 112200 kw 123500 kw 137.5 m3/sec 93% Clockwise 382 T 55% 35% Electro-hydraulic Disc valve diameter 4200 mm

 2.2 Francis Hydro Turbine

The Francis turbine is a type of water turbine that was developed by James B. Francis. It is an inward flow reaction turbine that combines radial flow and axial flow concepts. Francis turbines are the most common water turbine in use today. They operate in a head range of ten meters to several hundred meters and are primarily used for electrical power production. Theory of Operation: The Francis turbine is a reaction turbine, which means that the working fluid changes pressure as it moves through the turbine, giving up its energy. A casement is needed to contain the water flow. The turbine is located between the high pressure water source and the low pressure water exit, usually at the base of a dam. The inlet is spiral shaped. Guide vanes direct the water tangentially to the runner. This radial flow acts on the runner vanes, causing the runner to spin. The guide vanes (or wicket gate) may be adjustable to allow efficient turbine operation for a range of water flow conditions. As the water moves through the runner its spinning radius decreases, further acting on the runner. Imagine swinging a ball on a string around in a circle. If the string is pulled short, the ball spins faster. This property, in addition to the water's pressure, helps inward flow turbines harness water energy. At the exit, water acts on cup shaped runner features, leaving with no swirl and very little kinetic or potential, energy. The turbine's exit tube is shaped to help decelerate the water flow and recover the pressure. 2.3 Elements of Water Path of Turbine Spiral Casing Stay Rings Guide Apparatus Draft Tube Shaft Bearings etc., Spiral Casing It has been designed to provide axial symmetrical flow to the guide apparatus and runner with proper angle of attack at the inlet to the runner. It consists of several round and elliptical segments of different thicknesses provided in accordance with the water path and strength requirements.

Stay Rings It is of cast welded construction and consists of upper and lower rims. The profile of stay vanes has been designed to give the minimum hydraulic losses. 8

 Guide Apparatus It regulates the water flow through the turbine for various conditions of the load and head. It serves turbines as closing during device normal for and

emergency conditions. It consists of guide vanes, turning mechanism of guide vanes, cover of turbine, guide vane bearings bodies housed in top cover and lower ring of guide apparatus containing the bearings for lower journals of the guide vanes. There are 24 asymmetrical guide vanes located on pitch circle of diameter 4200mm. The guide vane profiles selected is optimum for the flow formed by spiral casing, stay vanes and suits the runner. A replaceable rubber ceiling is provided at places to prevent leakages. Each guide vane has three supports, one for the lower journal and two for the upper journal. The turning mechanism of guide vanes is designed to ensure the simultaneous turning of guide vanes during opening and closing of the guide apparatus and is located inside the pitch circle diameter of guide vanes. It consists of regulating ring, link assembly, strap, lever and shear pin. Regulating ring is turned with the help of servo motors. Bronze pads are provided at the rubbing faces between regulating ring and its support. These are kept submerged in oil to minimize friction. Servo Motors of Guide Apparatus Two servo motors of

diameter 500 mm are provided for turning the regulating ring. One of the servo motors is provided with a manually operated stopper for retaining the turbine in closed position without oil pressure in it for a long period. The stopper is provided with contact switches which indicate its closed or open position on the control panel. No oil pressure is allowed inside the servomotors when stopper is in position.

Leakage, if any, passes on to the leakage unit from where it is pumped to oil tank of oil pressure unit

Emptying of servo motors is also carried out through the leakage unit. Runner Assembly Runner converts the energy of flow of water into rotational energy which is transmitted to the generator through the shaft. The Francis runner (Diameter 3600mm) possesses high hydraulic and cavitational properties. It consists of lower and upper rims of slot type made of stainless steel. For unloading the runner and turbine cover from water pressure, 16 holes have been provided in the upper rim of the runner which converts the zone above the runner to that below the runner. The runner is connected with the shaft which transmits the torque and takes axial load. Draff Tube The draft tube knee lining has been made of welded construction in ten parts to facilitate its transportation. Foundation ring assembly forms the upper part of the conical portion of the draft tube. It consists of foundation ring and a conjugating bolt in eight pairs. Its purpose is to minimize the effect of cavitations in this portion of the draft tube. The draft tube cone forms the lower part conical portion of the Draft tube. A block out has been provided in the concrete portion of the draft tube for locating the drainage valve. The bottom of the block out has been provided at a lower level than the bottom level of draft tube for its complete dewatering. The valve is operated manually with the help of hand wheel and spindle arrangement. The spindle is fitted with universal joints for its easy and smooth working. In its open position the valve allows the water from draft tube to flow through an embedded pipe to draft tube gallery. A grill is provided in the block out from inside the draft tube for preventing large pieces of foreign matter flowing with water entering it. Turbine Shaft The turbine shaft of external diameter of 1000mm and internal diameter of 700mm is forged from high quality carbon steel. The upper flange of turbine shaft is connected to the flange of the generator shaft. At its lower flange, the turbine shaft is connected with the runner. The axial load as well as the torque is transmitted through the bolts which are fitted the internal core of the shaft has been closed at the runner end with the flange for preventing water from entering it. 10

 Guide Bearing

Self-lubricating turbine guide bearing of

segment type has been provided. The segments rests on a ring fixed to the horizontal flange of the bearing body and are kept pivoted against the spherical end of the bolts. Under stationary conditions, the lined segments are kept immersed in an oil bath up to the centre line pivoting bolts. When the shaft rotates the oil flows through the holes, due to centrifugal force and rises along bearing body cylinder lubricating the segments. The oil overflows over the cylinder and falls on the oil cooler tubes. The oil after passing through the cooler flows to the inner tank through the radial holes provided in the bearing body base. Thus the complete circulation of oil is achieved for controlling the flow of cooling water through the guide bearing.

Turbine Sealing The turbine shaft sealing serves to prevent the water leaking through the labyrinth sealing from flooding the turbine cover. A pressure gauge is provided for measuring the pressure of clean water supply. Just below the base plate of the turbine sealing a rubber ring is fixed on the shaft flange. This ring presses against taper surface specially provided in the turbine cover when rotor of the unit is lifted upon the jacks. Water Pipe Lines The system of water pipelines serves for supplying technical water to guide bearing cooler and oil cooler unit for governor oil system and clean water to turbine sealing. The flow of Water to the oil cooler of governor oil system is maintained automatically by an electromagnetic valve and globe valve which facilitates repairs and servicing. A pressure gauge located after the electromagnetic valve indicates the pressure of the cooling water being fed to the oil cooler. Another pipe carries technical water to the guide bearing oil cooler, on the outlet pipe from the guide bearing cooler, a flow failure Relay has been provided to give a signal in case of flowfailure through the pipe. The outlet pipe discharges water from the cooler into the drainage channel. Oil Pipe Lines of the Governing System: The elements of the governing and automation system i.e., governor, Oil pressure unit, Oil cooler unit, turbine servo motors, different electromagnetic slide valves, emergency slide valves etc, are inter connected by pipe lines. Oil under pressure from OPU is fed to the main slide valve of Governor from which two pipes are connected to the emergency slide valve which in turn inter connected to the corresponding ports of servo motors. The return oil from servo motors is fed back to the sump tank of OPU. Oil under pressure is fed directly to the valve with electro magnet 70 Kg/cm 2 for operating the emergency slide valve.

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Another pipe working directly under oil pressure interconnects the pressure accumulator and oil pumping unit for actuating the pressure the pressure relays meant for automatic operation of OPU. Feed-Back Connection The feedback gear is intended for the restoration of governor main slide valve to the main position during the process of governing. It consists of rope drive which transmits the movement of the servo motor through the system of rollers of the main slide valve. Oil Leakage Unit The oil leakage unit is intended for the collection of oil leakages from servo motors, drawing of oil from servo motor, controlling valves and oil pipe lines and periodic pumping from the tank of the oil leakage unit in the sump tank of OPU. The oil leakage unit consists of a tank and on this mounted are a pump and electro motor. In the tank, level relay is installed for automatic operation of the pump, controlling of oil level and alarm in case of higher oil level.

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CHAPTER3
3.0 3.1 ALTERNATORS Introduction The Generators employed in Srisailam Right Bank Power house are Three Phase Alternating current Synchronous Generators, called the Alternators. This Hydro-Electric power plant consists of seven Alternators each of capacity 110MW. A three phase synchronous machine is a Doubly excited AC machine because its field winding is energized from a DC source and its armature Winding is connected to an rotor under steady state conditions its operating speed depends on the frequency of the Armature current and number of the field poles. Speed = 120 * Frequency /No. of Poles 3.2 Main Specifications of the Alternator: 1. Type of alternator 2. Capacity 3. Speed 4. Stator 5. Rotation 6. Power factor 7. Frequency 8. Excitation 3.3 Operating Principle The Rotor of an Alternator consists of single phase winding and the stator consists of three phase winding. The rotor winding is fed with DC supply. The single phase winding on the rotor creates a field and, with the rotation of rotor this will move in space at the speed of rotation of the rotor. This will induce EMF in the stator three phase winding according to the Faradays Law. Michael Faraday states that an EMF will be induced in that conductor, when it experiences the rate of change of Flux Linkages. The magnitude of EMF is given by the below expression. : 3-phase water wheel : 122000 KVA : 187.5 rpm : 11 KV, 6420 A : clockwise : 0.9 : 50 H z : 216 Volts, 1214 A (DC)

The magnitude of this induced EMF depends on the strength of the DC field and the frequency corresponds to the rotor speed in case of Generator For the higher capacities of the Alternator, the conductors (stator) are placed constantly and the magnetic field (rotor) will be rotating.
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3.4

Main Parts of Alternator a) Stator Stator contains Armature winding, in which working EMF is induced by the working flux. It

carries only load current in the machine. The stator is a donut-shaped structure surrounding the rotor. The stator is made up of a steel frame supporting stacked steel laminations. The conductors, called the stator winding, are recessed in slots in this lamination structure. The stator winding is arranged so that when the rotor turns, the field poles pass only a fraction of an inch from it. The movement of the magnet next to the conductor causes electricity to flow in the conductor. b) Stator Frame The fabricated stator frame is cylindrical or polygonal in form. The frame is made of horizontal annular rings and Vertical ribs with an outer steel casing. It is designed to withstand satisfactorily the stress to which it is subjected during handling, short circuits or other fault conditions which may arise during operation. c) Stator Laminations The stator core is made up of steel laminations that are assembled in a stationary steel frame work. The laminations are punched, or laser-cut from electrical grade sheet-steel, approximately 0.014 inch thick. A thin coat of insulating varnish is baked on each lamination to insulate it from the other laminations to reduce eddy current losses. Notches are cut into the inner radius of the lamination, so that after assembly the stacked lamination notches align to form stator slots. The laminations are stacked, one at a time and clamped in a framework to form a rigid structure. After approximately 2 inches of the core is stacked, spacers are placed to provide air ducts for cooling air circulation.
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d) Stator Heaters Stator heaters are provided under stator to avoid formation of condensation on the Insulation while unit in idle condition. e) Stator Air Coolers Air coolers are fixed on the openings provided on the outer casing of the Stator frame, which cools the hot air coming out of the machine The air coolers have coil type tubes through which the cold water flows. f) Rotor The field structure is the largest and heaviest component of Alternator and is called the Rotor. Rotor contains Exciting or Field winding, which produces the working flux. It handles only the exciting current (dc), which is supplied to the rotor through two Slip-Rings and Brushes. The field windings are connected in series to form the Excitation winding which is supplied with dc at 216 volts. Magnetic field will be generated in the rotor circuit to obtain the rate of change of flux lines, that Magnetic field is obtained by exciting the field winding with DC supply. Exciting system is classified into two types 1. Static Excitation 2. Brushless Excitation 3. The recent Alternators make use of static excitation. The rotor will be rotated by a hydro turbine at a constant speed. The speed of the turbine is determined by the frequency of the electrical system. Proportional to this, the speed of the turbine is 187.5 RPM. In Srisailam Hydro Electric Power Plant Alternators are of vertical configuration, which employs Low speed Reaction Type Francis Turbines. Since the speed of the turbine is quite Low the Frequency of the alternator decreases as frequency is directly proportional to speed of the turbine. So to give required frequency the Alternators have large number of poles (32 poles). To accommodate such a large number of poles, these machines use Salient Pole Type Field Structure which has large diameter and small length. The Salient pole Rotor resembles a Fly wheel with Electro-Magnets, bolted on all round the periphery. It is usually made of Cast-Iron or Cast-Steel and has a heavy central hub, a number of radial arms, and a heavy rim which forms the Yoke of the Magnet System. The Fly Wheel Type Rotor is constructed to give adequate mechanical strength to withstand Centrifugal and driving forces

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The special features of Salient pole field structure 1. They have large diameter and short axial length. 2. The pole Shoes covers about 2/3 of pole pitch. 3. The poles are laminated to reduce Eddy current losses. 4. These are employed with Hydraulic Turbines which rotates at speed of 100 to 375 RPM. g) Rotor Shaft It is of high grade steel forging, accurately turned to gauge and bore throughout its length. A half coupling forged integral with the shaft is provided at its lower end for coupling with the turbine shaft. h) Rotor Poles The pole core is built of thin laminations punched stampings to reduce the pole Shoe losses. These stampings are clamped between two strong end plates. Pole coils are made of special profile or rectangular copper strings wound on edges. These coils are insulated between the turns and to the earth with class-B insulation. The inter polar connections are made up of flexible copper strips. Inter polar spaces are placed between the pole coils or clamps are mounted on the each side of the pole coil. A low resistance short circuited cage type damper winding is provided in the pole shoe and is inter connected between poles with flexible jumpers (to avoid magnetic losses). The pole coils are passed to the pole shoe by means of springs placed in the slots provided in the rim. The poles are fixed to the rotor rim with T heads and tapper keys.

i) Slip Rings and Brush Rocker Assembly The slip rings are fitted on the shaft at a suitable position for an easy inspection and maintenance. The rings are connected with the poles by means of current carrying leads, either fixed on the rotor surface of the shaft or laid in the slots milled on the outer surface of the shaft. The current carrying leads are in the form of copper bus bars insulated with class-B insulation.

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j) Brackets Brackets are fabricated construction are provided for housing Thrust and Guide Bearings. 1. Upper Brackets: It spans across the stator frame. In suspended type machine it transfers the vertical and radial forces to the generator foundation and radial jacks if any fixed on its arms. In semi umbrella type machine the upper guide bearing is located in the upper bracket. 2. Lower Bracket: In suspended type, it accommodates lower guide bearing, in umbrella type it accommodates thrust bearing. This lower bracket rests on generator foundation. Brake-cum-jacks are placed on these brackets. k) Turbine Pit Cover It is a light fabricated construction to prevent the circulating air from going out of the machine and serves as a switching platform for lower bracket and brakes. l) Thrust Bearings It is of pivoted segmental pad type it is self lubricated and immersed in oil bath for removing thrust bearing losses. It consists of a collar which is mounted on the shaft. Thrust bearing runner is fixed to the collar and is insulated from it to prevent the flow of bearing current. Thrust pads which are lined with high quality Babbitt Metal and are supported on thrust bolts which are screwed in the cylinder of thrust bearing frames.

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Pads support placed between thrust bearing pads and thrust bolts work like spring plates to provide cushioning effect to the whole assembly. Lock plates prevents radial and circumferential movement of the pads. m) Guide Bearings: Guide bearing is of self adjusting segmental pad type. The pads are lined with the high quality Babbitt Metal. The pads are insulated from rest of the assembly to prevent the flow of bearing currents and are immersed in oil. Water cooled oil coolers are plugged into the oil bath bearing. n) Braking and Jacking Sysyem In order to stop the machine a set of brakes is fixed on the lower brackets. Sometimes these brakes are noted on the generator foundation. The brake is a piston type mechanism with a rubber sealing cup and a friction block. Braking is performed by means of compressed air at a pressure of 7 Kg/cm2. Brake shoes are pressed against the brake track on the rotor to bring the machine to the rest. The same brakes are also used as a jackets for lifting of the rotor from which the oil under the pressure (about 100 Kg/cm2.) is fed to the brakes from high pressure pump unit. After jacking, the rotor can be maintained in lifted position by turning the locking net and releasing oil pressure. o) Ventilating System Closed circuit ventilated system is used for efficient cooling of the generator. Cooled air coming out of the air cooler divides itself into two streams. The lower stream passes through the ducts in the foundation. While the upper stream flows through the bracket arms. Suitable types of fans are fixed at both ends of rotor. Air after cooling the pole winding passes into the ventilating system of the stator core. The leakage of air is prevented by means of cover plates on the upper brackets and turbine pit cover below the lower bracket.

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CHAPTER4
4.0 4.1 POWER TRANSFORMERS Introduction Srisailam Right Bank power House consists of seven Hydro generators having capacity of 110MW (11 kV) each. The generated 11 kV is stepped up to 220 kV with the help of single phase 2 Winding Generator transformers (42.5MVA, 11/220 kV) for transmission and then stepped down to 132KV & 11 kV at Switch Yard for feeding distributing Transformers which further steps down the voltage to 400/23OVolts for the consumer use. Generally Transformer is an AC machine that transfers electrical energy from one electric circuit to another without change in frequency by the principle of ELECTROMAGNETIC INDUCTION. The Transformer construction requires no moving parts, so it is often called the Static Transformer, and it is very rugged machine requiring the minimum amount of repair and maintenance. Owing to the lack of rotating parts there are no Friction and windage losses so that the Efficiency of Transformer is high. Typically at full load the Efficiency lies between 96% and 97%. The cost per KVA Output of Transformer is quite low as compared with other electric machines. As there are no teeth, slots or rotating parts, and the winding can be immersed in oil, it is not difficult to insulate Transformers for very high voltages 4.2 Name Plate Details of Power Transformer Make Rating Voltage Amps Impedance Voltage Type of cooling Quality of Oil circulation Water circulation 4.3 Transformer Accessories Buchholz Relay Breather Expulsion Vent Conservator Tank Oil Temperature Indicator Winding Temperature Indicator : TELK : 42.5MVA, single phase 2 Winding : 11/(220/1.732) KV : 7335 A : 12.78% : OFWF(Oil Forced Water Forced) : 1000 Ltrs/min : 400Lts/Min from unit penstock tapping

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a) Buchholz (Gas Actuated Protective) Relay The gas actuated Buchholz relay comprise a cast housing which contains two pivoted aluminum buckets, each bucket being counter-balanced by a nickel-plated brass weight. Each assembly carries a mercury switch, the leads from which are taken to a terminal block. In both the alarm and surge element assemblies ,the representative weights of the bucket and balance weight are so distributed that the balance weight predominates, thus tilting The assembly to the switch open position .This condition exists when the transformer is oil filled , ready for service and also when completely empty prior to commissioning. When a light fault occur in transformers, small bubbles of gas will be generated and these, attempting to pass from the tank to the oil conservator, will be trapped in the relay Housing. As this gas accumulates, the oil level in the relay will fall, leveling the top bucket full of oil. As this bucket will not now be fully immersed, the extra weight due to the contained oil will over-come the balance weight and cause the whole assembly to the balance weight and cause the assembly to the tilt , there by closing its mercury switch and completing the alarm Circuit. With a serious internal fault, the gas generation is rapid, causing the displaced on to surge though the relay. The oil Flow will impinge on the baffle plate and cause the bottom bucket assembly to tilt, closing the mercury switch and completing the trip circuit to the circuit breaker to the circuit breaker. Thus the transformer will be isolated from the supply. If the transformer causes a loss of oil causing the oil level to drop below the level of the relay the buckets of the two elements will be left full of oil and first the alarm and then the surge element will operate to close the respective circuits. An inspection window is fitted on either side of the relay casting through which the oil level can easily be read viewed from the volume of gas presents indicated in cubic centimeters on a calibrated scale. The clear viewed from the front, the volume of the gas present is indicated in cubic centimeters on a calibrated scale. The clear view from rear of the relay also enables air bubbles to be observed when drying out the transformers b) Breather Transformer performs breathing action as a result of expansion and construction of oil due to variation of its load and ambient temperature. When the transformer breathes through a silica Gel breather, the moisture presents in the air will be absorbed by the gel, thereby permitting only dry air to go inside the transformer. c) Expulsion Vent The Expulsion vent has a bursting plate as a safety device for the gas discharge, when the internal pressure of the transformer tank is increased by abnormal phenomena.

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d) Conservator Tank It is a tank which stores transformer oil of circulating through the winding. It is mounted on top of the transformer and a level indicator is provided to check the oil level during operation. This tank is connected through a pipe of the transformer shell. It permits the installation of Buchholz relay. Allow expansion & Construction of oil during operation, ensures. total submerging of transformer winding & core with oil for the cooling. It reduces the areas of interface between air &oil which in turn reduces level dissolved oxygen in oil. e) Oil & Winding Temperature Indicators Winding & oil temp indicator functions are to indicate the temp of the winding & oil, to operate an alarm & trip circuit at a predetermined temperature. Also to switch on standby oil pump when the winding temperature rises above a preset temperature. f) Cooler control scheme: Transformers are provided with OFW (forced oil, water circulated) cooling method. Oil pump sucks hot oil from the top of transformer tank and discharges oil to heat exchange. In oil to water heat exchanger, hot oil is cooled by the water flowing in tubes. Oil flow indicator mounted in the oil pipe line gives the visual indication of the Flow/Stop condition on the dial. When flow is stopped or reduced, indicator gives an alarm at the remote panel. Water is led to the heat exchanger from indicator when water flow is stopped or reduced; this indicator gives a remote alarm indication. For controlling the water flow rate, a valve is connected in the inlet pipe. Visible free water discharged at the outlet avoids any pressure build up in the water circuit. In order to keep trash and other in soluble foreign matters in water away from the cooling tubes, the inlet water shall be filtered through 1/4lh square wire mesh. 4 No.s. pipe lines are used in flow per minute, during full load, in oil and water pipelines will be 1000 and 400 liters oil circuit and 3 pipe lines in water circuit approximately nominal respectively. Oil pipe lines from transformer tank to the heat exchanger also aligned as to assure a low friction head loss. The cooler system is so designed that under all conditions oil pressure inside the heat exchanger will be more then the water pressure. Hence even if any leak occurs in the heat exchanger it will pressure and max. Water pressure inside the heat exchanger to pressure gauges (02.0kg/cm2 range for oil and 0-lkg/cm2 range for water)are mounted at oil outlet and water inlet to heat exchanger . 4 No.s butterfly valves are mounted on pipeline at appropriate positions to isolate oil flow. 4 non-return valves is provided at the oil inlet of each cooler to prevent short circuit between the two coolers while the oil pump of one takes over automatically due to failure of others.

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Each transformer is provided with two heat exchangers of 100% capacity and both are mounted on the side of transformer tank side by side. In case cooling circuit of water cooler unit develops fault the other can put into operation 4.4 On-Load Tap Changer The Generator Transformer ar Srisailam Right Bank Power House is provided with a onLoad Tap Changer. Through this Voltage can be adjusted to desired level in between range provided by the taps. The details of the Taps are given in the following table. HV Tap Selector Connections Position Connection HV Volts (%) 1 A1 109 2 A2 108 3 A3 107 4 A4 106 5 A5 105 6 A6 104 7 A7 103 8 A8 102 9 A9 101 10 A10 100 11 A11 99 12 A12 98 13 A13 97 Transformer Testing The following tests must be performed on transformer before charging the Transformer. Tests on Winding a) b) c) d) e) f) g) h) i) Insulation resistance test Ratio test Magnetising current test Magnetising balance test Winding resistance test Tan-Delta & Capacitance test Partial discharge test vector group test Residual life assessment test a) b) c) d) e) f) g) h) i) Tests on Oil Appearance Test Breakdown voltage (KV) Test Moisture (ppm) Test Acidity (mg KOH/g) Test Interfacial tension Test Resistivity (ohm-cm ) Flash point (c) Dissolved gas analysis Tan-delta Test

4.5

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4.6

Emulsifier System In case of any fire in the shell or around the tank, a system is provided to quench the fire

instantaneously without further spreading it, this system is known as Emulsifier system. This system works on the principle of atomization of water with such force that it causes emulsion at the surface of oil. Such an emulsion is difficult to ignite and will smoother, an existing oil fire and prevent recombustion by lowering the surface oil temperature below its flash point. Sub systems: a) Main hydrants b) Fire detectors c) Ring mains & nozzles d) Pumps Main Hydrant is used to carry water to various parts of transformer. Fire detectors are specially designed bulbs, which bursts when high temperature is applied and releases a valve to start the water spray. Ring mains surround the transformer to feed the water to the nozzles at various levels. Pumps are provided to fill the hydrants initially and to maintain its pressure.

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