AUTOMATION OF HYDRO POWER PLANT

Project Report

Submitted by

KONIKA SOLANKI

Under the Supervision of

Mr MANDAR JOSHI
TEAM MEMBER, AUTOMATION TECHNOLOGY

INSTITUTE OF ENGINEERING AND TECHNOLOGY

DAVV INDORE-452014
ELECTRONICS AND TELECOMMUNICATION ENGINEERING
Project Details
Student Details
Student Name Konika solanki
Register Number DE17304 Section / Roll B
No
Email Address Konika.solanki@yahoo.in Phone No 9179284707
(M)
Project Details
Project Title AUTOMATION OF HYDRO POWER PLANT
Project Duration 2 weeks Date of 03 june
reporting
Organization Details
Organization Andritz Hydro Pvt. Ltd.
Name
Full postal D-17 MPAKVN Industrial area Mandideep phase-1, 462046
address with pin
code
Website address http://www.andritz.com/hydro.htm
Supervisor Details
Supervisor Mr. Mandar Joshi
Name
 CERTIFICATE

This is to certify that the above project is being carried out under my supervision and
guidance

Place:

___________________
Date:

(Supervisor signature with Seal)

 DECLARATION
I’m Konika Solanki, hereby declare that the work presented in this major
training is an authentic record of my own work and this work has been carried
out taking care of engineering ethics and company rules and regulations under
the guidance of Mr. Mandar Joshi. The work presented does not infringe any
patented work and not been submitted to any company/university for the award
of any industrial training or any professional diploma.
 ACKNOWLEDGEMENT
Our deep sense of gratitude to MR. HARSH JOSHI, HOD-AUTOMATION
TECHNOLOGY “ANDRITZ HYDRO MANDIDEEP” for their excellent
and needful support and guidance, for that I am heart thankful to you. I would
like to express my sincere and heart fully thanks to MR. MANDAR JOSHI for
his timely and practical suggestion and knowledge also for help and co-
operation which was very helpful for completion of my report. I also like to
thank MR. AJAY PANDAY-Human Resource to facilitate our training
at”ANDRITZ HYDRO MANDIDEEP” and allow us to expand our knowledge
and exposure to enrich our technical understanding.
I also thanks to staff of “andritz hydro “for their support in providing the
adequate working knowledge of machines for completion of this report.
 INTRODUCTION
AUTOMATION OF HYDRO POWER PLANT is done to reduce the human
dependency of system and to make it more reliable and error free. At this stage
when we need to shift toward renewables at a speed greater than the current,
Automation could save labor; however, it is also used to save energy and
materials and to improve quality, accuracy and precision.

Rifkin, Jeremy (1995) in their work: The End of Work, have defined
automation as the use of various control systems for operating equipment such
as machinery, processes in factories, and other applications with minimal or
reduced human intervention.
 MOTIVATION
Hydro power plants provide us access to clean renewable energy and ensure
unlimited power supply as well. Hydropower stations are mainly located in
remote mountainous area and far from town, which use computer monitoring
and control system instead of manual operation and timing tour of inspection
and record etc. miscellaneous labor to realize the unattended or less unattended.
With help of Automation optimal efficiency is achieved and safety issues are
addressed well. Machines that are automatized could sense and rectify
irregularity and are not easily subjected to mishaps, slowed production, and
profit loss and with latest technology everything could be well regulated
through computerized control system. Thus with the integration of automation
technology and mechanical machinery efficient and safe clean renewable energy
is produced.
 LITERATURE REVIEW
A generating station which utilizes the potential energy of water at a high level for the
generation of electrical energy is known as hydro-electric power station. In Hydro Power
Plant we use gravitational force of fluid water to run the turbine which is coupled with
electric generator to produce electricity. This power plant plays an important role to protect
our fossil fuel which is limited, because the generated electricity in hydro power station is the
use of water which is renewable source of energy and available in lots of amount without any
cost.
The big advantage of hydro power is the water which the main stuff to produce electricity in
hydro power plant is free, it not contain any type of pollution and after generated electricity
the price of electricity is average not too much high

3.2 Hydro Generators

Hydro Generators convert the mechanical energy from the turbine into electrical energy using
an excitation system. These days’ generators are characterized by their compact design, high
efficiencies, and long lifetime with the help of modern calculation methods and optimized
manufacturing procedures and materials.
The “normal” operation sequence & tasks associated with Generator in Hydro Power Plant
are:

 standstill
 run-up
 stabilization at grid frequency (speed control at no load)
 synchronization and switch-in to interconnected operation mode
 power output control, load swings with constraints (see below)
 unloading and switch-out to speed/no-load mode
 or, as a frequent case of “non-nominal” operation, trip (switch-out under load,
speed increase and stabilization at nominal speed for re-synchronization); and
 shutdown: speed coast-down and final braking to standstill

Depending on the hydropower plant characteristics, the turbine used and the required speed,
the following generators are available:

 Vertical shaft generators

 Motor-generators
 PIT type generators
 Bulb generators
 Special machines
Automation
Power station automation is aimed at increasing output and decreasing costs. Whether it is
newly constructed or modernized, each hydropower station requires specially adapted
architecture meeting its specific requirements.

Automation solutions are available for many portfolios, some of them are

 Automation & control

 Excitation
 Power plant management
 Monitoring & diagnosis
 Protection
 Synchronization
 Turbine governors

The advantages that customers gain from an integrated automation concept

 Lower investment costs

 Simplified start-up
 Short standstill times during system replacements

Modernization and replacement projects must take the history of the station into account,
which is reflected in different products, functions, cables, and sensors used over the different
time periods. These projects typically require a step by- step approach. Modernizations as
well as new construction of large systems are characterized by a large extent of complex
hardware architecture, differing communication systems, and integration of the latest
technologies. In small hydropower stations, cost-optimized hardware architectures with
functional integration are typical features.

Each operational and maintenance concept takes a number of modern technologies and
products into account. The global use of mobile phones, internet, and GPS are state-of-the-
art. Any modern automation concept can utilize these technologies for optimization and
simplification of maintenance.
OBJECTIVE OF THE WORK

Objective of the project is to learn the various steps involved in an industry

while automatizing a Hydro Power Plant to be installed in a hydro power plant.

TARGET SPECIFICATIONS

Target of the project is to learn about how automation of Hydro Power Plant
takes place along with the functioning of department and interface with other
departments. This internship is a great opportunity to get exposure to the
various industrial processes, technical as well as managerial.

PROCESSOR
 METHODOLOGY
The process of receiving to completion of a project follows the below steps
Contract award
Receiving a project from customer

Highlights of target
The department then highlights the target and prepare project schedule according to
contract and proceeds according to the customer’s requirement.
Then equipment for automation are identified according to the size of generating
units.

List of documents and drawing to be provided and designed is made and

approved by department and customer.

Functions Integration of inputs from cross

The necessary information required about generating unit is collected from other
departments, which are

 Control
 Excitation
 Protection
 EPS (Electrical power System)
 MBOP (mechanical balance of process)
 Turbine
 Generator

Design memorandum of control system

A memorandum is the set of documents or the handbook of the product to be
delivered to the customer with all the specifications of the tools and parts used in
system.

Topology of network system

Network topology is the arrangement of the various elements (links, nodes, etc.) of a
computer network. Essentially, it is the topological structure of a network and may be
depicted physically or logically. Physical topology is the placement of the various
components of a network, including device location and cable installation, while
logical topology illustrates how data flows within a network, regardless of its physical
design. Distances between nodes, physical interconnections, transmission rates, or
signal types may differ between two networks, yet their topologies may be identical.
.
Input/output list preparation or signal list
This list segregates the input and output signals on the basis of their type: like AI, AO,
DI, DO

Signal List for some parts of UCB of Thoung kon tum (TKT) Hydro Power Project

Panel design
Size of panels, placement of equipment in panels are decided and drawing are
generated accordingly

Circuit diagram of panels are prepared

Logic diagram for the functioning of automation system is also prepared

Logic diagrams are designed for PLCs.

Procurement of material

Required materials with suitable ratings are ordered

Software development on basis of logic diagram is done for PLC

SCADA designing

SCADA is designed for the system according to system’s requirement: using ‘SAT
250’

TESTING

Tests that are done on panels are:

 General tests
Parts and devices, and grounding are checked manually of all panels using the
designed protocols.

 Test for Control

1. Functional Check test: all the DI, DO, AI, RTD signals are checked
[D – Digital, A- Analog, I-Input]
2. Control Philosophy
3. Communication B/w Panels to SCADA
4. HV & IR test (high voltage and insulation Resistance test): these tests are done
on excitation panel to check the insulations of circuits. Tools used for
performing these tests are Megger and HV kit.
5. Synchronization: using secondary injection kit like OMICRON

AI,DI CARD
The products are ready for FAT (FACTORY ACCESS TEST)

Dispatch and commissioning of product on site

Commissioning involves the on-site tests and proper desirable working of product at
the site

TOOLS REQUIRED
Complete Automation of Plant is generally done by using three types of panels. They
are
Control Panel
Control system has been configured to enable complete operation and monitoring of the plant
from the control room as well as locally from local control boards. The configuration of the
system is distributed and de-centralized so that in case of a fault in any one of the equipment,
others are not affected and system continues to function effectively.

The control system is divided in to various functional areas as follows,

 Unit Control Board (UCB) located in Electronic Room: The Unit Control Board
(UCB) is provided for control and supervision of the entire generator and turbine
set.
 Common Auxiliary Board (CAB) located in Electronic Room: This component shall
control all relevant plant facilities which are responsible for common auxiliaries e.g.
Air compressor, low voltage system/switchgear etc. and monitoring of Drainage &
Dewatering System, Common Cooling water System and DG Set, etc.
 Central Station Control Board located in Control Room: This component shall use
for communication with Load dispatch centre.

 Weir Station Auxiliary RTU located in Intake Control Room: This component shall
control all relevant plant facilities which are responsible for interfacing with Dam
area components.
 Bottom Outlet RTU located in Intake Control Room: This component shall control
all relevant plant facilities which are responsible for interfacing with Bottom outlet
area components.

 Weir RTU located at each weir: This component shall control all relevant plant
facilities which are responsible for interfacing with Weir area components.

 Switchyard Control Board located in Switchyard Control Building: The

SWITCHYARD CB performs the following:
8.1.1.1 Monitoring of Switchyard Bay etc.
8.1.1.2 Control of station auxiliaries
  Switchyard Bay Controller located in Switchyard Control Building:
Separate Bay controller will be provided for Unit and line. This component
shall control all relevant plant facilities which are responsible for
interfacing with Switchyard bay components.
Or
GIS Control Board located in GIS Control Building: This component shall
control all relevant plant facilities which are responsible for interfacing
with GIS LCC panels

 Central Control Room Equipment including Operator Station 1&2, Fixed

Engineering Station, Information System, Historical Data Storage Server,
Web Server.: The control level in the power station shall be designed for
automatic control and monitoring of entire power plant, Monitoring of the
generating units, station auxiliary and station services. All system at this
level can work in Automatic, Semi- Automatic & Manual mode.
These components vary according to the customers demand.
Excitation Panel
Excitation system is of a well proven and nearly maintenance free design. It is
characterized by the use of thyristor type converters as power elements and digital
sequenced voltage regulator (AVR) with integrated sequencer type GMR3 regulator.
The exciter cubicle contains all power circuits (except excitation transformer), the
automatic voltage regulator and the complete sequencer, which is necessary to control
the individual components. The system also comprises a local operating panel with
alarm indication, which enables local operation and quick trouble-shooting in case of
excitation failures.
The main features of excitation system are:

• Full static excitation for synchronous machines with slip rings

• Redundant power rectifier
• Power supply via excitation transformer in shunt field connection
• Dual channel digital sequencer (microprocessor based)
• Dual channel digital regulator (microprocessor based)
• Manual excitation as rotor current regulator (separate part of software)
• Automatic follow-up and changeover of regulator channels
• Provisions for limitation- and additional regulator functions

PROTECTION
The excitation equipment will be protected against internal faults, failure of thyristor
bridges, cooling fans etc. for which contacts shall be provided for alarm and shut
down of the unit.
Protection Panel

Electric machinery, such as generators, transformers, auxiliary systems, bus bars, overhead
lines and cable feeders, etc. have to be provided with protective feature which will respond to
internal and external faults and/or overloads or inadvertent false control operations to limit
damages to a minimum by selective and co-ordinate isolation of the respective electrical plant
portion thereby ensuring continuity of supply and safe operation for the remaining power
system. The properties of the electrical plant and the kind of applied equipment as well as the
operating experience of the Power Authority and economic considerations for new
constructed equipment will eventually determine the selection of the electrical protection
system.

SOFTWARE
 for SCADA: SCADA 250
 for Program Software: Siemens Toolbox II

RESULTS ANALYSIS
After completion of this project Whole Hydro Power Plant will be automated and
could be operated easily from Control room or even manually. All the actions and
functioning data will be recorded for future reference and easy operations. Listing few
areas that are generally covered

 Control equipment for each unit

 GIS unit (all CB, motor operated disconnectors and earthing switches)
 Inlet valve
 outlets Turbine and speed governor
 Generator breaker
 Generator and excitation system
 Power transformer
 Water cooling equipment
 All-important auxiliary equipment
 Control equipment for general service of power plant
 Station service system including ac and dc system
 power supply system
 Power intakes, spillway gates, & bottom
CONCLUSIONS

Water and energy are essential elements of humanity’s life and

civilization, and hydropower relates to both. Setting up of Hydro Power
Plant requires great amount of capital, labor, time and land. Thus investing so
much into something should be as fruitful as possible, which could be achieved
by automation. Making the system intelligent and self-sustainable improves its
efficiency and reduces losses and faults.
With the growing power demand by consumer, it is must that we should
upgrade our system or build the new ones so that they could work at their
maximum efficiency and fulfill the growing demand.
TECHNICAL REFERENCES
Journal / Conference Papers
[1] Sukhmeet Kaur, Namita Kathpal and Nitika Munjal, “Role of SCADA in Hydro Power
Plant
AUTOMATION”, International Journal of Advanced Research in Electrical, Electronics
and Instrumentation Engineering Vol. 4, Issue 10, October 2015, 8085, 2015

[2]Adolf Hermann Glattfelder, Ludwig Huser and Peter Dörfler and Johann Steinbach,
“AUTOMATIC CONTROL FOR HYDROELECTRIC POWER PLANTS”, CONTROL
SYSTEMS, ROBOTICS AND AUTOMATION - Vol. XVIII, Switzerland.

Reference / Hand Books

[1] J.B. Gupta, “A course in Power Systems”, SK Kataria & Sons, Tenth Edition, ISBN
number: 81-88458-52- X
[2] D. P. Kothari & I J Nagrath, “Electric Machines”, Tata McGraw-Hill Education, ISBN
number: 0-07-061666-3

Web
[1] https://www.electrical4u.com
[2], http://www.andritz.com/hydro.htm
[3], https://en.wikipedia.org