Operation Manual

Malakand-III Hydro Power Complex OPERATION
MANUAL
Qazi Khalid Masood

Turbine Operator HTPPL
Irshad Ahmed
Asst Turbine Operator HTPPL
Hydro Tech Pak. (Pvt.) Ltd.
Hydro Tech Pak. (Pvt.) Ltd. (Symbol of commitment in Hydro Power) Page 1
MANUAL
DEDICATION
“To our instructors / teachers, who had put their efforts in our training
/ learning of hydropower operation field and whatever we are,
narrating in the following pages is all because of them. May Almighty
Allah reward them for their selfless contribution”
MANUAL
PREFACE
Besides qualified senior instructors, a brief O&M manual describing the basics
concepts of hydropower station is a supplement for the new comers. At the same
time, the deputed staff may be benefitted with the same for review or guidance.
In order to meet this requirement, an effort is made to provide the site specific
O&M methodology through this manual. This manual encompasses the general
operational techniques of Malakand-III Power Complex. It covers essential
knowledge about the plant and its auxiliaries. For detailed information about a
specific equipment, its manufacturer’s O&M Manual must be consulted. Level
best efforts were put in but the room for improvements is always there, so it
would be highly appreciated to point out errors or deficiencies for further up
gradation.
Thanks.
MANUAL
ACKNOWLEDGMENT
“We are grateful to the Plant Manager and Deputy Plant Managers, who
appreciated us in preparation of this document. With their perpetual cooperation
and guidance, we are able to present this manual”.
MANUAL
CONTENTS
SUMMARY Page No.
Authors 1
Dedication 2
Preface 3
Acknowledgment 4
Contents 5
Introduction 6
Salient features of the Project 7
Salient structures of the Project 8
Operation Methodology of Forebay 10
Filling of penstock 10
Intake gate operation 11
Filling and un-filling draft tube: 13
Filling of spiral case: 15
Dewatering of draft tube 15
Dewatering of spiral case 16
Inlet valve operation 17
Cooling water system 19
Unit pre starting checks after maintenance 23
Mode of operation for starting the unit 26
Operation of diesel generator 29
Limits for operation 32
Trip signals relating to unit 34
Switchyard 35
Operation methodology of switchyard 39
Protection system 40
Excitation system 45
Scada and DCS systems 46
Lv/hv switchgear 48
Station drainage and dewatering system 54
Governor’s hydraulic system 56
Compressed air system 57
Heating ventilating and air conditioning system (HVAC): 61
Dc battery system 63
Fire and firefighting 65
Name plate data of turbine, generator, and transformer. 71
Significant Elevations related to Malakand-III HPC 73
MANUAL
INTRODUCTION
Water is led from Swat River through Upper Swat Mainline Canal commencing at village
Amandara in the Malakand Agency where head works were constructed in 1914. The whole
irrigation system, finally commissioned in 1918, is called Upper Swat Canal system and was
designed to provide irrigation water to 113, 312 hectares (280,000 acres) of barani wastelands
in the Malakand Agency, Mardan and Peshawar districts. This was made possible by piercing a
tunnel (Named Benton Tunnel) through the Malakand hill range. Taking advantage of the
elevation difference between the hilly and plan area Power Station Jabben (Malakand-I) was
constructed in 1937 followed by Power Station Dargai (Malakand-II) in 1952.
As the pressure of population grew, high water consuming, rich cash crops like sugarcane and
tobacco became wide spread and the Upper Swat Canal could no longer deliver what the whole
land demanded. It became unavoidable by early eighties to make a major remodelling effort to
increase the irrigation water supply. Luckily, Swat River had the water for the Kharif season
(April to September) whereas, requirements though Rabi (October to March) was a period of
some shortages. The remodelling effort appeared in the form of projects by the name of
Mardan SCARP, Swabi SCARP and Pehur High Level Canal Project.
The Swabi SCARP (Upper Swat Canal) included the construction of an additional tunnel across
the Malakand range of hills, which already had one tunnel as a part of the old irrigation system
of the Upper Swat Canal. The new Auxiliary tunnel was constructed to carry a discharge of 51
m3/sec (1,800 cusec), which nearly doubles the supplies for the Kharif season.
The availability of additional water created the possibility of producing more electricity. A
power generation scheme was so conceived out of Swabi SCARP as to serve the needs of
remodelling of Swabi SCARP and generates additional power, as well. This scheme was initially
prepared by WAPDA but was taken over later by the provincial government of KPK to generate
81MW of power and a net saleable energy of 550 million units. This new electricity generation
scheme was named Malakand-III Hydropower Project.
MANUAL
SALIENT FEATURES OF THE PROJECT
 NAME : Malakand III Hydropower Complex

 LOCATION : Dargai, District Malakand, KPK, Pakistan
 CAPACITY : 81MW
 DESIGN DISCHARGE : 51 cumecs
 NET HEAD : 181 meters
 ENERGY : 550 GWh per Annum
 ESTIMATED COST : Rs. 6379.55 million
 UNIT COST GENERATION : 2.16 US cents / KWh
 TOTAL PROJECT LENGTH : 10 km
 HEADRACE CHANNEL : 2.62 km
 TUNNEL (5 Nos.) : 3.33 km
 SEDIMENT EXCLUDER : 140m (Length) x 45m (Width) x 11.25m (Depth)
 FOREBAY : 60m (Length) x 14m (Width) x 14.2m (Depth)
 SPILLWAY : Total Length; 888m (Spillway Cascade length; 728
m) and (Spillway Tunnel length; 160m)
 PENSTOCK : Total Length; 831m, Diameter; 4m and
running 290 m through Tunnel
 POWER HOUSE: : 46m Long x 36m Wide (32 m deep excavation)
 TURBINES: : 3 Vertical Shaft Francis Turbines
 TAILRACE: : 1 km Long concrete lined channel
 WASTEWAY: : 2.385 km Long Stone Pitched Channel discharging

in to Wartair Khwar
MANUAL
Salient Structures of the Project

 Sediment Excluder
 Fore bay
 Penstock
 Spillway
 Power House
 Switch Yard
Sediment Excluder;
A 140 m Long x 45 m Wide x 11.25 m deep pond forms the Sediment Excluder. The increase in
area tremendously dropped the water velocity to trap the suspended / dissolved silt. In
addition, the garbage and trashes are dragged out through Automatic Trash rack cleaning
machines. Sediment Excluder is divided into four parallel chambers. Each chamber is
subdivided into three sections and each section contains a hand operated sliding gate. A
flushing pipe connecting four sliding gates of four equilateral sections is laid to flush out the
trapped sand. This flushing pipe discharges silt into flushing channel through Gate valve. The
flushing channel is rectangular in shape and its size is about 3m wide by 1.5m deep. The
Sediment Excluder at its exit, converges into a radial channel, which thereafter leads to the fore
bay through tunnel # 3.
Fore bay
forebay is basically a pond of water at the head of penstock. The pond is required to serve two
main and some subsidiary purposes depending upon the design concepts of the power plant.
Principally a forebay provides enough submergence for the penstock inlet to guard against air
entrap from possible vortices, provide space to house the inlet end of the penstock and creates
tranquil conditions for smooth entry of water into the penstock.
The flow from Forebay structure is diverted to powerhouse through penstock. The fore bay is
having dimensions 14m x 14.20m x 60m. The bed level of the fore bay is 630.30masl and
Penstock transition cone is placed at 630.70masl.
Penstock
From the Intake structure and Fore bay water is taken to the turbines by a conduit system
known as Penstock. There are two types of Penstocks namely the low-pressure and the high-
pressure. The low-pressure type consists of a canal, a flume or a pipe. The high-pressure
consists of a steel pipe which can take water under pressure. Malakand-III has a high pressure
MANUAL
type of Penstock with diameter of 4m.The thickness of penstock gradually increases as it

comes down. The Penstock at its manifold is further divided into three branches for the three
units and the branch pipe has diameter 2.7m.
An intake gate sizing 5.705m × 4.2m is provided to open and close water entry in the penstock,
as and when required. The intake gate control mechanism is gear operated motor system.
Spill way
Spill way is used to discharge excess water in the forebay beyond the maximum permissible
level. An automatic operated Syphon Spillway is provided, capable to discharge 2000 cusecs, if
required. The total length of spillway is 888m comprising 728m concrete buckets and 160m
spillway tunnel. The spill way operating level is 642.06masl.
Power House
A Powerhouse is the source where hydraulic energy is converted into electric energy with the
help of Turbines coupled to generators. Malakand III has three generating units with total
installed capacity of 81MW. The building dimensions are 42m x 20m.
Switchyard
The switchyard is the electrical interconnection point with the National Grid for dispatching
energy. Malakand-III HPP 132KV switchyard collects energy generated by three units and
dispatches it through two 132KV transmission lines. Two redundant, energy meters are
installed here to record the energy dispatched for billing purpose. Malakand-III switchyard is
connected by two 132kV transmission lines with 132KV Dargai Grid Station. One and a half
breaker scheme comprising SF6 type circuit breakers is deployed. .
132KV Malakand-III switchyard comprises the following main equipments constituting

breaker and a half scheme:
 02 Busbars.
 03 Bays.
 08 Breakers.
 23 Isolators.
 24 CTs.
 12 PTs.
 05 Earth Switches.
 06 Surge Arrestors.
 04 wave traps.
MANUAL
OPERATIONAL METHODOLOGY
Fore bay
Filling of fore bay

 Pre checks
 Confirm that Intake Gate is fully closed.

 Confirm that Penstock bypass valves are closed.
When the water reaches forebay, let the spillway be operated for 5 to 10 minutes so as the
flush out the suspended garbage.
Filling/ un-filling or watering /Dewatering of Penstock

Basically two methods are recommended for filling of Penstock.
 Filling through Penstock bypass valve

 Filling through crack opening of Intake Gate.
Normally the first method is preferred and used for routine filling of the Penstock. The second
method is seldom used, in emergency conditions only.
 Pre checks
 Confirm that inlet valves and their bypass valves of all three units are closed
 Confirm that penstock dewatering valves of all three units are closed.
Filling of penstock through Penstock bypass valve.

 Steps:
 Open both the manual gate valves of penstock bypass line.

 Open the motorized valve of penstock bypass line.
 Confirm the flow through bypass line by noting the noise emanating as result of flow.
 Check the air vent pipe of the penstock. Air shall be released out with a shrilling sound.
 Check for gradual pressure rise at the Pressure Gauge installed upstream of each Inlet
valve for ascertaining normal and continuous filling process.
 When the pressure reaches 1.8Mpa, closed the manual gate valves of the Penstock
bypass line.
MANUAL
Filling of penstock through crack opening of Intake Gate
 Steps:
 Switch ON the main supply breaker.

 Close the breaker cubical door.
 Confirm the availability of power supply.
 Pull out the manual pin.
 Crack open the Intake Gate by giving “OPEN” pulse till the gate is raised up to 80 mm.
 Immediately, press “STOP” push button to prevent lifting of gate beyond 80 mm or an
abnormal sound is heard while raising the gate even before it reaches 80mm.
 Check the air vent pipe of the penstock. Air shall be released out with a shrilling sound.
 Check for gradual pressure rise at the Pressure Gauge installed upstream of each Inlet
valve at Powerhouse for ascertaining normal and continuous filling process.
Dewatering / un-filling of penstock
 Prechecks
 Confirm that intake gates is fully closed.

 Confirm that intake gate bypass valves are also closed.
 Steps
 Open the penstock dewatering valves of all the three units.

 Observe the pressure at penstock ensure that the pressure gradually decrease from 1.8
Mpa to 0 Mpa.
Intake Gate Operation
Gate Opening Operation:

During normal operation of the power complex, the Intake Gate remains open. For the safety of
penstock, it is imperative to ascertain the gate to be in open position during running of the unit(s).
Additionally, the intake gate is also kept open while draining the power channel / forebay. This
draining process is accomplished through either rolling the units or penstock dewatering valves.
MANUAL
Gate Closing operation:

The closing of gate is required to isolate penstock from forebay to carry out maintenance works in
penstock or Inlet valve. When the Intake gate is fully closed, the dewatering of penstock is carried out
exclusively through penstock dewatering valves, which are installed upstream of inlet valves of each
Unit.
Closing of intake gate
 Pre checks
 If the gate is to be closed, ensure that all the units are shutdown.
 Steps for closing
 Switch “ON” the main supply breaker namely “intake gate” located at breaker room
down stairs the forebay control room.
 Switch “ON” the auxiliary supply breaker QF3 namely “Gate breaker” by pushing the
black button in distribution panel located at forebay control room
 Confirm the availability of power supply at intake gate control panel at the top of
forebay building.
 Give close pulse through Green push button from intake gate control panel at the top of
forebay building.
 Confirm the fully closed position of intake gate showing around 44.00 mm. At the same
time, it may be re-confirmed physically by loose holding ropes of the gate as well.
 Re-insert the manual pin in its designated slot.
 All three valves (two manual and one motorized) located on bypass line of penstock
shall be turned close.
Opening of intake gate

 Pre checks
 Confirm that the Penstock Pressure Gauges installed upstream of inlet valves show
pressure as 1.8MPa for more than 10 minutes.
MANUAL
 Steps
 Switch “ON” the main supply breaker namely “intake gate” located at breaker room
down stairs the forebay control room.
 Switch “ON” the auxiliary supply breaker QF3 namely “Gate breaker” by pushing the
black button in distribution panel located at forebay control room
 Confirm the availability of power supply at intake gate control panel at the top of
forebay building.
 Give opening pulse through red push button from intake gate control panel at the top of
forebay building.
 To stop at any desired position, press “STOP” push button.
 The full opening will be attained around 6295 mm opening value shown by the
indicator installed in the intake gate control panel at the top of forebay building.
 Re-insert the manual pin in its designated slot.
 Switch OFF the main supply breaker.
Filling and un-filling / watering and de-watering of Draft Tube:

There are three methods of filling Draft Tube.
 Through Tail race

 Unit to unit filling
 Through the window of draft tube Gate.
Filling of Draft tube through Tail race

 Pre checks
 Confirm that draft tube window and spiral case window are closed and properly bolted.
 Confirm that gate valve of dewatering common header in drainage pit is in closed
position.
 Confirm the draft tube dewatering valves of other two units are closed.
 Confirm that both Dewatering Pumps are “OFF”.
 Steps
 Open the draft tube dewatering valve of the unit.

 Open all the three manual gate valves, one by one, located besides the eastern wall near
station drainage pit.
MANUAL
 Observe the draft tube pressure through pressure gauge and physically confirm its
filling through draft tube inspection valve.
 After confirming the filling, closed draft tube dewatering valve of the unit.
 Also close the manual gate valve located beside the eastern wall.
 Draft tube gate may be raised, if desired/requested.
Unit to unit filling of Draft tube
 Pre checks
 Confirm that draft tube window and spiral case window are closed and properly bolted.
 Confirm that gate valve of dewatering common header in drainage pit is in closed
position.
 Confirm the draft tube dewatering valve of third unit is closed.
 Confirm that both Dewatering Pumps are “OFF”.
Steps
 Open the Draft tube dewatering valve of the sink unit.
 Open the Draft tube dewatering valve of the source unit.
 After confirming the filling, close draft tube dewatering valves of both units.
 Respective draft tube gate may be raised, if desired/requested.
Filling through window of the Draft tube gate
 Pre checks
 Confirm that Draft tube window and spiral case windows are closed and properly
bolted.
 Confirm that draft tube dewatering valve of the sink unit is in closed position.
 Steps
 If the ropes of lifting device for draft tube gate are just tightened, a window gets open
allowing tailrace water access to draft tube.
 After confirming the filling, respective draft tube gate may be raised, if desired /
requested.
MANUAL
Filling of Spiral case:
 Pre checks
 Confirm that Draft tube window and spiral case windows are closed and properly
bolted.
 Confirm that Spiral case Dewatering valve is in closed position.
 Steps
 Open the manual gate valve and motorized valve for inlet valve bypass line.
 Observe that air is releasing through the air releaser vent of spiral case.
 Confirm the spiral case pressure is 1.8MPa at respective pressure gauge.
Dewatering of draft tube

 Pre checks
 Confirm the inlet valve, manual gate valve and motorized valve on bypass line for inlet
valve, penstock dewatering valve and spiral case dewatering valve of respective unit are
fully closed.
 Confirm the draft tube dewatering valves of other two units are fully closed.
Steps
 Open the draft tube dewatering valve of the respective unit.

 Confirm that water is coming towards dewatering common header.
 After confirming the respective discharge gate valves fully opened, start the dewatering
pumps.
 Confirm the adequate discharge of dewatering pumps in tail race.
 When the pressure drops to zero indicating completion of dewatering process, switch
“OFF” the Dewatering pumps.
 Monitor the pressure of draft tube, start the pumps immediately in case the pressure
escalates.
MANUAL
Dewatering of spiral case.

 Pre checks
 Confirm that Inlet valve, manual gate valve and motorized valve on bypass line for inlet
valve are fully closed.
 Steps
 Open the spiral case dewatering valve of the unit.
 Confirm that water is coming to Draft tube and dewatering common header.
 After confirming the respective discharge gate valves fully opened, start the dewatering
pumps.
 Confirm the adequate discharge of dewatering pumps in tail race.
 When the pressure drops to zero indicating completion of dewatering process, switch
“OFF” the Dewatering pumps.
 Monitor the pressure of spiral case, start the pumps immediately in case the pressure
escalates.
Opening of motorized valve on bypass line for Inlet valve.
 Pre checks
 Confirm that manual gate on bypass line for Inlet valve is open.
 Steps
 Turn both the mode selection switches to Local and Manual at Inlet valve control
cubical.
 Press “Bypass Open” push button.
 Observe the opening of motorized valve.
MANUAL
Closing of motorized valve on bypass line for Inlet valve.
 Steps
 Turn both the mode selection switches to Local and Manual at Inlet valve control
cubical.
 Press “Bypass Close” push button.
 Observe the Closing of motorized valve.
Inlet valve operation
Opening of inlet valve:

There are four methods for opening of inlet valve;
 SCADA from CCR

 DCS from ULCP
 From Inlet valve control cubicle
 Manually
 Pre checks
 Confirm that Differential pressure is zero i.e. Spiral case pressure be 1.8Mpa.
 Confirm that Inlet valve manual lock is removed.
 Confirm that power supply is available at the cubical and all MCB`s are switched ON.
Opening of Inlet valve through SCADA.
 Pre checks
 Confirm that "Mode Select" control switch at GA-05 is on "Remote" for the respective unit.
 Confirm that "Mode Select" Control switch at GA-06 is on "Auto".
 Confirm that "Mode Select" Control switches at Inlet valve cubical is on Remote and Auto.
 Steps
 In unit start sequence the step 12-1 is for inlet valve opening.
MANUAL
Opening of Inlet valve through DCS.
 Pre checks
 Confirm that "Mode Select" Control switches at Inlet valve cubical is on Remote and Auto.
 Steps
 Turn the "Mode Select" control switch at GA-05 to “Local".

 Turn that "Mode Select" Control switch at GA-06 to "Manual".
 Turn the control switch of “Inlet valve” to ON position.
 Observed that the bypass valve is opened to equalize the differential pressure.
 Verify starting of pump for inlet valve and development of hydraulic pressure.
 Observe the lifting of Inlet valve counter weight.
 When the Inlet valve opens completely, confirm its hydraulic lock is properly engaged.
Opening of Inlet valve from its control cubicle.
 Steps
 Turn both the mode selection switches to Local and Manual.

 Press `Butterfly valve ON` push button.
 Observed that the bypass valve is opened to equalize the differential pressure
 Verify starting of pump for inlet valve and development of pressure.
 When the Inlet valve opens completely, confirm its hydraulic lock is properly engaged.
Opening of Inlet valve manually.
 Steps
 Open bypass valve through local control panel to equalize differential pressure.
 Put a suitable pipe or handle in to manual mechanism of Inlet valve hydraulic system.
 Built the pressure in the hydraulic system by up and down motion of the handle, manually.
 Observe that the pressure is increasing.
 When the Inlet valve opens completely, engage its hydraulic lock.
MANUAL
Closing of Inlet valve
There are three methods for closing of Inlet valve.
 Auto closing
 Closing through DCS
 Closing through control cubicle.
Auto closing of Inlet valve:
The Auto closing of Inlet valve occurs only when some accident occur at the machine i.e.
Emergency trips.
Closing of Inlet valve through DCS
 Pre checks
 Confirm that "Mode Select" Control switches at Inlet valve cubical is on Remote Auto.
 Steps
 Turn the "Mode Select" control switch at GA-05 to “Local".
 Turn that "Mode Select" Control switch at GA-06 to "Manual".
 Turn the control switch of “Inlet valve” to “OFF” position.
 Confirm that the counter weight properly sets down.
 Insert the Manual Lock, if required.
Closing of Inlet valve from Control cubicle.
 Steps
 Turn both the mode selection switches to Local and Manual.
 Press `Butterfly valve OFF` push button..
 Observe the counter weight properly sets down.
 Insert the Manual Lock, if required.
Cooling water system:

The moving parts of the machine generate heat due to friction like in bearings, Shaft seal, etc.
Consequently, the temperature of bearing pads and shaft seal surface increases and may lead
to significant damages. Similarly, the temperature of Generator winding increases due to
current flow and need proper cooling to maintain temperature within permissible limits. In
order to address aforementioned issues, adequate and efficient open cycle cooling water
MANUAL
system is deployed by taking water from penstock. The raw cooling water is passed through
Pressure reducing valves and strainer to achieve the objective. Thereafter, it is passed to the
different parts of the machine like Guide Bearings, Thrust Bearing, Surface air Coolers and
Shaft seal. In Bearings and Coolers, this cooling water enters in copper tubes, absorb heat by
conduction and later drain in the tail race. In shaft seal, the cooling water serves the additional
purpose of sealing, too.
Main Cooling Water System
In each unit, a 8” conduit upstream of inlet valve is taken from penstock with a manual gate
valve for operation. Thereafter, the 8” conduit is divided into two branches; one for individual
main cooling water system of the unit and other connecting to the common header serving
redundant source for all three units and feeding to the standby cooling system, too. The first
mentioned branch leading to the unit main cooling water system has been provided with a
motorized valve for taking water supply in and out of service which is followed by two PRVs to
reduce the pressure. First PRV reduces the pressure from 1.8MPa to 0.8MPa and the second
from 0.8MPa to 0.4MPa. After PRV an overflow 8” conduit is provided to drain the excessive
flow to the tail race. A cooling water strainer is provided to grasp the suspended garbage and
pass filtered water onwards. Two gate valves, upstream and downstream of the strainer are
provided to execute maintenance / cleaning activities of strainer. Thereafter, a common inlet
header of CW having delivers cooling water into five branches as mentioned in the following;
1. Turbine Guide Bearing

2. Surface are cooler
3. Thrust bearing
4. Upper Guide Bearing
5. Lower Guide Bearing
An 8” conduit is taken from the Main Cooling Water system after the strainer and provided to
the shaft seal system, which is further divided into two branches namely main and bypass.
Both the branches are provided with the fine filters and globe valves.
The cooling water after passing through the bearings and surface coolers return in the
respective five branches and drain through the outlet common header to the tail race.
MANUAL
Stand by Cooling Water system:
An 8” conduit which is taken from the common header is provided to stand by cooling water
system comprising PRVs and strainer. It is connected to the downstream cooling water
common header which may route the cooling water to any of three units, as and when
required.
Changing of Cooling Water system:
There are two methods for changing cooling water system of a unit;
 From stand by to unit

 From unit to unit
From stand by to unit:
 Pre checks
 Confirm that the Main Gate Valve of Standby Cooling Water System is Open.
 Confirm that the all gate valves of stand by cooling water system are Open.
 If strainer is going to be taken in service for the first time after its cleaning, first release
air from it.
 Steps
 Press “ON” push button at Standby Motorized Valve Cubical to open the stand by
motorized valve of sink unit.
 Maintain the flow in cooling water system between 300m3/h to 330m3/h.
 Close the main cooling water motorized valve by pressing “OFF” push button at Main
motorized valve cubical.
 Adjust the flow by PRVs to the normal range.
 Keep a close watch on the flow if it decreases continuously then stop closing the main
supply by pressing “STOP” push button at Main motorize valve cubical and inform
Turbine Operator.
Changing of Cooling Water from Unit to Unit:
If a unit is under PTW or stand by and its cooling water system is available for operation, in
such a case, its cooling water may be diverted to another unit.
 Steps
 Close all the cooling water inlet valves of the source unit.
 Open the Main Gate valve of the source cooling water system.
MANUAL
 Open all the gate valves of the source cooling water system.
 Open the main cooling water motorize valve of the source cooling water system.
 Open the Standby cooling water motorize valve of the source cooling water system.
 Open the Standby cooling water motorize valve of the sink cooling water system.
 Maintain the flow in cooling water system between 300m3/h to 330m3/h.
 Close the Main cooling water Motorize valve of the sink unit.
 Close the inlet and outlet gate valves of the strainer of sink unit.
Cleaning of shaft seal filter:
 Steps
 Open the upstream and downstream valves of bypass line for shaft seal filter.
 Close the upstream and downstream valves for shaft seal main filter.
 Verify the pressure of shaft seal cooling water to be 0.2MPa.
 Remove the cover nut of the main filter with a spanner / wrench, take out the cartridge and
wash it thoroughly. Then refit the assembly in reverse order.
 Open both valves of main filter to bring it back in service, close both valve of bypass line.
Confirm the required pressure at the gauges and then close the valves of the bypass filter.
Back Flushing of Cooling Water Strainer:
The cooling water strainer has cartridges for trapping the garbage which need cleaning at
regular intervals for its efficient and reliable operation. For this purpose, back flushing of
strainer is carried out through a flushing motor mounted on the top of the strainer, which
rotates the cartridge assembly in anti-clockwise direction. The garbage is drained through the
drain line to the tailrace.
Steps:
 Ensure the power supply at the back flush motor cubical is available.
 Open the back flush drain line gate valve.
 Change the selection switch to manual and start the back flush motor through the
‘START’ push button.
 Ensure the opening of back flush drain line motorize valve.
 Perform the back flushing for 5 to 10 minutes at an interval of two hours.
 After completion of the back flushing, close the back flush drain line gate valve.
MANUAL
Unit Pre Starting checks After Maintenance.
 GENERAL CHECKS
 Confirm all PTWs on respective unit are cancelled.
 Ensure Penstock branch pipe pressure is 1.8MPa.
 Confirm Spiral case window is close and has no leakage.
 Confirm Draft tube window is close and has no leakage.
 Ensure draft tube filling has been accomplished and the respective gauges show
appropriate pressures.
 Confirm the Penstock dewatering valve, Spiral case dewatering valve, Draft tube
dewatering valve, Inlet valve and Bypass valve for inlet valve are closed.
 Confirm Draft tube gate is fully raised and properly docked.
 Physically confirm the oil levels for Turbine guide bearing, Lower guide bearing, Upper
guide bearing and Thrust bearing are appropriate and no leakage is observed.
 Thoroughly check Turbine pit and generator housing cleanliness and abnormality, if any.
 Ensure generator housing door is closed.
 Confirm the manual pin / lock for Inlet valve is removed and no leakage is observed from
hydraulic system.
 Confirm the AC supply is available at the Governor Pumping Set Panel. Ensure the
Governor hydraulic system is pressurized and the pressure is around 4 MPa. Also confirm
the oil levels for Pressure Vessel and Sump Tank are appropriate.
 PROTECTION PANEL (GA-03)
 Check that “Ready” LED is glowing on both “A” & “B” systems.
 Confirm that no LED glowing under "CH OUT" of Card 21DB61 (Set A&B) at REG 216.
 Confirm that both LEDs Alarm (Yellow) and Trip (Red) are not glowing on LCD module of
RET 521.
 Confirm that no target persists on auxiliary relays.
 UNIT CONTROL BOARD (GA-04)
 Confirm that all Control Switches are at Neutral (Ø) position.

 Confirm that indication lamps for "Gen Trip", "Accident Stop", "Emergency Stop" and
"Alarm Sequence" are not glowing.
 Confirm that "Mode Select" control switch is either on "Remote" or "Local" depending
on the unit to be started either from "CCR" or "Local DCS" respectively.
 Check Icons for "Standstill", "Start Condition", "TO Release", " TE Release" and "LO
Release" on "Unit sequencing" display are persistent green.
 Confirm the "Alarm State List" display of Touch Screen has neither unacknowledged
alarm nor persistent trip.
MANUAL
 If an alarm persists even after acknowledgement, physically check the reason or

intimate concerned Section.
 Confirm that "Mode Select" Control switch is on "Auto".

 Confirm that "SYN GCB" control switch is on Neutral (Ø).
 Check that "Ready" LED is glowing on SYN 3000.
 POWER & FLOW MEASURING PANEL (GA-07)
 Check the voltmeter for DCI 220V, DC II 220V, DC 24V and AC 220V are showing
correct voltages.
 Confirm all the MCBs are switched ON.
 Check that the unit flow metering system (NARI) indicates flow for all the three units.
 GOVERNOR ELECTRIC CONTROL PANEL (GA-09)

 Confirm the governor selections to be "Remote" and "Auto".
 Confirm that no trip signal persists on Touch Screen.
 Confirm that Emergency Stop switch is reset.
AIR GAPE/VIBRATION MONITORING SYSTEM

 The values displayed on Air gape/Vibration monitoring system should be recorded
hourly on station log sheet maintained by Turbine Operator.
 BRAKE FLATABLE AREATION PANEL (GA-01)
 Check that Brake air pressure is normal i.e, 0.7MPa.

 Check for air leakage in the system, if any.
 Confirm proper operation of brakes by manual release and application through respective
switches at GA-04 Board.
 Confirm proper operation of maintenance seal by manual exhaust and application through
respective switch at GA-04 Board.
 CONTORL PANEL OF HIGH PRESSURE OIL LIFT (GA-02)
 Check the control power supply indication lamp is ON.

 Re-confirm the brakes are engaged. Start and Stop AC and DC oil lift pumps one by one and
confirm each built pressure to the range of 4MPa during operation.
 Confirm the selector switch is on "Auto".
MANUAL
 GENERATOR CIRCUIIT BREAKER CUBICLE (GCB)
 Confirm the Red indication lamp at GCB is Reset.
 AUTOMATIC VOLTAGE REGULATOR CUBICLE (EPI)

 Check that both “Main” and “Standby” CPUs are “ON”.
 Check that rectifier bridges in “EP2” and “EP3” panels are switched “ON”.
 Confirm that the "Manual Reverse" control switch is "OFF".
 Confirm that the "Auto Flashing" control switch is on "Auto" position.
 Confirm that the "Operation mode" is on "ROP" at Touch Screen.
 Confirm that the "Working mode" is on "VOREG" at Touch Screen.
 MANUAL FIELD FLASHING PROCEDURE

 Confirmed that the “Auto Flashing” control switch is on “Manual” Position.
 When the generator is on “SNL” manually closed field breaker.
 Push initiate field flashing button at EP4 panel for a few second and observed the filed
voltage on DS voltmeter rises 10-15 volts.
 When the said voltage is observed on DC voltmeter, adjust the voltage through “I/D
Excitation” control switch to rated value.
 CONVERTER CUBICLE (EP2)
 Check the Red indication lamp for "Switch ON" is glowing.
 CONVERTER CUBICLE (EP3)
 Check the Red indication lamp for "Switch ON" is glowing.
 DE-EXCITATION CUBICLE (EP4)

 Check the Green indication lamp for "Indication of Switching OFF" is glowing.
 BUTTERFLY VALVE CONTROL PANEL (V01)
 Check the indication lamp for "Power" is glowing.

 Confirm the control selector switches are on "Auto" and "Remote".
 GOVERNOR OIL SUMP TANK
 Physically check that oil level in glass indicator is at normal position.

 Confirm the "Emergency Valve" at actuator is not operated, otherwise reset to normal
position.
MANUAL
 COOLING WATER SYSTEM
 Confirm the main gate valve at upstream of butterfly valve is open.

 Confirm all cooling water inlet and outlet valves including tailrace gate valve are open.
 Confirm the pressures at various stages of cooling water strainer assembly and flows
are appropriate.
 MANUAL START (at lower Speed)
 Open the Bypass valve for Inlet valve while keeping Inlet valve closed.
 Exhaust the maintenance seal.
 Start HP Oil lift pump and ensure appropriate pressure.
 Open hydraulic lock for servomotor.
 Release the brake to let the unit creep for ten (10) minutes due to leakage water from
the wicket gates. (Provided it already exists)
 Cautiously observe the Speed, temperatures of all bearings & coolers, Oil and water
leakages, excessive vibration, abnormal noise and other similar undesirable phenomena
 Accelerate the speed by opening Inlet valve and observe the parameters for ten (10)
minutes.
 If all the conditions remain normal, the unit may be started for commercial operation.
 If the condition remains normal, the unit may be started for commercial operation.
Mode of operation for starting the Unit
Following are three possible modes for starting the unit;
 Remote / Auto Operation

 Local / Auto Operation
 Local / Manual Operation
Remote / Auto Operation
In this mode the unit is started from CCR through SCADA. It must be kept in mind that the
Operation staff must check the start condition and sequence of the Machine starting step by
step.
Pre checks
Release" on "Unit sequencing" display are persistent green.
alarm nor persistent trip.
MANUAL
 Confirm the AVR "Working mode" is on "VOREG" at Touch Screen.

 Selector switch at GA–05 (MMI panel) must be at “REMOTE”.
 Selector switch at GA–06 (Synch panel) must be at “AUTO”.
 Selector switch at GA-09(Governor Panel) must be at “AUTO”.
Remote / Auto Operation Steps
Step 1
CCR operator clicks at Turbine in order to display the stating sequence flow diagram. Keep a
close watch at the start sequence steps “12-1”(Inlet valve open), “12-2”(cooling water ON),
“12-3”(Inflatable seal exhaust), “12-4”(wicket gate unlock ), “12-5”(Brake release),”12-6”(HP
oil pump start). In case of some abnormality, the operation staff at generator floor shall check
and appropriate measures taken to rectify. When the step is completed, the icon “TO release”
glows green which indicates that the unit has reached to the rated speed.
Step 2
After ensuring that all the previous steps have successfully completed and the Machine has
attained the rated speed, the CCR operator may proceed by clicking icon “No Load” of the
starting sequence. The step “23-1”(voltage at phase A, B, C ) starts and on its completion the
icon ”TE release” glows green, which indicates that the rotor of the unit is excited to the rated
level as shown by the values appearing against A,B and C phase.
Step 3
After ensuring that the unit attains rated speed and terminal voltage, the CCR operator may
clicks at “Generator” and as a result steps “34-1”(GCB closed), “34-2” (P >7 MW & Q > 7Mvar)
start. The synchrotech relay gets activated and starts matching voltage and frequency of the
unit with the system. When both machine and system parameters gets coincides, the GCB
closes and machine gets synchronized. Immediately change Exciter mode from “VOREG" to
"CUREG" at respective Touch Screen. The unit active and reactive power set points may be
issued.
Stop the Machine through Remote / Auto.
The CCR operator may stop the unit by clicking directly “Stand still” and as a result stop
sequence of the unit gets initiated. The CCR operator and operation staff shall keep close watch
MANUAL
at the stop sequence and be ready to take appropriate action, if necessary. The steps “43-1”,
“43-2”, “32-1”,” 21-1”, “21-2”, “21-3”, “21-4”, “21-5”, “21-6”.. will execute in the mentioned
sequence and finally the icon “Stand still” glows green and stop flickering which indicates
completion of the stop sequence.
Local / Auto operation
This operation is performed by Operation staff through ULCPs at generator floor.
Pre checks
Release" on "Unit sequencing" display are persistent green
alarm nor persistent trip
 Confirm the AVR "Working mode" is on "VOREG" at Touch Screen
 Selector switch at GA–05 (MMI panel) must be at “LOCAL”.
 Selector switch at GA–06 (Synch panel) must be at “AUTO”.
 Selector switch at GA-09 (Governor Panel) must be at “AUTO”.
Local / Auto operation Steps
Step 1
Click “Turbine” at local touch screen of the machine the following steps will initializes.
 “12-1” Inlet valve open.

 “12-2 “ Cooling water “ON”
 “12-3”Inflatable seal “OFF”.
 “12-4”Wicket gates “Unlock”
 “12-5”Brakes release.
 “12-6”H.P oil pump start.
Keep a close watch at the pressure of HP oil pump which shall be 4-5 MPa. In case of lesser
pressure, start the DC pump on manual along with the AC pump. The unit will gradually gain
the rated speed. Meanwhile, the operation staff must watch the following icons at Governor
Panel.
 Brake away speed

 Off line speed (at 460 RPM electronic limit starts reducing from 11% to 8%)
 Synchronizing.
MANUAL
If sequence moves normally, unit will reaches to Turbine mode.
Step 2
After ensuring that all the previous steps have successfully completed and the unit has gained
the rated speed, the Operator may clicks at “No Load” of the starting sequence at unit Local
touch screen. Consequently, step “23-1” (voltage at phase A, B, C ) starts and on its completion
the icon “TE release” glows green, which indicates thinned the rated voltage.
Step 3
After ensuring that the unit attains rated speed and terminal voltage, the operator may clicks
at “Generator” and as a result steps “34-1”(GCB closed), “34-2” (P >7 MW & Q > 7Mvar) start.
The synchrotech relay gets activated and starts matching voltage and frequency of the unit
with the system. When both machine and system parameters gets coincides, the GCB closes
and machine gets synchronized. After synchronization, check that unit load is automatically
raised to 5MW through internal set point of Governor. Immediately change Exciter mode from
“VOREG" to "CUREG" at respective Touch Screen at exciter panel. The unit active and reactive
power set points may be issued from MMI of DCS system.
Turn the Selector switch at GA–05 (MMI panel) to “REMOTE” and intimate CCR operator for
further control, as appropriate.
Stop the Machine at Local / Auto.
The Operator may stop the unit by clicking directly “Stand still” and as a result stop sequence
of the unit gets initiated. The Operator and operation staff shall keep close watch at the stop
sequence and be ready to take appropriate action, if necessary. The steps “43-1”, “43-2”, “32-
1”,” 21-1”, “21-2”, “21-3”, “21-4”, “21-5”, “21-6”.. will execute in the above mentioned sequence
and finally the icon “Stand still” glows green and stop flickering which indicates completion of
the stop sequence.
Local / Manual, Operation
This mode of operation also called DCS/Hardwire operation. Normally, this mode of operation
is carried out either at the request of PTW holder or if the Auto sequence got disrupted due to
any reason. The following steps are taken after essential pre-starting checks.
 Turn the selector switch at GA-05 panel to “LOCAL”.

 Turn the selector switch at GA-06 panel to “MANUAL”.
 Turn the respective selector switches at GA-09 panel to LOCAL and MANUAL.
 Turn the switch at GA-04 panel for “Main valve” to ON. Confirm physically the inlet
valve gets open.
MANUAL
 Turn the switch at GA-04 panel for Tech water to “ON” and confirm that the cooling
water flow is established between 280 m3/h and 330 m3/h.
 Turn switch at GA-04 panel for maintenance seal to “OFF”. As a result, the maintenance
seal gets depressurize and respective red lamp glows “ON”. Also confirm the
depressurizing of maintenance seal at Brake air cubical.
 Turn switch at GA-04 panel for Wicket gate lock to “OFF”. As a result, the respective
green lamp glows “ON”.
 Release Brakes by turning “Brake Lower switch” to “OFF”. After 5 seconds, turn “Brake
upper switch” to “ON” position. Wait for another 5 seconds and turn the “Brake upper
switch” to “OFF”. Also confirm the releasing of brake at Brake air cubical.
 Start HP oil pump by pressing the push button at GA-04 panel, which shall glow “Red”.
Verify the HP oil pump pressure at HP oil pump cubical to be 4~5 Mpa. Otherwise, start
DC pump manually to supplement AC pump in building the required pressure.
 Move to GA-09 panel and initiate “start” command. Raise the Gate Limiter switch to
11%. Monitor the gradual increase in speed. The HMI for Governor shall display the
modes, firstly “Brake away”, then “OFF Line speed” when the speed reaches 460 rpm.
Now, reduce the Gate limiter to 8%. The Unit will attain rated speed, i.e, 500 rpm. If
speed has continuous increasing trend, then lower the value for “Gate limiter”
proportionally to attain rated speed. Once the Unit speed gets smooth and stable, the
“Synchronizing” mode shall be displayed at Governor HMI.
 Put the Excitation switch at GA-04 panel to “ON”. Monitor the analog meters for voltage
and frequency at GA03 panel. When the terminal voltage reaches 09 KV and the
“Synchronizing” mode persists at Governor HMI, press “ON” switch at GA-04 panel for
GCB.
 Observe the synchronizer and synchrotact relay. Match the speed and voltage of
upcoming Unit with Grid system by increasing or decreasing speed and from respective
switches and push buttons. Once the synchronizing conditions are fulfilled, the LED for
“GCB close” will glow (once) at synchrotact rely.
 Turn the switch clockwise for GCB to “Close”.
 As soon as, the GCB gets close, raise the “Gate limiter” for loading of unit.
 In local/manual mode, the operation staff to remain very cautious as the governor will
not staff for any trip signal initiated by DCS or protection system of the generator.
Hence all the operating conditions of the generator and turbines should be closely
watched for any abnormality.
LOCAL / MANUAL STOP SEQUENCE.
 Reduce the load to 03 MW by lowering the Gate limiter.

 Open GCB.
 Reduce excitation.
 Open FCB.
 Start HP oil pump. (Watch pressure 4~5 Mpa).
 Reduce gate limit to zero.
MANUAL
 Fully close wicket gates and insert hydraulic lock to ON.

 Apply brakes at or below 150 RPM by turning “Lower port” ON at GA-03 panel and also
confirm application of brakes.
 When speed reaches to zero and the shaft is physically confirmed to be stationary, then
Stop HP oil pump by pressing push button at GA-04.
 Apply the inflatable seal by turning “maintenance seal” switch to ON.
 Close cooling water by turning “Tech water” switch to OFF.
 Release the brakes (if required) by turning “Upper port” to ON.
 Close inlet valve (if required) by turning “Inlet valve” switch to OFF.
Operation of Diesel Generator
Starting Procedure
 Pre checks
 Physically check the water level at radiator and tank oil (Diesel) level.
 Open both front and back side doors of DG room.
 Steps of operation
 Open the oil tank valve of the respective DG set.
 Switch “ON” all the MCB’s in the left side (upper row) of cubicle control panel.
 Put the self switch to “Manually”
 Wait for one or two minutes.
 Confirm that the DG set engine has started normally and there is no abnormality.
 Charge the diesel generator circuit breaker by manual handle
 Close the breaker.
L.T gallery Operation

 Cut off ESB at CSB and UAB 1, UAB 2, UAB 3 at ESB Breaker.
 Confirm that the generating voltages of DG are normal.
 Rack in the DG set breaker at ESB panel and Switch ON.
 Gradually put load on Diesel Generator.
Stop Sequence
 First of all gradually decrease the load
 Open DG set Breaker at ESB.
 Open circuit breaker at diesel generator set.
 Restore ESB at CSB and UAB 1, UAB 2, UAB 3 at ESB Breakers.
 Put off the self switch
 Switch OFF all the MCB’s.
MANUAL
Note
Don’t switch OFF MCB # 12 inside the Diesel Generator Set cubical Left side.
Always keep the selector switch of Battery Charging at Trickle position.
Limits for Operation

Besides running and operating the units, the Operator is responsible to ensure the unit is being
operated within safe limits as prescribed by the manufacturer(s). The mentioned limits
relating to various systems and sub-systems are presented below for safe, smooth and reliable
operation of the Unit.
 Voltage
Over voltage
1.2 % of the rated (11 KV) for time of 20 seconds. (Approx 13.2 KV)
1.3 % of the rated (11 KV) for time of 0.02 seconds. (Approx 14.3 KV)
Under voltage
There is no trip on under voltage.
 Stator current
The rated stator current of the generator is 1680A. When delivering 32MW at rated power
factor (0.85) and rated generator voltage (11KV). During operation check that the rated
stator temperature (100ᵒC) is not exceeded.
 Temperatures
Upper guide bearing

Lower guide bearing
Thrust bearing
Upper limit 3 (Alarm) 70 °C

Upper limit 4 (Trip) 75 °C
MANUAL
Turbine guide bearing

Stator coils
Air coolers
Upper limit 3 40 °C
Upper limit 4 50 °C
Governor oil pumps

Main pump Start at 3.7 Mpa
Main pump Stop at 4.0 Mpa
Standby pump Start at 3.6 Mpa
Standby pump Stop at 4.0 Mpa
Low pressure Accident trip at 2.8 Mpa
Air released valve of Governor oil pressure operates at 4.4 Mpa
Leakage oil tank pumps

Stop at 05 cm
Start at 25 cm
Governor air compressors
Start at 4.126 Mpa

Stop at 4.468 Mpa
MANUAL
Brake Air Compressor
Compressor No. 1
Start at 0.64 Mpa

Stop at 0.72 Mpa
Compressor No. 2
Start at 0.64 Mpa

Stop at 0.69 Mpa
Trip Signals relating to Unit

In order to avoid human error, automatic tripping of the Unit is incorporated to avoid any
possible adverse implications, which may arise due to fault or failure. Thus the Unit or
equipment is isolated immediately for safety. Three types of shutdowns are configured, based
on the nature of faults, as detail below.
Trip Signals (Mechanical Stop) of the Unit.
 Thrust bearing temperature trip.

 Lower guide bearing trip.
 Upper guide bearing temperature trip.
 Turbine guide bearing temperature trip.
 Stator coil temperature trip.
 Generator fire alarm.
 Unit temperature too high trip.
 Governor emergency valve trip indication.
 Governor fault.
 Shaft seal flow (6LK) break for 10 minutes.
 Speed of 115% 2 second trip.
 N > 115 % nr.
 Unit mechanical Protection accident stop activated.
 Unit mechanical protection emergency trip activated.
MANUAL
Electrical Stop
 Generator transformer protection.

 Generator transformer REF protection operated.
 Generator transformer differential protection.
 Generator transformer overloads protection.
 Excitation transformer over current protection operated.
 Electrical over speed.
Emergency Trip
 Governor Accumulator accident low pressure.

 Shear pin broken when accident occur.
 N > 140 % nr.
 LCU Emergency Shutdown push button pressed.
Switchyard
Switchyard is the location where incoming generators and outgoing lines are inter connected through
busbars. MalakandiIII switch yard comprises two 132KV busbars, three bays, and breaker and a half
scheme.
Different types of Switchgear generally used in switchyard are:-
Switchgear of switchyard
Circuit breaker:
A circuit breaker is defined as “a mechanical switching device capable of making and breaking
Currents under normal and abnormal such as short circuit conditions for a specified time. It can
operate automatically and clear fault currents safely and quickly. They are mounted are support
structure in switchyard.
A circuit breaker is a switching device having the ability of arc quenching to protect an electrical circuit
from an abnormality. It receive tripping signal from the protective relay and open the path to avoid any
abnormality.
Whenever a circuit is opened under load condition so an arc produces between the contacts this arc is
quenched with different methods therefore Circuit breakers are generally classified according to the
interrupting medium used to cool and elongate the electrical arc permitting interruption.
The types are:
MANUAL
o Air magnetic
o Oil
o Air blast
o Vacuum
o SF6 gas
In Malakand III switchyard SF6 circuit breaker have been used employing SF6 gas as the interrupting
medium. Sulfur hexafluoride is an inert, nontoxic, colorless, odorless, tasteless, and nonflammable gas
consisting of a sulfur atom surrounded by and tightly bonded to six fluorine atoms. It is about five times
as dense as air. SF 6 has two to three times the insulating ability of air at the same pressure.SF6 is
highly electronegative so it absorbs electrons from the current and hence interrupts the flow of current.
The operation staff during each shift should check that the SF6 gauges installed at each breaker shows
normal pressure between 0.45Mps to 0.58Mpa.
Current Transformer (CT)

CT is a type of instrument transformer which is used in power system for instrumentation and
protection of the system. It is a device used to measure large current by stepping down primary current
to smaller secondary current and this secondary current is fed to an ammeter for scaling, and to relays
for protection.
Potential Transformer (PT)

PT is also a type of instrument transformer which is used in power system for instrumentation and
protection of the system. PT measure large voltage by stepping down primary voltage to smaller
secondary voltage and this secondary voltage is fed to a voltmeter for measurement, and to relays for
protection.
Busbar
Busbar is a set of two or more electric conductors that serves as common connection between outgoing
circuits and source of electric power.
Insulator
It is a device having high electrical resistance used for supporting or separating conductors.
Isolator
It is also known as disconnector switch and is just like a mechanical switch. It is an off load device i.e. it
can’t be operated during load. Isolator is used with the breaker to ensure its complete isolation from
the healthy side during maintenance. Malakand III switchyard has the horizontal break isolators which
operate with DC motors.
MANUAL
Lighting arrester
A protective device design primarily for connection between a conductor of an electrical system and
ground to discharge excessive to earth. It is also known as surge arrester. These are normally installed
at the take off point of trnasformer lines.
Earthing Switch
It is a switch which connects a conductor to the earth so as to discharge charges on the dead conductor
to the earth. Earthing switches are generally installed on the frames of the insulators.
Line trap / Wave trap

An electronic filtering device designed to exclude unwanted signals or interference from a receiver.
Line trap also is known as Wave trap. What it does is trapping the high frequency communication
signals sent on the line from the remote substation and diverting them to the telecom/teleprotection
panel in the substation control room (through coupling capacitor and LMU). This is relevant in Power
Line Carrier Communication (PLCC) systems for communication among various substations without
dependence on the telecom company network. The signals are primarily teleprotection signals and in
addition, voice and data communication signals. Line trap also is known as Wave trap.
The Line trap offers high impedance to the high frequency communication signals thus obstructs the
flow of these signals in to the substation busbars. If there were not to be there, then signal loss is more
and communication will be ineffective/probably impossible.
Breaker and a half Scheme
Such a scheme has three circuit breakers for two circuits, hence the name derived as compared to
duplicate circuit scheme. This scheme has two bus bars, three circuit breakers are connected in each
branch between two bus bars. Each branch is named as a Bay. This breaker scheme is commonly used
as it is very flexible in operation. In this scheme central breaker i.e. EQ3 along with EQ1 and EQ2 works
as controlling breakers, failure of a circuit will trip the two adjacent breakers and not interrupt any
other circuit. With the three breaker arrangement for each bay, a center breaker failure will cause the
loss of the two adjacent circuits. However, a breaker failure of the breaker adjacent to the bus will only
interrupt one circuit. Maintenance of a breaker on this scheme can be performed without an outage to
any circuit. Furthermore, either bus can be taken out of service with no interruption to the service.
Structure of Malakand III switchyard
The switchyard is designed on one and a half breaker scheme having three bays with three incoming
lines from the three power transformers of power house and two out going lines (Dargai I, Dargai II) to
Dargai Grid station and one line left for future.
MANUAL
Single line diagram of 132 KV Switchyard
Bay-1
It is a half bay having the circuit breaker E1Q1 and E1Q3 and isolator i.e. E1Q11, E1Q12, E1Q31,
E1Q32.
Bay-2
It is a complete bay having three circuit breakers i.e. E2Q1, E2Q3, E2Q2 and six isolators i.e. E2Q11,
E2Q12, E2Q31, E2Q32 E2Q21, E2Q22.
Bay-3
It is also a complete bay having three breakers i.e. E3Q1, E3Q3, E3Q2 and six isolators i.e. E3Q11,
E3Q12, E3Q31, E3Q32 E3Q21, E3Q22.
MANUAL
Operation Methodology of switchyard

Normal status
 “SM” switch should be set to “OFF” Position.

 “QF” switch should be set to “Post open” position when breaker open.
”Post close” position when breaker close.
Operating Sequence
Manual synchronizer (Local/Manual)
 Set SSA1 to “Manual”

 Reset SID-2X-11:
 Put SM to “ON”, when synchronizer meet requirement (The green lamp in the TBB will be
lighting), press manual close button, at the same time, and operate “QF” to close then breaker
will close.
Auto synchronizer (Local Auto Switch yard Bench)
 Set SSA1 to “Auto”:

 Set SA “Switch for no voltage synchronizing” to following position:
One side no voltage, set SA (switch for no volt synchronizing) to “non-energized for one
network”
Two sides no voltage, set SA (switch for no volt synchronizing) to “non energized for both
network”
Both sides have voltage, set SA to “OFF”
NOTE: The two side voltage of every CB is showed in the following list:
 Reset SID-2X-11:
 Confirm the “QF” position; it should be in post open”
 Put SM to “ON”, then breaker will be closed.
Circuit Synchronizing Circuit Synchronizing Circuit Synchronizing

Breaker Voltage Breaker Voltage Breaker Voltage
Bus 1 Bus 1 Bus 1
E1Q1 E2Q1 E3Q1
G1 G2 G3
Bus 1 G2 G3
E1Q3 E2Q3 E3Q3
G1 Dargai 2 Dargai 1
Dargai 2 Dargai 1
E2Q2 E3Q2
BUS 2 BUS 2
MANUAL
Operation from CCR / Switchyard MMI
 Pre checks
 Before closing of the Breaker confirm that all the protection operated is reset.
 Confirm that all the selector switches at the local control cubical of Breakers and
isolators are at “Remote” mode.
 Confirm that the selector switches of Bay 1, 2, 3 at switchyard control room are at
“Remote”.
 Steps
 Click “Right” button of mouse at the respective switchgear which you want to operate.
 Select “Open” or “Close”, then press “Yes” and then “Ok”.
Operation from Local/Control cubical
 Steps
 Turn the selector switch of breaker/isolator/earth switch to “Local”
 Press “RED” push button for closing and “GREEN” push button for opening.
 To stop at any desired position, press “STOP” push button.
Operation By hand with lever
 Steps
 Insert the lever in its designated slot.
 Move the lever in clock wise direction to close.
 Move the lever in anti clock wise direction to open.
Protection System
High-voltage system requires high-speed protection to reduce possible damages by isolating
the faulty equipment and maintain stability. Following protection schemes are deployed at
Malakand-III HPP, in this regard.
MANUAL
Generator Protection
87G
 Trip GCB
 Trip FCB
 Close Inlet valve
 Initiate signal GCB ,BFP signal
40 Loss of excitation protection (signal)
46-1, 2
(Negative current protection)
 Trip GCB
 Trip FCB
64-51
(95% stator E.F Protection)
 Trip GCB
 Trip FCB
64-52
(100% stator E.F Protection)
 Trip GCB
 Trip FCB
64F
(Rotor earth fault protection signal)
MANUAL
49G
(Generator overload protection)
 Trip GCB
 Trip FCB
 Initiate signal GCB ,BFP
59-1, 2
(Generator over voltage protection)
 Trip GCB
 Trip FCB
32
(Generator reverse power protection)
 Trip GCB
 Trip FCB
21T
(MT HV side impedance protection)
 Trip 132 KV CB1

 Trip 132 KV CB3 and lock CB3 AR Trip GCB
 Trip FCB
 Initiate 132 KV CB1 ,CB2 ,BFP
 Initiate GCB Signal
21G1-2
(Generator side impedance protection) Trip GCB
 Trip FCB
MANUAL
78
(Generator pole trip protection signal)
24-1, 2
(Generator over excitation protection)
 Trip GCB
 Trip FCB
50BFP-1, 2
(GCB failure protection)
 Trip 132 KV CB1

 Trip 132 KV CB3 and lock CB2
 GCB Trip signal
61-2
(Voltage Balance protection signal)
Main Transformer Protection
51NMT
(MT Fault protection)
 Trip 132 KV CB1

 Trip 132 KV CB3 and lock CB3 AR
 Trip GCB
 Trip FCB
 Initiate 132 KV CB1 ,CB3 ,BFP signal
49-1 MT
(Overload protection)
87GT
(Generator Transformer differential protection)
 Trip 132 KV CB1

 Trip GCB
MANUAL
 Trip FCB
87REF
(Restricted earth fault protection of MT)
 Trip 132 KV CB1

 Trip GCB
 Trip FCB
 Initiate GCB, BFP signal
50-51 /ET
(Excitation Transformer current protection)
 Trip GCB
 Trip FCB
 Initiate GCB, BFP signal
64C
(11 KV system E/F signal
RXMT1 + RXKL1
(MT heavy Buchloz)
 Trip 132 KV CB1

 Trip GCB
 Trip FCB
MANUAL
MT Light Bucholz signal
MT pressure release
 Trip 132 KV CB1

 Trip GCB
 Trip FCB
 Signal
MT winding temperature Trip
 Trip 132 KV CB1

 Trip GCB
 Trip FCB
 Signal
Excitation system
The application of voltage to the field coils to produce magnetic field as required for the
operation of an excited field generator is called excitation system
Malakand III has a static type of exciter having Excitation Transformer which receive 11kv at
its primary side and gives two secondary out puts of 270 V & 380 V. 270 V is provided to
bridges rectifier consisting of thyristers (silicon control rectifier) to convert the AC input to DC
out put and then this DC is provided to the field winding to magnetize the poles of rotor. The
380 V is provided to exciter’s fans. Additionally 220V station supply/220V essential supply is
provided to various auxiliary equipment of the excitation system.
Initially field flushing is carried out through UAB for 90 seconds and when the rotor generates
its own voltage then self excitation starts.
MANUAL
SCADA AND DCS SYSTEMS

SCADA stands for “Supervisory Control and Data Acquisition”. As the name indicates, it is not
the primary functional control system, rather focuses on the supervisory level. As such, it is a
purely software package that is positioned at the top of hardware to which it is interfaced.
VA TECH SAT supplied a functionally distributed automation and control system. Functional
decentralisation of the "hydroelectric power station" process means division of the process
into sub processes, which are as independent of each other as possible. The structure of these
sub processes is reflected in the design of the process control technology, which is divided into
autonomous function areas. The function areas configured and implemented for Malakand-III
HPP project are following:
 Plant Control System
 SCADA system
 Networking equipment
 Time synchronisation through GPS
 Printing facilities
MANUAL
 Local control units (LCU)

 Unit LCU 1, 2 and 3
 Common auxiliaries LCU 4
 HV Switchyard LCU 5
 Intake LCU 6
 Communication LCU 7
FEATURES OF SCADA
 Dynamic process graphics.
 Alarm summary.
 Alarm history.
 Real time trend.
 Historical time trend.
 Security. (Application security).
 Database connectivity.
 Device connectivity.
 Scripts.
 Recipe management.
SCADA AND DCS relating to Operation:
The SCADA system at Malakand-III HPP facilitates the operation staff to supervise, monitor,
control and operate the equipment (field devices). Apart from initiating control commands, the
status and numerical real values are displayed, too. Each abnormality is reported in real time
to take corresponding appropriate action. Two operator consoles are installed in CCR to
achieve the intended purpose. Each Unit has a MMI, configured for local/Auto control.
In order to scroll among various menus efficiently and comfortably, the plant equipment is
divided into subsystems which are made accessible by clicking respective icons. These icons
are arranged on main display in the toolbar, which is comprised of the following:
MANUAL
 Unit control.
 Unit sequence control.
 Unit water system.
 Unit oil system.
 Unit braking air system.
 Unit turbine.
 Unit generator.
 Unit temperature.
 Unit main Transformer.
 Unit event list.
 Unit alarm list.
The information/events are listed in MMI under signals, which can be differentiated by their
colors.
 Blue mark (For signaling of command)

 Green (For satisfactory completion of command)
 Yellow (For alarm)
 Red (trip alarm)
 Pink (For initiating set point)
OTHER MISCALLENOUS SYSTEMS
LV/HV Switchgear
The 11KV switchgear is fed from Unit # 1 and Unit # 3 through respective Unit Auxiliary
Transformer (11KV/11KV), namely UAT1 and UAT2. The secondary of UAT1 and UAT2 are
feeding 11KV Busbars I and II respectively. The provision for interconnecting both burbars is
made available through bus-couplers. Both Busbars have 11KV Breakers for onward
distribution to different loads, detail as below.
Busbar I
 UAT 1 Incoming
 Out going to AT I
 Out going to Intake and Sediment Excluder
 Bus coupler I (BC I)
MANUAL
Busbar II
 UAT 3 Incoming
 Out going to AT II
 Local Feeder
 Bus coupler II (BC II)
HV Switchgear Operation
If isolation / de-energization of Incoming feeder from Unit Auxiliary Transformer are required
for preventive or corrective maintenance purposes, the affected bus may be energized by
closing both the bus couplers BC I and BC II after ensuring opening of 11KV breaker for
respective incoming feeder.
 Steps
 Open the respective incoming 11KV Breaker of the busbar to be isolated.
 Close bus couplers BC I and BC II, one by one.
LV Switchgear
Each 11KV busbar has an 11KV outgoing feeder, which is connected to respective Auxiliary
Transformer (11KV/0.4KV). These AT-I and AT-II are feeding auxiliaries of the plant i.e.
Common service board, Essential service board and Unit auxiliary board. Further distribution
to various connected load is accomplished through these boards.
Load shifting at HT Gallery

If it is required to shift load from HT (11kv) Busbar I to II or from II to I then the following
operation should be carry out.
 Steps of Operation
 Put the Key in incoming Breaker of the busbar to be isolated and turn it.
 Turn the selector switch to “Trip” and confirm that the incoming breaker is opened.
 Close the Tie Breakers BC-I & BC-II by putting key and turning the selector switch to
close.
MANUAL
Load shifting at CSB/ESB
If it is required to shift load from CSB one busbar to the other so the following operation should be
carried out.
 Turn the selector switch of Tie breaker and breaker of the busbar to be isolated to “Manual”
 Press “OFF” push button at the breaker of the busbar to be isolated.
 Close Tie breaker by pressing “ON” push button.
Single line diagram of power plant auxiliary system
MANUAL
Auxiliaries at Common Service Board (CSB)
CSB A, Busbar 1
 DB 1 EL 268.20 control block.

 Dewatering pump – 1 control block 1
 DB 4 EL 463.15 outdoor light
 DB 7 EL 459.40 Electrical equipment gallery
 Power ceiling (speed ventilator)
 Power ceiling 452.2 (Ventilator 1)
 Power ceiling 452.2 (Ventilator 2)
 Governor air compressor – 1
 Road way lights
 EL 456.35 AC room air conditioner
 EL 463.35 AC Room Air conditioner K – 2
CSB – B, Busbar 1
 Power house ceiling (speed ventilator – 2)

 Power house ceiling (speed ventilator – 3)
 Unit Brake air compressor # 1.
 Oil purifying pump power socket box
 ACP chiller water pump – 1
 Station air compressor
 Unit auxiliary board 1 UAB - 1
 Essential service board ESB – 1
 Switch yard Auxiliary board SAB – 1
CSB – G, Busbar 1
 CSB Busbar 1 Main breaker
CSB – I
 CSB Busbar 1 and Busbar 2 Tie breaker.
CSB – H, Busbar 1
 CSB Busbar 2 Main breaker
CSB – C, Busbar 2
 Electrical Lab sockets

 Dewatering pump – 2
 Governor air compressor – 2
MANUAL
 Gantry crane
 ACP chiller water pump – 2
 EL 463.35 AC room air conditioner K – 3
 Switch yard Auxiliary board SAB – 2
 Essential service board ESB – 2
CSB – D, Busbar 2
 Battery charger room ventilator

 Toilet ceiling speed ventilator
 Ventilator central box 16
 DAB # 6.12 combined EL 463.15 HVAC room water cooling.
 DB # 8A EL 459.40 Generator floor
 Lighting and heating Marshal box – 2
 Work shop
 Elevator
 Unit Auxiliary board UAB – 3
CSB – E, Busbar 2
 Overhauling power box turbine floor

 Overhauling power box Generator floor
 Overhauling power box Excitation Bay
 Overhauling power box Erection Bay
 box Central control room
 Power socket box Transformer Deck
 Computer room
CSB – F, Busbar 2
 Battery room ceiling speed ventilator – 1

 Lighting sub board – 2 Generator floor
 Turbine oil store room ventilator
 Power house 452.2 venerator – 3
 Spare automatic filter
 EL 472.05 exhaust fan
 Water treatment receptacles
 Overhauling power box turbine floor (OPB - 1)
MANUAL
 Overhauling power box turbine floor (OPB - 2)

 Overhauling power box turbine floor (OPB – 3)
 Unit auxiliary board UAB – 2
 Tailrace Gate
Auxiliaries at Essential Service Board (ESB)
ESB A, Busbar – 1
 48V Battery charger – 1 (SCADA)

 Drainage pump – 1
 EDB # 2 EL 463.15 control block
 EDB # 2 EL 463.15 indoor lighting
 220V AC UPS (Master unit)
 220V Battery charger – 1
 Unit Break Air compressor – 2
 Communication Power – 1
 Unit Auxiliary Board – 2 (UAB – 2)
 Emergency fire pump
ESB B, Busbar – 2
 EDB # 6 EL 463.15 HVAC room

 Drainage pump – 2
 Unit # 1 space heater
 EDB # 7 EL 459.40 Electrical equipment gallery
 EDB # 10.11 EL 452.5 + 459.35 Water cooling + oil gallery
 EDB # 9AB EL 456.35 Turbine floor + offices+ passage
 EDB # 4EL 463.15 Out door lights
 48V Battery charger – 2 (SCADA)
 Unit Auxiliary Board – 3 (UAB – 3)
 Communication Power – 2
MANUAL
ESB B
 Main breaker of ESB Busbar 1, Tie and Busbar 2
Auxiliaries at Unit Auxiliary Board (UAB)
UAB 1, A
 Automatic filter
 Automatic filter
 Jacking pump
 Head cover Drainage pump – 1
 Unit # 1 + GA – 07
 Unit cleaner control box CAT – 08
 Governor oil pump # 1
 Oil return pump -1 (Leakage oil pump – 1)
 Unit heaters
UAB 1, B
 Head cover Drainage pump – 2

 Generator space lighting
 Heater cable of enclosed Busbar control Box – 1,Box – 2
 High pressure oil pump
 Governor oil pump - 2
Station Drainage and Dewatering System

A hydel power station must have effective drainage system to avoid flooding. The water may
accumulate as result of leakage, seepage, station service water through drains provided at all
floors in station drainage pit. This station drainage pit is along the eastern wall of power plant
at the Inlet valve floor.
Two drainage pumps of submersible centrifugal types are installed in station drainage pit,
which start and stop automatically. Their control is PLC based with a lead/lag switch for
uniform operation. Each drainage pump is capable to discharge 10 lit/s in tailrace through a
common header. These pumps are electrically driven having 4.5KW ratings. The Drainage
MANUAL
pump selected for lead starts at the water level 448.50masl. The Drainage pump selected as lag
starts at 449.00masl. The first pump stops at 447.50masl and second pump stops at
448.00masl. If the water level escalates in the drainage pit due to any reason, 1st stage water
level higher alarm and 2nd stage water level higher alarm appear at 449.50masl and
450.50masl respectively in SCADA consoles and HMI for LCU 4. The Operator has to rush for
checking the reason besides manually starting the pumps or additional submersible pump to
maintain the level with safe zone.
The dewatering system for the turbines is of closed circuit type. Each draft tube being
connected to a dewatering suction bus main by means of an isolating valve. The dewatering
pumps discharge through individual discharge pipes to the dewatering manifold, which leads
to tailrace. To handle the large quantity of water involved in dewatering a Penstock, spiral
casing and draft tube, two volute-type centrifugal pumps are installed. Both dewatering pumps
are located in drainage pit. The two dewatering pumps are connected to the dewatering bus
main manifold which spans the drainage/dewatering gallery. Each dewatering pump has a
capacity of 25 lit/s. Pumps have stainless steel impellers and capable of handling the
impurities. These may be operated manually by turning respective switches for start and stop.
Manual Starting of Station Drainage Pumps
 Pre checks
 Confirm that there is no “Do not operate” tag on the pump.
 Confirm that Drainage pit has no garbage like plastics or cloths.
 Confirm that the manual gate valve of the pump’s discharge line is open.
 Turn the selector switch to “Manual”
 Press the “Start” push button.
 Visually verify its discharge through the common header having opening in
tailrace (lower one).
 Similarly this pump can be stopped by pressing “Stop” push button or changing
the selection switch mode to “OFF” or “Manual”.
MANUAL
Governor’s Hydraulic System
A device which keeps the speed of a machine constant at variable load is called Governor. The
electrical signal initiated by digital governor approaches the Proportional valve, which
controls the pilot valve. The pilot valve converts the electrical signal to corresponding
mechanical opening to control main distribution valve, which in turn controls the opening or
closing of hydraulic servomotors. The servo motors are coupled with regulating ring which is
primarily responsible for opening/closing of wicket gates.
The Governor Hydraulic system consists of governor oil sump tank, pressure vessel tank,
motor/pump sets, FC valve and servomotors. The motor/pump set lift the oil from governor oil
sump tank and supply to the pressure vessel tank, where the oil is pressurized with
compressed air to attain maximum pressure of 4.0MPa. One motor/pump set is selected at
“Lead” while the other at “Lag”.
The ratio of oil and air in pressure vessel tank is kept 1:2. When the pressure in the pressure
vessel tank drops to 3.7MPa, the lead pump starts to bring the pressure back to nominal value
of 4.0MPa and get stop thereafter. If the lead pump fails to do so and pressure continues
dropping, the lag pump starts at 3.5MPa. If the pressure further keeps on dropping, the Unit
will get emergency trip command at 2.8MPa for safety.
The operator should carefully monitor the pressure of vessel tank. In case of any abnormality,
the pump(s) should be started manually, when the pressure drops below 3.5MPa. However,
during manual operation, the oil pressure should not exceed 4.0Mpa.
Pressurizing of Governor
 Pre checks
 Ensure the main power supply at Governor Pump cubical is available.
 Ensure the availability of Governor Air compressors.
 Ensure that there is no fault alarm at MMI of Digital Governor in GA-09.
 Governor pumps should be kept OFF.
MANUAL
 Close the drain gate valve of governor oil Sump tank.
 Slowly open the pressure vessel tank discharge valve.
 Open both valves for the servomotor hydraulic lock feeding / return lines.
 Switch ON the governor oil pumps. One as lead and other on lag.
 Confirm air inlet valve is open. Put the selector switch of air admission to auto.
 The level and pressure of hydraulic oil should be maintained to permissible limits.
Depressurizing of Governor
 Put off the Governor Oil pumps.
 Fully close the pressure vessel tank discharge valve.
 Slowly open the drain gate valve of governor oil Sump tank.
 If required, close both valves for the servomotor hydraulic lock feeding / return lines.
Compressed Air System

Compressed air is required for various purposes like application of brake, building pressure in
Governor Pressure Vessel and meets station service requirements. It is accomplished in power
house by three dedicated sources, mentioned as below.
 Brake Air compressor.

 Governor Air compressor.
 Station service Air compressor.
Brake Air System
Brake air system comprising two Brake Air Compressor and three main reservoir tanks. The
later is feeding three Brake Air receiver tanks through a common header, one for each unit.
Brake Air compressors are located at El 456m in down stream gallery. Both brake air
compressors are product of “INGRESOL” having ratings 18.5KW and 25HP. The compressed air
may be used for following three purposes.
 Jacking
 Brakes
 Maintenance seal
MANUAL
The compressors set are operated on Lead / Lag mode. The display of compressor shows the
mode is either lead or lag. Similarly, if the display shows “AUTO READY”, the compressor is on
auto mode and if it shows “READY TO START”, the compressor is on manual mode. The lead
(AUTO RESTART) compressor starts at 0.68 MPa and stops at 0.72 MPa. If the lead compressor
doesn’t starts due to any reason / problem, then the lag compressor shall start at 0.64 MPa, as
per the Auto Control configuration.
The brake air source cubical is consisting of 12 manual valves and 3 solenoid valves. The valve
Nos. 1, 2,3,4,5 and 6 shall be normally close, while valve Nos. 7,8,9,10,11 and 12 are normally
kept open. Valve Nos. 2, 4 and 6 are for releasing the air. If the positions of the valves are same,
as stated above, the operation of brake and maintenance seal will take place, automatically.
Auto Application of Brakes and Maintenance seal
As per the control logic, the brakes are applied or released, automatically provided the unit
control mode is either selected for Remote/Auto or local/Auto. The brake is applied during
stop sequence at 30% of the rated speed i.e., 150 rpm or below and release during start
sequence after unlocking of wicket gates.
Similarly, the maintenance seal will apply automatically during stop sequence, when the
machine gets dead stopped. It depressurizes in start sequence after starting of the cooling
water.
Manual Application of Brakes
The practice is adopted when machine is to be either stopped through Local/Manual mode or
the Auto sequence fails due to any reason. Before brake application, the following
prerequisites need to be confirmed.
 Pre checks
 Confirm brake air source pressure is normal (0.64 MPa to 0.72 MPa).
 Confirm the position of valves in the cubical. (1, 2, 3, 4, 5 & 6 should be closed, while
7, 8, 9, 10, 11 & 12 should be opened).
 The speed of Unit should be 150rpm or below.
MANUAL
Application Procedure for brake and maintenance seal
 Open valve No. 01 to energize the Lower Port.

 If the Lower Port does not get energizes, close valve No 12.
 Confirm the application through Analog Gauge for Lower Port, which should display 0.7MPa
pressure.
 Open valve No.3 to energize the Upper Port.
 the Upper Port does not get energizes, close Valve No. 09.
 Confirm the application through Analog Gauge for Upper Port, which should display 0.7MPa
pressure.
 Open valve No 06 to energize the maintenance seal.
 If the maintenance seal does not get energizes, close valve No 10.
 Confirm the application through Analog Gauge for maintenance seal, which should display
0.7MPa pressure.
TO RELEASE BRAKE / SEAL
 Open valve No. 05 and confirm the exhausting of maintenance seal through its Analog
Gauge, which shows pressure as 0.
 Close both valves Nos. 05 & 06.
 Open valve No. 02 for releasing Lower Port of brakes and confirm through its Analog
Gauge, which shows pressure as 0.
 Close both valves Nos. 01 & 02.
 Open valve No. 04 for releasing Upper Port of brakes and confirm through its Analog
Gauge, which shows pressure as 0. The same may be confirmed by glowing of “Brake
release” lamp at GA01 Panel. Otherwise, energize upper port again after 5 seconds and
release through valve No. 03.
 Then close valve Nos.03 & 04.
MANUAL
Sketch of the Brake Air Source Cubical Panel
MANUAL
GOVERNOR AIR SYSTEM
The compressed air for governor is used to built hydraulic oil pressure in Pressure Vessel
Tank, which is required for opening and closing of wicket gates.
For this purpose, a set of two Governor Air compressors are provided in Governor Gallery. The
compressor works on lead / Lag principle. Either of the Governor Air compressors feeds
compressed air to a main tank, which is connected to Pressurize Vessel Tanks of each unit
through a common header. The lead compressor starts at 4.127 MPa and stops at 4.643 MPa. If
the Lead compressor doesn`t starts due to any reason, then the Lag compressor starts
automatically to develop the pressure.
STATION SERVICE AIR COMPRESSOR
The compressed air is also required in Power house for different purposes like cleaning,
cutting, grinding, flushing, etc. A dedicated air compressor is provided for serving the purpose,
which can be start or stop either on Auto or Manual. Normally, it is kept on manual mode. If the
display shows “AUTO RESTART”, it means the selection is on Auto. The manual selection shall
be displayed by “READY TO START”.
The compressed air is accumulated in main tank and further distributed to all essential
locations through piping network, laid all around the power house.
 Steps of operation
 Confirm that its main breaker at CSB – B is “ON”.
 To start the compressor press the green “I” push button at its keyboard.
 To stop the compressor press the red “O” push button at its keyboard.
HEATING VENTILATING AND AIR CONDITIONING SYSTEM (HVAC):
HVAC system is basically used to maintain the temperature convenient in a close building like
hospitals, factories, power house and others. The system deployed in power generating houses,
additionally serves the purpose of maintaining the temperature within permissible limits for
sensitive electronic equipments to avoid overheating, which may either damage or reduce
their operational life. The objective may be achieved by either chilled water plant or air
conditioner system (Gas condition plant).
MANUAL
The HVAC system provided at Malakand III comprises both types. The cool / hot air is provided
in power house through AHU (Air handling units). Besides, air conditioner plants are installed
for CCR and offices.
AHU:
An AHU (Air handling unit) works on the principles of condensed blowed air. The cool water
flow in coiled tubes of radiator, while the motor or blower blow air. The air passes through
radiator and circulated to required places through a close duct. The duct is wrapped with
insulation, which reduces the environmental impact on the temperature of air and maintains it
normal. Air grills are provided in the duct at desired locations, which disperse the cool air. The
air duct contains adjustable baffles for its regulation. A return duct is laid, which sucks the air
and carry it back to the AHU. For fresh air, another suction duct is provided for supplying the
fresh air to the AHU system. In this way, close air system operates.
Five AHUs are installed at El 463m in the upstream gallery. The cooling water is off-shooted
from upstream cooling water common header, located at El 452m. Ensuring, clean cooling
water entry in AHU, which is first passed through strainers to trap suspended garbage. The
pressure on inlet is kept as 0.25 bars for appropriate function. The air handling units are
provided with heater too, which may be operated during winter season. The heater provides
hot air to the power house.
DESCRIPTION OF AHUs:
Serial No. Supply source Intended for Area
K-1 CSB-F Generating Hall
K-2 & K-3 CSB-A, CSB-C LT & HT gallery
Workshop and downstream offices at Gen. floor at El

K-4 CSB-D
459m
K-5 CSB-D Downstream offices at turbine floor El 456m
At El 468m on upstream side of power house, two ducts are provided, which supply fresh air to
all AHUs.
Control:
For Remote control, HVAC supervisory control panel is installed in CCR. The panel has a touch
screen. AHUs can be started or stopped by selecting the AHU & initiate command for operation.
Additionally, for Local control, dedicated AHU control cubicles are provided for each AHU in
the HVAC room.
MANUAL
 Turn selector switch, Auto/Manual.

 Press the start push button.
 The satisfactory operation may be verified by swelling of duct cloth.
Precautions:
Whenever, the auxiliary supply trips, an alarm indication (yellow) glows on the marshaling box
of AHU. Once the supply is restored, press the alarm reset push button for 5 to 10 seconds. If
selection is Auto, the AHU will start.
Air Conditioner System:
This system provides cool air to the CCR and offices in the block. It works like split air
conditioner. The sensors are provided at different locations, which provide signals for its
operation. The condensing unit is installed at roof of HVAC room, EL 468m. The condensing
unit is cooled by cool water.
DC Battery System
Like all other power stations, the D.C system deployed at Malakand III consists of two types i.e.,
220V and 48V systems. The 220V system consists of two battery banks, each bank having 106
numbers of battery cells and each cell is of 2 volt. The 48V battery bank has 24 cells in each
bank of 2V each. These batteries systems ensure consistent and reliable source of electrical
energy, if the AC sources fail. Primarily, these systems are installed for UPS to feed the control
and protection circuits. During routine checking, the operation staff should check that the
voltage displayed on charging modules within normal range (220V ± 10%). Also check that
there is no abnormal signal displayed on the alarm module of UPS system.
When AC is available, the batteries remain on charging mode. There are three modes of
charging the batteries.
 Normal charging.
 Float charging.
 Boost charging.
Float charging is a process in which, when AC is available, the charger converts AC into DC,
charge batteries and provide load to the system simultaneously. When the batteries are fully
charged the charger provide minor voltage to cope up the internal discharging of batteries.
MANUAL
Boost charging is a process in which the charger provides higher voltage to batteries but take
less time to charge the batteries. This mode is use for charging new batteries. Here is given the
single line diagram to understand the DC system.
Note: - The main AC supply provided to charge –1 and charger –2 from ESB –A and ESB-B.
CHECKS
 Check batteries of any leakage.

 Keep the battery room neat and clean.
 Keep the door of battery room close.
The load distribution of Chargers is as under.
Charger # 1
1. AVR & Excitation U # 1.

3. ACUPS.
4. GCB U # 1.
5. GCB U # 2.
6. GCB U # 3.
7. HP oil pumps U # 1.
10. Unit local control panel U # 1.
13. + U-3
14. + U-3
Charger # 2.
2. + CA 02.
MANUAL
6. +HA 01.
7. + U –3.
8. +U –3.
Fire and Fire fighting

Combustion or burning, in which substances combine chemically with oxygen from the
air and typically give out bright light, heat, and smoke
OR
Fire is chemical reaction in which oxygen and fuel react while heat and flame are
produced.
Fire is abbreviation of four words i.e.
F= Find
I= Information
R= Restriction
E= Evacuation / Extinguish.
MANUAL
Principles of Fire
Whenever water vapors from an area or a body evaporate, basically the oxidation took place in
this process, it catches fire.
There are five classes of fire according to burning fuel.
Class A:
These are fires involving flammable solids, e.g. wood, cloth, rubber, paper, and some types of
plastics. An example of this type of fire would be a camp site fire.
Class B:
These are fires involving flammable liquids or liquefiable solids, e.g. petrol, oil, paint and also
some waxes & plastics, but not cooking fats or oils.
Class C:
These are fires involving flammable gases, e.g. natural gas, hydrogen, propane, butane.
Class D:
These are fires involving combustible metals, e.g. sodium, magnesium, and potassium.
Class E:
These are fires involving any of the materials found in Class A and B fires, but including
electrical appliances, wiring, or other electrically energized objects in the vicinity of the fire,
with a resultant electrical shock risk if a conductive agent is used to control the fire.
Class F:
These are fires involving cooking fats and oils. The high temperature of these types of fats and
oil when on fire far exceeds that of other flammable liquids which means that normal fire
extinguishers should not be used.
Burning Fuel
Burning fuel can be dividing in three categories
 Tinder. Such matter which caught fire immediately like petrol, acid and alcohol.
MANUAL
 Kindling. The fuel which need the support of tinder for burning like wood, paper, and
card board.
 Bulk fuel. The fuel which requires support of Tinder and Kindling for burning like metal
etc.
Causes of fire
 Accidents and Carelessness

While, it is true that being careful will make you safer but it will not stop fire from
happening. Most fires are not caused from carelessness.i.e. throwing burning match or live
cigarette, transporting explosive material without care, carelessness in cutting, welding
and grinding. Many people believe that if they are careful, they are much less likely to have
a fire.
 Electrical Wiring, Electrical Outlets and Faulty Wiring

Whether it is in an electrical outlet or a shock in the wall, many fires are caused by
electrical wiring. Older homes are particularly susceptible, as they were not wired for the
many appliances that we have filled our homes with. Many homes that were built in the
50′s -70′s have aluminum wiring that gets very hot and increases the chance of fire.
 Appliances
Lamps, toasters and even baby monitors can short out. Be particularly careful with older
appliances and extension cords. Even new appliances can be the source of a home fire. To
be safe, appliances should be unplugged when not in use.
 Abruptly increase in temperature

Some time a sudden increase in temperature also leads to fire because due to that sudden
increase in temperature the environment become suitable for fire. It is observed that in
winter season mostly fire accidents are rare but in dry/summer season there are chances
of fire to flare up of its own due to high temperature.
 Unattended Stoves
Another cause of residential fires is due cooking, but not due to defective stoves or
ovens. Often, it is because of unattended pots or the burner being left on accidentally -
and who hasn’t done that at least once or twice?
MANUAL
Process of Fire Extinguishing
 Smothering.
If the supply of oxygen cut off from the area, which caught fire, the fire can be
controlled. The area should be covered with some material like sand, cloth (Blanket)
etc.
 Cooling
If the fire area temperature reduced by some means, it could be controlled.
 Starvation.
If the burning fuel is removed from the area, where fire happened, the fire can be
controlled.
As it has been discussed earlier that fire is abbreviation of four words. If by any means, the
advance information of fire appears, the fire hazard can be reduced and the process of fire
fighting becomes easy. There are different devices, which are use to inform about fire.
 Fire heat detector.

 Fire smoke detector.
 Fire flame detector.
 Fire gas detector.
FIRE FIGHTING
1. Fire extinguishers.
2. Fire buckets. (Sand + water)
3. Stirrup pump.
4. Sand and shovels.
 Precautions
 When CO2 gets release, an alarm rings and red light mounted at Generator housing wall
glows. When the lights went off then try to enter in Generator housing with oxygen
mask and cylinder.
 Do not enter in Generator housing when CO2 is discharging.
MANUAL
 Try to provide fresh air, by exhaust fan after controlling of fire.

 Keep the door of Gen. Housing closed.
 Do not try to play with detector, emergency push buttons etc.
Generator Fire Protection System
CO2 Bank:
A CO2 bank is provided for each unit. It may operate on Auto or Manual, if required. If the
Generator Differential Protection gets activated, CO2 will be released, automatically. The
activation of smoke detectors or heat detectors installed in generator housing will trip the unit
but do not release the CO2. If the unit trips as a result of aforementioned protections, the
Operator should rush to generator housing immediately and look for any fire. If observed, CO2
should be released by pressing the manual push button installed at the CO2 controller (GA08).
Similarly, if CO2 does not discharge on auto, when supposed to, the bank should be operated
manually. The operator will go down at CO2 bank of respective Unit and pullout the safety pin.
Then he will approach at generator floor on GA08 and push (red button), at fire fighting
instrument panel.
As the CO2 gas is heavier than ordinary air, so, it cut off oxygen from the area and fire can be
extinguished.
CO2 banks are located at EL. 456m at turbine floor, near turbine pit in downstream gallery.
Each bank contains 08 No’s of CO2 cylinder. The first cylinder is called pilot cylinder. Either of
Auto or Manual commands activates the solenoid of pilot cylinder, which not only operates the
pilot cylinder but also initiates the other 07 cylinders to operate. All cylinders supply CO2 to a
common header pipe, which leads to generator housing. The discharging of CO2 in generator
housing takes place through nozzles fitted at the end of piping.
General Fire Fighting system
 Dry Powder cylinder

Can be use for “A, B, C & E” Class,” flammable solids, e.g. wood, cloth, rubber, paper, and
some types of plastics. Flammable liquids or liquefiable solids, e.g. petrol, oil, paint and also
some waxes & plastics flammable gases, e.g. natural gas, hydrogen, propane, butane and
MANUAL
electrical fire. “But cannot be use for Class D “combustible metals, e.g. sodium, magnesium, and
potassium”.
 CO2 cylinder
CO2 fire extinguisher can be used for “B & E” class of fire i.e. flammable liquids or liquefiable
solids, e.g. petrol, oil, paint and also some waxes & plastics, Electrical appliances, wiring, or
other electrically energized objects.
 AFFF (Aqueous Film-Forming Foam)

AFFF fire extinguisher can be used for “A & B” class of fire i.e. flammable solids, e.g. wood,
cloth, rubber, paper, and some types of plastics flammable liquids or liquefiable solids, e.g.
petrol, oil, paint and also some waxes & plastics,
AFFF can never be used on “E” class of fire “Electrical” because AFFF has conducting property.
Operation Procedure of Fire extinguisher Cylinder

 Precautions
 The fire extinguisher cylinder should be use according to the class of fire.
 In case of Electrical fire first of all tries to close the respective power supply.
 Confirm from the pressure gauge of cylinder that the pressure of extinguisher is in
normal “green” range.
 Pull out the pin from the handle of cylinder.
 Keep the nozzle of the extinguisher in one hand towards the base of fire and press the
handle with the other hand.
 Twin-agent firefighting equipment
For the big fires large capacity twin-agent (dry chemical/foam) units are available. Large dry
chemical systems combine the flexibility of a hand portable extinguisher with the greater fire-
killing power needed to combat large flammable liquid and gas fires. it has two tanks one of
Dry chemical ( use for class A, B, C & E) and other of AFFF (use for class A & B) having large
length rubber hose.
 Pull the pin, and push lever on actuator.
MANUAL
 Pull all the hose from reel

 Open nozzle fully
 Direct the stream at the base of flame with side to side motion.
 Fire Hydrants
Fire Hydrant is the system used for extremely high fire. These systems have been distributed
in different places at different elevations in the power house building having large hose. There
are hand wheels provided out side the fire hydrant point. To operate the fire hydrants derail
the hose pipe, direct to fire and open the hand wheel.
Name Plate data of Turbine, Generator, and Transformer.

TURBINE
 Type = HLA 550a-L J-175
 Nominal Diameter of runner = 1750 mm
 Outer Diameter of runner = 1785 mm
 Height of Runner = 718.5 mm
 No. of Blades = 17
 Rated Head = 180.5 m
 Rated Discharge = 16.8 m3/sec
 Rated Power = 27.9 MW
 Rated Speed = 500 rpm
 Runaway Speed = 880 rpm
 Weight of Runner = 3.4 Ton
 Material = 06Cr 13Ni 4Mo (A 743 CA-6NM)
 Manufacturer = Harbin Electric Machinery Co. Ltd. P.R. China
The runner blade, crown and band are separately made of stainless steel cast material and then welded
together.
MANUAL
Generator
 Type = SF 27.2 – 12/3600
 No of phases = 3
 Rated power = 27.2 MW
 Rated voltage = 11 KV
 Thrust Load = 175 t
 Rated current = 1679.6 A
 Rated power factor = 0.85
 Rated frequency = 50 Hz
 Manufacturer = Harbin Electric Machinery Co. Ltd. P.R. China
Rotor
 Rated Voltage = 125V dc

 Rated Current = 651A dc
 No of Poles = 12
 Insulation Class = F
Power Transformer
 Rated Power = 32000 KVA
 Rated Voltage and tapping range = (132 +/- 2 *205 %)/ 11KV
 Type of cooling = ONAN
 Rated frequency = 50 Hz
 No of phases = 3 phase
 Vector group symbol = YNdI
 Load losses = 128.8 KW
 No load losses = 22.3 KW
 No load current = 0.15 %
 Impedance = 9.61 %
 Total weight = 58880 Kg
 Tape changer = off load
 Manufacturer = China TBEA Hengyang transformer co ltd.
MANUAL
Significant Elevation Related to Malakand-III HPC

S.No Description Elevation (masl.)
1 Sill level of Outlet Auxiliary Tunnel Gate 644.80
2 Sill level of Headrace Conduit Gate 644.30
3 Sill level of Sediment Flushing Gates 633.07
4 Sill level of Forebay Intake Gate 630.30
5 Roof of Forebay Intake Building 653.95
6 Forebay maximum water level 624.06
7 Talirace maximum water level 458.55
8 Tailrace minimum water level 457.73
9 Turbine centerline 454.70
10 Penstock manifold centerline 454.70
11 Sill level of Tailrace Stop log 456.85
12 Drainage Pit bottom. 446.43
13 Inlet Valve Gallery 452.20
14 CW equipment Gallery 453.04
15 Turbine Floor 456.35
16 Generator Floor 459.40
17 Loading Bay 463.15
18 HVAC Gallery 463.35
19 Central Control Room 468.20
20 32MVA Transformer Deck 463.15
21 Draft Tube Deck 463.15
22 Draft Tube Aeration Pipe 462.10
23 Cooling water discharge line into Stilling Basin 452.84
24 Sill level of Waste way Diversion Gates 456.40
25 Sill level of Machai Regulator Gates 457.66

Operation Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operation Manual

Uploaded by

Copyright:

Available Formats

Malakand-III Hydro Power Complex OPERATION

Qazi Khalid Masood

Hydro Tech Pak. (Pvt.) Ltd.

SALIENT FEATURES OF THE PROJECT

 NAME : Malakand III Hydropower Complex

 WASTEWAY: : 2.385 km Long Stone Pitched Channel discharging

Salient Structures of the Project

type of Penstock with diameter of 4m.The thickness of penstock gradually increases as it

132KV Malakand-III switchyard comprises the following main equipments constituting

Filling of fore bay

 Confirm that Intake Gate is fully closed.

Filling/ un-filling or watering /Dewatering of Penstock

 Filling through Penstock bypass valve

Filling of penstock through Penstock bypass valve.

 Open both the manual gate valves of penstock bypass line.

Filling of penstock through crack opening of Intake Gate

 Switch ON the main supply breaker.

Dewatering / un-filling of penstock

 Confirm that intake gates is fully closed.

 Open the penstock dewatering valves of all the three units.

Intake Gate Operation

Gate Opening Operation:

Gate Closing operation:

Closing of intake gate

Opening of intake gate

Filling and un-filling / watering and de-watering of Draft Tube:

 Through Tail race

Filling of Draft tube through Tail race

 Open the draft tube dewatering valve of the unit.

Unit to unit filling of Draft tube

Filling of Spiral case:

Dewatering of draft tube

 Open the draft tube dewatering valve of the respective unit.

Dewatering of spiral case.

Opening of motorized valve on bypass line for Inlet valve.

Closing of motorized valve on bypass line for Inlet valve.

Inlet valve operation

Opening of inlet valve:

 SCADA from CCR

Opening of Inlet valve through SCADA.

Opening of Inlet valve through DCS.

 Turn the "Mode Select" control switch at GA-05 to “Local".

Opening of Inlet valve from its control cubicle.

 Turn both the mode selection switches to Local and Manual.

Opening of Inlet valve manually.

Closing of Inlet valve

There are three methods for closing of Inlet valve.

Auto closing of Inlet valve:

Closing of Inlet valve through DCS

Closing of Inlet valve from Control cubicle.

Cooling water system:

Main Cooling Water System

1. Turbine Guide Bearing

Stand by Cooling Water system:

Changing of Cooling Water system:

 From stand by to unit

From stand by to unit:

Changing of Cooling Water from Unit to Unit:

Cleaning of shaft seal filter:

Back Flushing of Cooling Water Strainer:

Unit Pre Starting checks After Maintenance.

 PROTECTION PANEL (GA-03)

 UNIT CONTROL BOARD (GA-04)

 Confirm that all Control Switches are at Neutral (Ø) position.