Date : 18/10/2011

Location : Kukuleganga Hydro Power station

Group :1

Today was the 2nd day at the Kukuleganga Power Station. According to the Training Schdule given to
day was allocated for training at following sections

- Head Race Tunnel - High Pressure Tunnel

- Bification - Steel and Lining
- MIV - Turbine
- Draft Tube - Tail Race

Mechanical Engineer Mr. Sanjeewa spent his whole day with us in the power caven to train in above
sections as well as some additional topics.

Power Caven

Detailed discription about the power caven was given with the aid of following drawings (Fig:1 and 2).
Power caven has been built in the rock itself with the Access tunel about 0.55km long. Power caven
consists of 5 seperates floors, namely starting from above Machine Floor (unloading bay), Generator
floor, Turbine floor, Valve floor and Dranage floor. Except the Dranage floor other floors were visited
and related main and auxilary systems were studied.
 Fig: 1 : Plan View of the Underground Power Station

Fig 2: Cross Sectional View of the Power Cavern

Imporatnce of the surge shafts at Tail Race and Head Race Tunnel were tought and their physical
location was observed using the drawings. Surge shaft at Tail race is a tunnel connected to the acces
tunnel with a slop towards the tailrace. They are impotant to reduce the back pressure to the tunnels in
case of closing MIV and flap gate respectively.

Following scetch was used to illustate the main and auxilary systems in the cavern and they were
studied separatly
 Fig 3: Main and Auxilary Systems

Bification

Bification is the place where 1.7m vertical tunels meet.

MIV

Main Inlet Valve is sperical type with internal diameter of 1.7m. it has a Safe Close mechanism
supported by hydraulic and counter weight. service seal is used to balance the hydro pressure befor
opening the valve and maintenance seal is used for isolation purposes.

Fig 4: MIV

Draft Tube

Draft tube has a flap gate which is opperated through a servo motor. Arrengement of the flap gate is
such that, it tends to close with the back flow, by omiting possible reverse flows.
Fig5: Draft Tube Flap Gate Fig 6: Draft Tube
Cooling Water System

cooling water intake is at beyond the flap gate. cooling water is used to cool the generator, and the oil
at bearing system, transformer cooling and air conditioning. plant has 3 main cooling water pumps and 2
auxilary cooling water pumps with backwash stainers.

Fig8: Auxilary pump

Fig 7: Cooling water intake
 Fig 9:Back wash stainer Fig8: Main Cooling water pump

Fig10: Cooling water supply header Fig 11: Cooling water discharge header

Cooling water for trust bearing, lower and upper guide bearings and generator cooling are
distributed through the supply header and discharge header collects heated water from the
corresponding exchangers. In turbine bearing oil coolers, cooling water is sent through the tubes
in the exchanger where as heated oil circulate in the shell to exchange the heat.

Fig 12: Turbine bearing oil cooler Fig13: Thrust bearing oil cooler

Bearing

The bearing arrengment of Kukuleganga plant is conventional.

 Fig14: Bearing arrangement

Govener and wicket gate controling

Govener is an electromechanical govenor. This responssibles to generate speed commands to the

turbine to run always at 500rpm in load changing conditions which will generates power at 50Hz. two
servo motors connected to 20 wicket gates oper

ates according to the command given by the governer. wicket gates control the amount of water
through the runner at varing loads in order to keep runing the generator at 500rpm.

Fig 15: Tthe Gavoner Fig16: Wicket gates (guide vains) with servo
controlling

HP Compressure
HP compressed air is used for gavoner and for the MIV. compressor has 3 comopression stages. stage 1
compress are up to 6bar, stage 2 upto 40 bar and stage 3 upto 64bar.

Fig17: HP compressor with air receiver and oil ar accumilator

HVAC System

Heat Ventilation and Air Conditioning system is very critical for the plan operation as the humidity in
side the cavern is high. so, required temperature should always be maintained for the proper operation
of the control cards and other accesories. HVAC system has 3 heat exchangers, namely Air Handling
Unit, Evaporator and Condensor.

Fig 18: Air Handling Unit

Fig19: Comprssor