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Aerators on spillways of Indian dam

Article · January 2009

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V. V. Bhosekar Vinayakam Jothiprakash

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 AERATORS ON SPILLWAYS OF INDIAN DAMS

Mrs. V. V. Bhosekar V. Jothiprakash P.B.Deolalikar

PhD Scholar, IIT Bombay Asstt. Professor Joint Director
Chief Research Officer, IIT Bombay, Mumbai CWPRS, Pune
CWPRS, Pune

ABSTRACT

Spillways of high head dams are susceptible to cavitation damage due to surface

deformities and high velocity. Aeration is the most effective method for mitigating

cavitation damage. Design of aerators is complex. Hence, recourse is always taken

to refer the existing designs while designing an aeration system for a dam. This

paper highlights the details of aerators for five major projects in India viz. Sardar

Sarovar, Tehri, Indirasagar, Karjan and Chamera Stage I. This data would be of

immense use to the designers.

Key words:

Cavtation, Spillway aerator, design features

INTRODUCTION

At independence, in 1947, there were fewer than 300 large dams in India. By

the year 2000 the number had grown to over 4000, more than half of them built

between 1971 and 1989. India ranks third in the world in dam building, after US and

China. Spillway is an important structure of the dam. In many dams heights are in

excess of 100 m leading to velocities exceeding 30 m/s. Thus, the spillways for these

dams are susceptible to cavitation damage. Low pressure regions on spillway

surfaces are created due to separation of high velocity flows leading to cavitation

damage. Aeration is the most effective method to mitigate cavitation damage.

Natural aeration of the flow on the spillway may not be sufficient for this purpose.

Therefore, aerators are provided to supply the air underneath the flow along the

spillway surface. An aerator basically consists of a ramp/ offset or a combination of

the two to lift the jet from the floor and an aeration duct to supply the air in the cavity

so created below the jet. A groove is used in conjunction with an upstream ramp and

/or a downstream offset or step, so that the bottom spray of the high velocity jet does

not impact within the confines of the groove and thereby some of its air conductance

capacity. Continuity of airflow in the duct requires a continuous supply of air to the

space beneath the nappe. The head losses in the side duct together with the

pressure change caused by the velocity change in the main duct result in the space

under the nappe being at a variable sub atmospheric pressure. The aerator

geometry produces a jet which lifts the water nappe from the floor. The nappe

reattaches on the downstream creating a cavity just downstream of the aerator. This

cavity is connected to the air supply system. The size of cavity is a function of the

incoming Froude number and depends on the geometry of the aerator. A typical

curve for a Froude no. is shown in Fig.1. The area of air supplying duct also controls

the air supply. Various curves for increasing duct area are also shown in Fig. 1. The

intersection of the two curves is the solution or the working point of an aerator

geometry and air supply system. Estimation of cavity sub pressure a priori is difficult.

Several researchers have suggested empirical equations based on the experimental

work. Thus, the functioning of the aerator is the combination of aerator demand

curve and the duct rating curve as shown in Fig. 1.

 Fig. 1: Aerator demand and duct rating curves (Volkart & Rutschmann 1991)

The design or performance of an aerator requires the determination of following

parameters (Pinto et al 1982, Cassidy and Elder 1984, Kokpinar 1996):

• Determination of chute flow characteristics viz. velocities and pressures to

calculate cavitation index to predict the tendency for cavitation damage

• Estimation of the quantity of air required to prevent cavitation damage

• Location of first aerator

• Aerator geometry and size

• Size, geometry and location of the air supply system

• Spacing between the successive aerators

Design of aerators is very complex and is a subject of continuing research. A

designer always takes recourse to the existing designs of the aerator in planning.

The feedback from the prototype performance suggests the changes to be made in

the future design. Thus, access to the data of the existing aerator geometries gains

importance. This paper highlights the design features of the existing aerators on the

following high dams in India:

• Sardar Sarovar Dam , Gujarat

• Tehri Dam, Uttarakhand

• Indira Sagar Dam, Madhya Pradesh

 • Karjan Dam, Gujarat

• Chamera Dam Stage I, Himachal Pradesh

The design of each of the aerator is different depending on the site conditions.

SARDAR SAROVAR DAM, GUJARAT

Sardar Sarovar Project is located on river Narmada in the state of Gujarat. This is

the terminal structure in the Narmada Basin Development Scheme. The project

consists of a 163 m high and 1210 m long concrete gravity dam, two power houses

generating 1450 MW, and a 458 km long canal with 38 branches. The dam is

provided with a 30 span spillway of width 18.3 m each separated by 4.7 m thick

piers and equipped with radial gates 18.3 m X 14.7 m. The service spillway of 23

spans has a sloping – cum- horizontal stilling basin as energy dissipater and the 7

span auxiliary spillway has two chutes terminating in to ski- jump buckets. Figures 2,

3 and 4 show the plan and elevation of the spillways.

Fig. 2: General layout plan of the spillway and power house

Fig. 3: Cross section of the service spillway

Fig. 4: Cross section of and auxiliary spillway

Fig. 5: Details of aerator on service spillway

 Aerators were provided on the service and auxiliary spillways for Sardar

Sarovar spillway. Aerator for the service spillway consists of an aeration groove of

2.45 m X 2.45 m with a ramp angle of 40 and ramp height of 0.4 m. The aerators in

bays 1, 3 and 5 are provided at El 82 m whereas aerators of bays 2 and 4 are

provided at El 78 m. The selection of location of aerator was governed by the flow

cavitation index and the availability of the straight length along the glacis between

the tangent point of the crest curvature and the tangent point of the lower circular

curvature leading to the energy dissipater.

The aerators were staggered to accommodate the air ducts in the divide

walls. Due to the staggered positions of the aerators in adjacent bays, the air intake

towers are placed just adjacent to each other, one opening in either bays. Air intake

towers are provided in the adjacent divide walls of the spillway. The intake of the

tower is provided with smooth bell mouth entries to minimize the head losses. The

one meter walk way in the aeration groove was provided for inspection. A slope of

1:1.358 was provided to connect the walk way with the original slope of 1:06 to the

spillway and to facilitate self draining of the groove. Figure 5 shows the details of

aerators for the service spillway.

Hydraulic model studies at CWPRS

Hydraulic model studies were conducted at CWPRS on sectional models for

both the service and the auxiliary spillway to ensure the performance of the aerators

and to improve upon their designs. The model studies were required to ensure that

the aeration grooves are not filled up with water, the formation of jet trajectory is

satisfactory under all discharges and no undesirable flow conditions develop where

the jet impinges on the downstream side. Model studies for the aerator were
conducted for the entire range of discharges ranging from discharge intensities of 25,

45, 135 and 145 cumec/m .The effect of completely closing the mouth of the air

intake towers; thereby stopping the air supply was also studied.

The ramp angle of 2.50 of the original design of aerator for service spillway

was found to be inadequate. Three ramp angles of 4, 5, and 6 degrees were studied

and angle of 40 was found to be suitable. It was observed that the performance of the

aerator was satisfactory for all the discharges. The jet trajectory was formed and the

jet was impinging down stream of the aerator without filling the aerator for any of the

discharges. The length of the jet was found to be between 18 to 22 m for various

discharges. Piezometers were installed on the spillway surface to insure the jet

length. A sudden rise in the pressure on the spillway surface was observed due to

impact of the jet. It was suggested that the location of the aerators and the

connecting air intake towers for each of the 5 bays of the spillway should be

staggered at El 82 m and 78 m respectively due to limited space available in the

divide wall.

The aerators for the lower chute of the auxiliary spillway consisted of a ramp

of 0.7 m with a ramp angle of 60 at El. 63.5 m and another aerator at El. 51.9 m with

a ramp angle of 50 and height 0.6 m. Sample calculation for the aerator of lower

chute spillway is attached as annexure for reference. The aerators of higher chute of

auxiliary spillway consisted of a ramp of 60 and height 0.7 m located at two locations

at El. 75.24 m and El. 67.74 m respectively. It is important to note that since the

slope of the auxiliary spillway was flatter, higher ramp heights and thereby larger

ramp angles were required. Model studies for the auxiliary spillway were conducted

for both upper and lower chute. The lower chute spillway would be operated only
when the inflow discharge exceeds the capacity of the service spillway at FRL.

Therefore, it was observed on the model that with the partial gate operation of the

lower chute spillway, the flow cascades over the lip of the ski jump bucket and

hydraulic jump forms in the bucket region. Due to this the water level heads up and

gradually closes the lower aeration groove making it ineffective. It was feared that

instead of mitigating cavitation the groove itself will act as a cavitating machine.

Therefore, it was suggested that the lower aeration groove could be dispersed with.

Figure 6 shows the aeration grooves for the lower chute.

Analytical calculations indicated that in the upper chute the magnitude of

cavitation index along the entire length of the spillway up to the ski jump bucket for

all the discharge intensities was higher than 0.2. Also, considering the frequency of

the operation of the upper chute spillway, it was found that there is no need of

providing any aerator for the upper chute. The performance of the upper aerator was

found to be satisfactory for all the discharges.

Fig. 6: Details of the aerators for the lower chute auxiliary spillway

The aerators needed special attention during construction stages. The top ends of

the divide walls were modified to form fan shape nappe over the partly constructed
blocks. No damage to the ramp or the air ducts have been observed when the water

was passed over the partly constructed spillway blocks. The dam has been

constructed up to the crest El. 121.92 m and the performance of the aerator for the

completed stage of spillway is awaited. Photos 1 shows the view of the aerator on

service and auxiliary spillway of the dam.

AERATORS

Photo 1: View of the aerator on service and auxiliary spillway

THEHRI DAM SPILLWAY, UTTARAKHAND

Tehri dam project consists of a 260.5 m high earth and rockfill dam with three

spillways and a power house complex with generation capacity of 1000 MW. The

three spillways are one chute spillway and two shaft spillways with the crest at El.

815 m, El. 815 m and El. 830.2 m and discharging capacity of 5500, 3650 and 3850

m3/s respectively. The FRL and MWL are at El. 830 m and 835 m respectively. The

chute spillway consists of 3 bays of 10.5 m width each with crest at El 815 m. The

spillway is 718 m long with a fall of 234 m. Due to the long length of the chute one
aerator would not have been sufficient, as the air supplied by one aerator would

detrain. Three aerators have been provided at El. 773.16 m, El. 731.05 m and El.

678.42 m respectively. The aerators are in the form of ramp of heights 0.2, 0.15 and

0.1 m respectively and an aeration groove connected with gallery which opens

downstream of the ramp with openings of size 1.5 m x 1.5 m. Figure 7 shows the

plan and cross section of the spillway with location and details of the aerators. Photo

2 shows the view of the chute spillway showing aerators at three locations.

The dam has since been completed and power generation has started.

However, the reservoir has not been filled up to FRL and the spillways have not

started functioning. Hence the performance of the aerators is yet to be known.

AERATORS

Photo 2: Downstream view of the chute spillway with the three aerators
 Fig. 7: Plan and cross section of the Chute spillway showing aerators

INDIRA SAGAR DAM SPILLWAY, MADHYA PRADESH

Indira Sagar Dam Project is located on river Narmada in East Nimar district.

The dam is a 92 m high concrete and 653 m long gravity dam. The spillway consists

of 20 spans of size 20 m x 17 m. with the crest at El. 245.13 m. The FRL/ MWL are

at El. 263.36 and El. 262.13 m respectively. The spillway has been provided with

roller bucket as energy dissipater. Since the length of the spillway to be protected is

short only one aerator has been provided at El. 225.97 m at the end of the pier in

the form of a 1.2 m high ramp. A wedge of 0.6 m has been provided on either side in

plan adjacent to piers to deflect the jet towards centre of span for allowing aeration

from the sides and in the wake of the piers. This is a very convenient location which

does not need any separate air duct system. Figures 8 and 9 show the plan and

section of the spillway with details of the aerator. Photo 3 shows the view of the

spillway passing discharge. The dam has been commissioned in 2006. The aerators

are functioning well as no cavitation damage has been reported.

Fig. 8: Plan and upstream elevation of the spillway

Fig. 9: Section of the spillway with aeration groove

 AERATOR

Photo 3: View of the dry and

functioning spillway

KARJAN DAM PROJECT, GUJARAT

Karjan dam is 100 m high masonry- cum –concrete dam in Gujarat. It is

located across river Karjan, a tributary of River Narmada. A 171.61 m length of

spillway with crest at El 101.23 m has been provided to discharge a design flood of

17,275 cumec. The FRL and MWL are at El 115.25 m and 116.10 m respectively.

There are 9 spans of size 15.55 m x 14.02 m for passing the design flood. A stilling

basin with horizontal apron has been provided for energy dissipation. An aerator in

the form of a 0.56 m high ramp, a groove of size 1.4 m x 1.4 m and an aeration

gallery of size 2.5 m x 3.75 m has been provided at El 63.5m .The ramp angle is

80.The ramp angle and the groove height seem to be little high for the steep slope of

the spillway and there is a possibility of jet trajectory crossing the spillway glacis and
falling in the stilling basin for some discharges. The aeration groove could have

been provided little higher on the spillway glacis, so that more length could have

been protected. Figures 10 and 11 show the section of the spillway and the details

of aeration groove respectively. Photos 4 and 5 show the view of the spillway under

construction and functioning.

Fig. 10: Section of the spillway

Fig. 11: Details of aerator

The dam has been completed in 1991 and the spillway has been functioning since

then. No cavitation damage has been observed on the spillway glacis. Photos 4 and

5 show the view of the spillway under construction and functioning.

Photo 4: View of the spillway with aeration groove.

AERATOR

Photo 5: View of the spillway functioning

CHMERA DAM PROJECT STAGE I, HIMACHAL PRADESH

The Chamera H.E. Project, Stage – I is the downstream most project in the cascades

on the river Ravi. It is a 125 m high concrete gravity dam with breast wall spillway. The

spillway is designed to pass a maximum discharge of 22,000 cumec. The spillway is

provided with openings at 32.5 m below FRL El. 762.5 m with breast walls and a ski-jump

bucket is provided for energy dissipation. The aeration groove is provided in the form of a

groove and connected with a duct in the pier. No ramp or air gallery has been provided.

Figures 12 and 13 show the plan and section of the spillway with the aeration groove.

The project was constructed during 1987 to 1993 and commissioned in the year

1994. Photo 6 shows View of Chamera dam spillway.

Photo 6: Chamera dam spillway functioning

No cavitation damage has been observed on the spillway glacis. Hence the performance of

the aerator is found to be satisfactory.

 Fig. 12: Plan of the spillway

Fig. 13: Section and upstream elevation of the spillway

CONCLUSIONS

Design of aerators is a complex process. The data on aerators on existing

dams is of vital importance as often a designer is required to take recourse of this

data for planning. Fine tuning of the design is done with the help of model studies.
This paper has highlighted the design features of the aerators on five existing

projects in India.

ACKNOLWDEGMENTS

The authors are thankful to Mrs. V.M. Bendre, Director, Central Water and

Power Research station for her encouragement and valuable suggestions given

during the preparation of this paper. The authors are thankful to various project

authorities for referring the model studies to CWPRS, participating in discussions for

finalizing the design of aerators and arranging site visits. The guidance given by the

Shri S.P. Sen, Director, NHPC and discussions with officers from NHPC, THDC,

GERI, SSNNL and NHDC are gratefully acknowledged.

References

1. Volkart P. and Rutschmann P. (1991). “Aerators on spillway”, Air entrainment in

free-surface flows, Hydraulic Structures Design Manual No. 4, A.A. Balkema

Publication.

2. CWPRS Technical report 1993 ,” Hydraulic model studies for design of aeration

grooves on spillway”
 Annexure

Sample calculations for design of aerator for Auxiliary spillway of Sardar

Sarovar Dam Spillway

Data:

No. of spans : 4
Span width : 18.3 m
Thickness of pier : 4.7 m
Width at toe : 87.3 m
Design max. Discharge : 11,785 m3/s
Max. Water level : 140.2 m

Need for aerator:

H= 140.2-63.5= 76.7 m

For 100% discharge

Vactual =36.3 m/s
D=3.7 m
V2/2g = 68.81 m
Cosα = 0.9946
Pb = 10.3 m
Pv = 0.233 m
3.7 × 0.9946 + 10.3 − 0.233
σ= = 0.2
68.81

For 50% discharge

σ = 0.175
Thus, there is a need for the region downstream of El. 63.5 m. Therefore, the first
aerator be located at El. 63.5 m

Aerator and intake configuration:

Angle of chute α = 5.950

Angle of ramp θ = 60 = 0.1047 radians
Height of ramp tr = 0.7 m
Height of step ts = 0
Also,
Vw = 36.3 m/s
d = 3.7 m
Fr = 6
tr + ts
T = = 0.188
d
−
Calculate effective angle θ
−
⎛T ⎞
θ = θ tanh ⎜ ⎟ = 0.1019 radians
⎝θ ⎠
Calculate λmax =8.9
− ⎡ ⎤
Fr 2 θ ⎢ 2T cos α ⎥
λ max = ⎢ 1+ 1+ ⎥
cos α −
⎢⎣ (θ Fr )2 ⎥⎦

⎡ ⎤
36 × 0.1019 ⎢ 2 × 0.188 × 0.9946 ⎥
= 1+ 1+
0.9946 ⎢ ⎥
⎢⎣ (0.1019 × 6)2 ⎥⎦
= 8.9
Calculate βmax. = 0.03(λmax-5)
= 0.117
Calculate Emin =
10 3
2.3
( )
(tan θ )1.15 exp 1.15(tan α )2

Emin =
10 3
2.3
(
(tan 0.1047 )1.15 exp 1.15(tan 5.95)2 )
=33
Qair =10 X W
= 10X87.3
= 873 m3/s
qw
Fq =
(
g H 11.5 )
135
=
(
9.81 76.71.5 ) =0.064

= 0.015 + 0.464 exp(− 31.58 Fq )

Qa
β=
Qw
= 0.015+0.464 exp (-2.026)
= 0.076
Qa = 0.076 X 135 X 87.3= 895 m3/s
Therefore Greater of the two Qa is adopted as 895 m3/s

Qa
β= = 895/11785= 0.076
Qw
⎡ 1
⎤
3
π β
⎛ ⎞
tan ⎢ ⎜⎜ a ⎟⎟ ⎥ = 378
10 0 .7
Calculate ∆E =
3 ⎢ 2 ⎝ β max ⎠ ⎥
⎣⎢ ⎦⎥
E = Emin+∆E
= 33 + 378 = 411
Calculate average atmospheric pressure below the jet
− 2
V
∆ p = ρ w w = 0.088
E
Calculate air velocity in the duct
 ∆p × 2 gd × ρ w
Va =
0.43(1 + 2ξ tot ) × ρ a
= 76.6 m/s
Number of air ducts = 2
1 Q
Area of each duct = × a
2 Qw
1 895
= × = 5.84 m2
2 76.6
say 6 m2

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