Submitted by:

Shakir hussain
Laraib Zafar

Discipline: Mechanical Engineering

From: University Of Engineering And Technology
Lahore
Submitted To:
RE Waheed Jakhrani
OE Saeed ur Rehman
 “Renewable And Environment Friendly Energy Source”

“Hydroelectric energy is a form

of renewable energy that uses
the power of moving water to
generate electricity.Hydropower,
or hydroelectric power, is a
renewable source of energy that
generates power by using a dam
or diversion structure to alter the
natural flow of a river or other
body of water”

Brief History of hydro power:-

(From its earliest beginnings to the modern era)
 Some of the first innovations in using water for power were conceived in
China during the Han Dynasty between 202 BC and 9 AD
 Hydropower, which first came to life in the 19th century, is the oldest of
the renewable sources.
 In 1827, French engineer Benoit Fourneyron developed a turbine capable of
producing around 6 horsepower – the earliest version of the Fourneyron
reaction turbine.
 In 1849, British–American engineer James Francis developed the first
modern water turbine – the Francis turbine – which remains the most
widely-used water turbine in the world today.
 In the 1870s, American inventor Lester Allan Pelton developed the Pelton
wheel, an impulse water turbine, which he patented in 1880.
 The world’s first hydroelectric project was used to power a single lamp in
the Cragside country house in Northumberland, England, in 1878.
 In the 20th century, Austrian professor Viktor Kaplan developed the Kaplan
turbine in 1913 – a propeller-type turbine with adjustable blades.
Generation of Hydropower in Pakistan:-

Pakistan has very good potential

in electric generation through water.
Pakistan has a potential of 40,000MW
hydropower, out of which the economic
Hydropower Potential is around 20,000
MW. Whereas total capacity of 13
existing hydel stations as today 6444 MW
which is 35.88 % of total
installed generation capacity of WAPDA
(Water and Power Development
Authority).Hydroelectric power
represents a third of Pakistan’s power
source, however, periodic droughts affect the availability of hydropower
production. WAPDA controls the country’s major hydroelectric plants.
Electricity in Pakistan generated, transmitted, distributed and retail by
two verticallyintegrated public sector utilities. WAPDA deals for all of Pakistan
except Karachi. The Karachi Electric Supply Corporation (KESC) for the city of
Karachi and its surroundingareas. There are around 16 independent power
producers (IPPs)

How to generate hydro-electric power:-

At the plant level, water flows through a pipe, also known as a pen-stock,
and then spins the blades in a turbine, which, in turn, spins a generator that
ultimately produces electricity. Most conventional hydroelectric facilities operate
this way, including,
I. Run-Of-The-River Systems.
II. Pumped Storage Systems.
Energy Transformation in hydro-electric plant:-
 The potential energy of the
of water in the reservoir
gets converted into the
kinetic energy of the
flowing water. The flowing
water rotates the turbine
shaft connected to the
generator which produces
electricity. and Thus kinetic
energy of water transforms
into the mechanical energy of turbine which further gets converted into the
electric energy.
 This electric energy then goes through various transmission processes before it
reaches you.
Sources of hydel energy:-
Because the source of hydroelectric power is water, hydroelectric power
plants are usually located on or near a water source. The volume of the water
flow and the change in elevation—or fall, and often referred to as head—from
one point to another determine the amount of available energy in moving water.
Benefits of hydropower plants:-
Because it relies only on the power of moving water,and not some type of
fuel, there are no price fluctuations to consider. And while it's expensive to build
the infrastructure, hydroelectric projects have long lifetimes (on average 50-100
years) and are relatively easy to maintain.
 It is clean and sustainable and a very flexible resource
 It stabilizes the power grid by preventing intermittency
 It reduces the risk of flooding
 It helps reclaim marshy areas
 It enhances tourist areas and water sports
 It protects biodiversity
 Water carries huge amounts of energy
 It is the cheapest source
 It lies at the heart of continuous innovation
 hashma hydropower plant is located on right abutment of Chashsma
Barrage. Chashma Barrage is a barrage on the River Indus in Mianwali
District of the Punjab 56 km downstream of Jinnah.
 The installed capacity of power
Station is 184 MW, The bulb
turbines have been installed for
the first time in Pakistan (lying
in horizontal position).
 The 8 Kaplan-type turbines and
synchronous generator units
were made by Fuji, Japan.
 It is low head power The head
range is 3 m-13.8m and the net
head of the project is 8.351m.

Description
Project name Chashma Hydro-power plant
River/lake/canal dammed Indus river
Plant type Run on the river
 Dam on the river with reservoir.
Total capacity 184 MW
Active capacity 161 MW since unit 2 is not active
Project stats Active,Operating Fully.
Project location Indus river ,Punjab , Pakistan.
Operating range of haed 3.7 to 13 meters
Maxi discharge through 8 turbines 84755 cusecs
Electric power grid connected to National Grid

 Main purpose of chashma barrage is irrigation later it is also used for power
generation purpose but still its main focus is on irrigation.
Development Status:-
 The President of Pakistan, Mr. Rafiq Tarar inaugurated Hydro Electric Power
Plant at Chashma Barrage, power generation started later in 2001.
 The project is currently owned by Pakistan Water and Power Development
Authority (WAPDA).
 It has been developed in single phase. The first unit was commissioned in
December 2000, while final commissioning of all units was completed in
July 2001.
Generation Capacity:-
 Chashma hydel plant has a total capacity
of 184 MW.
 Fauji Electric was selected as the turbine
supplier for the hydro power project.
The company provided 8 units of bulb
turbines, each with 23MW capacity
 Annual generation of the CHP is 675
Gwh.

Major Sections:- Figure 1Kaplan bulb type turbine

There are 4 major sections in chashma hydel plant.

 3 mantinance sections.
1) Mechanical scetion.
2) Electrical section.
3) P & I section.
 1 Operation section.

Output Distribution:-
Power generation in this plant is distributed to 4 grid stations through
132 kv transmission lines.
 D.I Khan
 Chashma left bank
 Wanbachran circuit 1
 Wanbachran circuit 2
 Step up
Bulk head Unit stop logs Main Gantry transformer
gates,inset gate projection rotating Bridge creane 11kv to 132kv Draft tube
at angle space shaft crane gate

Trash racks Synchronous

Headrace 24 panels generator bearing Runner blades Runner Draft tube
Tailrace
s fixed in runner nose Divergence
Bulb nose hub tube

(Kaplan bulb type turbine)

 Governer.
 GST(governer sub tank).
 Pumps and valves (Proportional,Distribution and FC-valves).
 Oil pressurizing tank.
 Turbine.
 Runner blades,runner hub and runner nose.
 Rotating shaft. Turbine guide bearing.
 Bearings. Generator guide bearing.
Normal(forward) Thrust bearing.
Reverse Thrust bearing.
 Vicket gates(16 in number).
 Discharge ring
 Shaft seal and maintenance seal
 Draft tube.
 Draft tube gates.
 GTG- tank with control panel
 Compressor.
 Electricity main Generator(with electro-magnetization effect).
 Rotor(moving,rotating part).
 Stator,with coil field winding(immovable,stationary part).
 Excitation system.
 Diesel generators(DG-Set).
 DC-Battery supply(105 cells).
 Excitation transformer.
 Resistor,transistor(with SCR) and AVR assembly.
 Excitation generator.
 Main Transformer:-
 Step-Up transformer (11kv to 132kv) , with 3 phase voltage supply.
 Transformer coolers.
 Turbine Kaplan bulb type turbine
Turbine cetagory Reaction turbine
Made by Foji, japan
Total no of turbines 8
Available head range Low head(-3 to 13m)
Net head 8.4m
Power each unit 23MW
Total capacity 184MW
Active capacity 161mw(Since unit 2 is not running
Run away speed 300 rev/min
Tripping speed 132-136 rev/min
 Turbines:-
A turbine is a machine that transforms rotational energy from a fluid that is
picked up by a rotor system into
usable work or energy. Turbines
achieve this either through
mechanical gearing or
electromagnetic induction to
produce electricity.
Working principle:-
Turbine is a rotary mechanical
device that extract the potential
energy and Kinetic energy of fluids
and convert into mechanical
energy. It is a prime mover which
transform the energy of working
fluid in to mechanical energy of
turbine shaft.
Ein Turbine Eout

( energy
Extract
(Ein > Eout)
 Types of turbine:- i) Impulse turbine
There are two basic types of turbine
ii) Reaction turbie
Difference between impulse and reaction turbine
Impulse turbine Reaction turbine
Impulse turbine uses only kinetic energy Reaction turbine uses both pressure and
of water to rotate its runner, kinetic energy of water to spin the
turbine.
In an impulse turbine, the steam flows In the reaction turbine, first, the steam
through the nozzle and strike on the flows through the guide mechanism and
moving blades. then flows through the moving blades.
During the flow of steam through moving During the flow of steam through moving
blades, its pressure remains constant. blades its pressure reduces.
The blades of impulse turbine are The blades of reaction turbine are not
symmetrical. symmetrical.
Pelton Wheel is the example of impulse Francis turbine, Kaplan turbine etc. are
turbine the examples of reaction
turbine

Kaplan bulb type turbine:

Kaplan Turbine works on the principle of axial flow reaction. In axial flow
turbines, the water flows through the runner along the direction parallel to the
axis of rotation of the runner. The water at the inlet of the turbine possesses both
kinetic energy as well as pressure energy for
effective rotation the blades in a hydro-power
station.
In 1913, an Austrian professor Viktor
Kaplan who developed this turbine combined
automatically adjusted propeller blades with
automatically adjusted wicket gates to achieve
efficiency over a wide range of flow and water
level. It is also called as propeller turbine and evolved from the Francis Turbine. It
is capable of working at low head and high flow rates very efficiently which is
impossible with Francis turbine.
Working principle:
A Kaplan Turbine is able to operate under the above described requirements:
 low hydrodynamic head
 bidirectional flow
 large flow rates
The water coming from the pen-stock is made to enter the scroll casing. The
scroll casing is made in the required shape that the flow pressure is not lost. The
guide vanes direct the water to the runner blades. The runner blade placed in
discharge ring(the narrow region of the turbine) causes the water pressure to
drop and kinetic energy increase to maximum to rotate the runner blades(but this
increase in kinetic energy causes the cavitation effect of the runner blades at the
same time)
Thus satisfies the Bernouli’s equation

If the fluid velocity is low, the pressure is high. The principle is derived from
Bernoulli's equation which expresses the relationship between pressure, fluid
velocity or flow rate, and height.

The direction of the water is axial to that of runner blades. The runner
blades start to rotate as the water strikes due to reaction force of the water. The
runner blades(movable blades,have angle adjustment) has twist along its length in
order to have always optimum angle of attack for all cross section of blades to
achieve greater efficiency. From the runner blades, the water enters into the draft
tube where its pressure energy and kinetic energy decreases. Kinetic energy is
gets converted into pressure energy results in increased pressure of the water.
The rotation of the turbine is used to rotate the shaft of generator for electricity
production.
Run-Away speed:-
When the system is in running condition with full potential.Suddenly the
electrical load drops to zero.This causes the extreme vibrations and sudden
increase in the speed beyond the rated rpm about(300 rev/min) this is called the
run-away speed of the unit.But this is not the safe zone for the system.
In order to protect system from adopting run-away speed.Auto control is
established with the help of speed sensors.If even then speed goes beyond
control then to protect the system emergency tripping of the unit is done.
Alarming 132-136 rev/min
Tripping More than 136-rpm

Major Components of turbine:

 Head race
 Electricity generator
 Rotor(movable part)
 Stator(fixed parts)
 Rotating shaft
 Break pads
1) Turbine guide bearing.
 Bearings. 2) Generator guide bearing.
3) Normal(forward) Thrust bearing.
4) Reverse Thrust bearing.
 Wicket gates
 Runner blades
 Runner hub
 Runner nose
 Discharge ring
 Shaft seal
 mantainance seal
 Draft tube
 draft tube gates
 Tail race
 Head race:
The headrace conduit, conveys the water from the reservoir to the turbine.
The conduit can be a channel, flume, penstock, tunnel, or combinations of these.
The length of the headrace can vary from a few meters to several kilometers.
 Trash racks:
Total number of panels 24
Hole size 6-inches
These are panels used to stop the trash moving into the unit machinery,
because trash effect the efficiency and power
output of the machinery. Trash increases the
load on the machinery. It only stops the trash of
size greater than 6-inches.
Unit Choking:- In case of water full of trash it
causes the trash to struck in the trash rack gills
trash accumulation effect the rated head of
water and also the efficiency of the unit is
effected badly. This trash causes the vibration in
the system, and systems reduces self electrical
load.the capacity and potential of the unit
decreases and can cause the back power effect Figure 2Trash rack gills
on the unit.
How to remove choking:
So in order to safe unit from this back power effect the unit is shut down
temporarly.The draft tube gates remains ON fully but the wicket gates are fully
closed and the water moves back with high potential and causes the trash
strucked in trash rack gills to move back with high force.
 Main inlet gate:
Unit stop logs gates 8 ( 1 for each unit)
each is 5 block set
Bulk head gates Inserted at angle 15o degrees
Each consist of 8 parts
Main inlet gate is a valve which is installed before water enters into bulb
like casing of the hydro turbine. Water from the dam enters the turbine,main inlet
gate is a equipment in between that stops the water for small maintenance
purpose in the turbine hall.The unit stop logs are inserted to close the inflow of
water.Bulk head gates inserted at angle, inclination sliding gates at trash racks.
 Runner:
The heart of the component in kaplan turbine are its runner blades
No of blades 4, adjustable blades
Blades material 13% Cr 4Ni stainless steel
 Less effected by cavitation
 Sustainable
 Less corrsion
Blade adjustment -30 to 340
Inlet diameter 6300-mm
Runner hub material cast iron
It the rotating part which helps in production
of electricity.Its shaft is connected to the shaft of
the generator.
Runner Hub:
The runner of the this turbine has a runner
hub on which its blades are attached and the the
blades of the runner is adjustable to an
optimum angle of attack for maximum power
output. The blades of the Kaplan turbine has
twist along its length. In hub and runner cone
hydraulic servomotor blades are accommodated
Cavitation effect:(Errosion)
The maximum K:E at blades end causes water Figure 3Runner blades (total 4 blades)
to covert into bubbles/ vapour’s that causes the wear and tear of blades called
cavitation (removes material from blades sides, pitting).
As the K:E decreases towards draft tube side so the effect of cavitation also
decreases.
Mechanism of Blade Control:
The blade of the turbine has a movable axis at the connection point. The
blade control mechanism controls the attack angle as the water hits the blade,
caused by the movable blade connection
Changing the blade angle actually changes the effective area of the runner
blades(effective area is the area that is facing water flow/area at which water
strikes).so by increasing or decreasing effective area according to the requirement
we can increase the efficiency of the turbine
 Shaft:
A shaft is a rotating machine element, usually circular in cross section,
which is used to transmit power from one part to another, or from a machine
which produces power to a machine which absorbs power.
Inner diameter 600mm
Outer diameter 900mm
Thickness 300mm
Shaft material forged carbon steel,
 Have two integrally forged coupling flanges. And Carries two concentric
pipes:
 For carrying pressure oil for closing and
opening operation of runner blades,
Servomotor.
 Restoring pipe for carrying lubricating oil
from oil gravity tank to runner hub. It
forms two journals which are supported
by turbine and generator guide bearings
In the turbine, one end of the shaft is simply
connected to the runner of the turbine, whereas
the other end is connected to the generator coil.
When the runner turns because of the rotation Figure 4 Main shaft assembly
of the blades, then the shaft also rotates, further, this rotation can be transmitted
to the generator coil(causes rotor rotation) .Once the generator coil turns it cause
electromagnetic induction , then it generates electricity.
Rated rpm:
 No of poles on main rotor=70 poles
 Standard frequeancy=50Hz
120∗ standard frequency
Ns=Synchronous Speed=Rated rpm of shaft=
𝑛𝑜 𝑜𝑓 𝑝𝑙𝑜𝑒𝑠 𝑜𝑛 𝑚𝑎𝑖𝑛 𝑟𝑜𝑡𝑜𝑟
120∗ f 120∗ 50
= = =85.7 rpm
𝑃 70
SO; when we change No.of Pole rated rpm will change.
Relation between no of ploes and rated rpm:
Speed of the induction motor is reciprocal to the number of poles..Inverse
relation exist between the no of poles on rotor and rated rpm of the shaft. So in
order to get high speed we should use small no of poles and vice versa.
 Bearings: ("parts that assist objects' rotation")
Bearings material Babbit (soft metal)
Alloy of(Tin, copper and Antimony)
Bearing type Plain journal bearing
Total bearing used 4( 2 guide and 2 thrust bearing)
They transfer motion, i.e. they support and guide components which turn
relative to one another. The main purpose of bearings is to prevent direct metal-
to-metal contact between two elements that are in relative motion. This prevents
friction, heat generation and ultimately, the wear and tear of parts. It also
reduces energy consumption as sliding motion is replaced with low-friction rolling
Bearing type:-
Plain bearings are very common in hydro turbines. Plain bearings are made
of cast iron and are suitable for medium-sized
applications.
1) Thrust bearings:-
These are used when there is a lot of force
being applied to the bearing. It is an axial bearing
that permits rotation between parts.Thrust
bearings support the axial thrust of both
horizontal and vertical shafts. The functions
are to prevent the shaft from drifting in the axial
Figure 5Thrust pads fixed in thrust casing
direction and to transfer thrust loads applied on the
shaft.
Thrust Runner:-
As start pulse is given to the system, the
shaft experiences a thrust force. Thrust runners
are fixed on shaft, it controls the thrust force.
Types of thrust bearing used:
Two types normal thrust bearing to absorb
forward thrust experienced by shaft and reverse
thrust bearing absorb thrust in opposite direction.

i) Reverse thrust bearing. Figure 6 Thrust casing….containing thrust pads

Types Used to withstand thrust produced in reverse direction in shaft

ii) Normal thrust bearing.
Used to withstand normal thrust in shaft.
2) Guide bearing:
The bearing opposite the thrust bearing
(usually the lower one) is called a guide
bearing Normally, a deep groove bearing is used
with grease for lubrication.Turbine guide bearing
is of forced oil circulating type and is a half
bearing with its lower half only being lined by
Babbitt metal.The upper half of the bearing is
lined at only it‟s both ends.
After lubricating the bearing the lubricating oil pas
ses to shaft cover mounted on the turbineguide
bearing, Then it returns to the lubricating oil tank.
The bearing shell is split in two partsin order to
Figure 7 Turbine guide bearing (Plain Jounal
facilitate assembling and disassembling bearing)

i) Guide bearing for Turbine

Guide Used to absorb vertical deflection of shaft on turbine side
bearing ii) Guide bearing for Generator
Used to absorb vertical deflection of shaft on generator side
Bearing temperature sensor:
Temperature sensors attached to bearings sense any temperature change
beyond the allowable range.This increase in temperature indicates any friction
contact in bearings and shaft or due to some other defect.
Alarming temperature 650C
Tripping temperature 750C
 Generator(electromagnetic induction)
"A hydraulic turbine converts the energy of flowing water into mechanical
energy. A hydroelectric generator converts this mechanical energy into
electricity.The operation of a generator is based on the principles of faraday law.
Generator type Synchronous generator
Magnet used Electromagnet,(not permanenet magnet)
No of poles of rotor 70
Induction type Self induction as well as mutual induction
Generator output 11kv
Current, Voltage 3365A , 11000V
Power factor 0.9
Phases 3
 Every rotating electrical machine such as motor and
generator consists of two major parts namely
stator and rotor.
Rotor:
The Rotor is also known as the rotating magnetic
core, or Flywheel, of an Alternator. Rotors are the
moving part.it contains 70 poles of magnet. The rotor
rotates inside the rotating magnetic field.
Figure 8main generator rotor
Stator:
The stator is the non-moving,stationary or fixed part in a machine.it has coil
winding og highly conductive material.
Max temperature of rotor 1200C
Max temperature of stator 1300C
Faraday law:
Faraday's first law of electromagnetic induction states, “Whenever a
conductor is placed in a varying magnetic field, an electromotive force is induced.
Electromagnetic induction:
Electromagnetic induction is the
phenomenon in which an emf is induced in
the coil if there is any change in the
magnetic flux linked to the coil. In a
generator, a coil is rotated in a magnetic
field, due to which magnetic flux linked with
the coil changes and induces an emf.
Working principle:
As shaft rotates due to motion of runner blades the other end of the shaft is
linked to the rotor part of the generator.The rotor acts as a large
electromagnet.rotor has 70 poles as rotor rotates the magnetic flux changes, this
change in flux passes through stationary stator ,generates an Emf(electromotive
force) it induces a voltage and generate an Alternating Current (AC) in the stator
windings.
 Wiclet gates:-
At a standard hydroelectric plant, series
of gates surround the entire turbine. These
gates can be closed completely to prevent any
water from reaching the blades of the turbine.
When a wicket gate is opened, water passes
through to reach these blades, causing them to
rotate.
Wicket gates are closed or opened
according to signal command in order to
maintain the rated rpm Figure 9 Wicket gates (total 16 gates)

Total No of gates 16
material 13% Cr-4% Ni stainless steel
Major function Maintain rated rpm
Wicket gates are made of 13% Cr-4% Ni stainless steel casting and have simple
rigidity to minimize the clearance between adjacent gates in closed position. The
side clearances of wicket gates can be adjusted with adjusting liner. The outer and
inner ends of wicket gates are machined to spherical shape to match the gate ring
and minimize leakage.
Wicket gates are in series of adjustable vanes that. control the flow of water
to a reaction turbine. Each vane, mechanically in parallel, is attached to an
adjustable gate ring.
 Discharge ring:
Ring material 13% Cr-5% Ni stainless steel
The discharge ring is fabricated from 13% Cr-4% Ni stainless steel plate is
split horizontally. Lower half of discharge ring has man hole. Before man whole is
opened, the water must be checked with test cocks provided near man whole. At
downstream end ring, the loose point to connected to draft tube liner is provided.
 Draft tube(Divergence tube):
The draft tube consists of steel lined parts i-e draft tube liner concreted parts,
and its profile is designed to gain maximum turbine efficiency.
The outer surface of draft tube liner is provided with sufficient ribs and
anchors for reinforcement to establish firm grip with surrounding concrete.
 Inlet diameter Ф 6625mm
Exit diameter Ф 8200mm
No of draft tube gates 8( one for each unit)
Draft gate shape Conical(Inc 90% effectiveness)
Draft tube material steel plates
Why Conical shape tube? (Divergence tube)
The pressure at the exit of the runner of
Reaction Turbine is generally less than atmospheric
pressure. The water at exit cannot be directly
discharged to the tail race. A tube or pipe of
gradually increasing area is used for discharging
water from the exit of turbine to the tail race. This
tube of increasing area is called Draft Tube. One end
is connected to the outlet of runner while other end
sub-merged below the level of water in the tail-race.
Draft Tube increases the pressure of the fluid.
Figure 10Conical shape draft tube
The water can not send directly to the tailrace
therefore this tube has been inserted. It works is to discharge the water from the
tailrace.
 Draft tube gates:
Draft tube gates are inserted in the discharge tube in order bring the system
to complete mechanical stop during maintenance or during emergency unit
tripping by closing the gates to 100%.
Draft tube gate lifting time 8-min
Draft tube gate closing time 1.5-min
Oil supply 2-way supply (Forward and Reverse)
DTG(Daft tube gate)-Tank:-

It is filled with oil required to lift the gate,

contains a pair of hydraulic lifting motors, and pi
rod drifting motors.It is connected to its control
Panel which contains the relays to control the
opening and closing of Draft tube Gates.

Figure 11DTG- tank (2 main motors,2 small

drifting motors
Draft tube gate lifting system:
DTG- Opening (lifting gate) Lifting By hydraulic motots
DTG-Closing (down move gate) Under gravity effect
There are 2 pairs of motor
Main motors:
Motors 2 large motors,30Kw: (1 running and 2nd stand-by).
Drifting motors:
2 small motors, 3Kw: (1 running and 2nd stand-by).
Large motors lift the draft tube gate by hydraulic pressure.Contains a pisto
and also counter weight to lift up gates fully. The oil leakage in the system causes
the Draft tube gates not to lift up 100% ,release hydraulic pressure. This leakage
causes the gate to drift some point below about 97% to 96% so in order to
compensate the drifting effect small drift motors are used these motors
compensate the effect of 3 to 4% of unit drifting.
Benefit of drifting motors:
If Drifting motors don’t compensate the effect up-to 4 to 5% drifting then
below 94% the draft tube gate moves down fully under effect of gravity and cause
the system to come to complete mechanical stop imidiately.
 Break pads (Manual break system):-
No of break pads 4
Break applying pressure 0.98Mpa
Break apply speed 20% of rated rpm=17 rev/min
After auto-stop of the unit for annual or monthly maintenance, it’s the best
for as safety precaution to apply brake pads manually. To eliminate any possible
risk of brake release during work.
 Four,4 brake pads applied to each shaft, and
air pressure supplied is 0.98Mpa
 (Almost 1Mpa) and fix in stick ring apply
through governor.
 Always apply break at 20% of total rpm. That
is 17rpm.because applying brake pads at
rated peak rpm can cause wear or ultimately
damage its rubbers

Figure 12Brake pads

 Shaft Seal:-
The basic purpose of shaft seal is to avoid the backflow of water
at the runner sides to move into turbine bulb nose, generator side.
Shaft seal pieces 8
Shaft seal material Phenolic resin, can also use wood.
Shaft seal pressure 80Kpa
The 8 pieces are arranged in circular ring with
groove inside where water flows.shaft seal
(stationary) is fixed along the sliding ring (movable
ring) and has a grove inside which water flows with
high pressure the shaft seal is fixed in its position
around the shaft with springs( these are helical
springs).
In case of frictional wear the shaft seal material
removal causes the spring to extend a little bit to fix
the shaft seal, and sensors indicates the shaft seal
wear.
Figure 13Shaft seal pieces with helical springs
Maintenance Seal:-
In case of annual shutdown of the unit.The shaft seal is not in running
condition at that time to perfume the function of shaft seal a temporary seal is
created called maintenance seal to avoid the back flow of water in the turbine
casing.The maintenance seal is created by air-pressure generated by the
compressor.
Maintenance seal Air pressure 0.70Mpa to 0.75Mpa
Over speed shutdown device:-
It consists of Fly Weight Assembly which rotates with the main shaft and
ControlValve Assembly. FlyWeight Assemblywhich attached to main shaft consist
of fly weight, The strike rod and the spring. The strike rod is connected to the fly
weight, and protrude out to outside according to increase the rotational speed.
When the rotational speed reaches the setting speed i.e 140 rpm, the strike rod
hit the strike lever of Control Valve Assembly and operate the control valve to trip
the water turbine. The rotational speed for turbine trip can be adjusted clearance
between strike rod strike levers.
 Tail race:
In simple the tail race is used to release the water which is already used for
the rotation of the runner blades or turbine blades.
Advantages and disadvantages of Kaplan turbine:

Advantages
 Kaplan turbines are widely used
throughout the world for
electrical power production.
 It can work more efficiently at
low water head and high flow
rates as compared with
other types of turbines.
 It is smaller in size and easy to
construct.
 The efficiency of Kaplan turbine is
very high as compares with other
hydraulic turbine.
Dis-advantages
 Cavitation:pitting of runner
blades
The only disadvantage of kaplan
turbine is cavitation, which
occurs due to pressure drop in
draft tube an increase in kinetic
energy.The water at higher
kinetic energy region converts
into vapours (bubbles) and react
with the material of blades can
cause their wear and tear(due to
material removal like pits)
 How to minimize this problem:
Use of draft tube and proper
material generally stainless steel
for the runner blades may reduce
the cavitation problem to a
greater extent.
 (Speed regulation)
(Maintaining runner blade speed of rotation as constant)
Governor is like the brain of the turbine it regulates rotational speed in
response to changing load conditions. .. It is accomplished by controlling the flow
of water through turbine. In Normal conditions the turbine should run at constant
speed irrespective to changes in load. This is achieved by means of a governor
called oil pressure governor.
Its main function is to govern /control the speed /rated rpm. Governing
system or governor is the main controller of the hydraulic turbine.
Governor oil temperature 25 degree approximately
Governor pressure 5 MPa
Governor oil type T-68
Working principle:-
Governor is an electronic system which sense the water flow rate and speed
of rotation(rated rpm) passing through the turbine unit with the help of governor
sensor then governor varies the water flow through the turbine to control its
speed or power output. Generating units speed and system frequency may be
adjusted by the governor.
Governor maintains the speed either;
1. By opening or closing the wicket gates
2. By changing the position of runner blades(angle change movement)
Purpose of governor:
 Governing of a turbine is necessary as a turbine is directly coupled to an
electric generator, which is required to run at constant speed under all
fluctuating load conditions. This is achieved by means of a governor called
oil pressure governor.
 In order to maintain there required generated frequency of 50
Hz(standardized for Pakistan), the speed of the rotation must be kept
constant. Here in Chashma Hydropower Project plant, this speed is always
maintained at 85.7 rpm.
 Main parts:-
 The oil pressure governor consisting of following parts namely
 Servomotor (or) Relay cylinder
 Pendulum (or) Actuator
 2-Oil pump
 Pipes connecting oil pump
 Speed control sensors (attached to the shaft).
 Governor oil pressurizing tank.
 GST( governor sump tank).
Proportional
Valves Distribution
FC- valves
 LVDT (linear voltage detector trans-meter).
 Governor sensors Level sensor.
 Temperature sensor.
 Pressure sensor.

GST (Governor Sump Tank):

The oil sump tank is designed for a capacity of 110% of total quantity of oil in
the entire governor system of the turbine. It may require heating or cooling
system to maintain usable oil temperature range for normal governor operation.
Level switches high/low are provided.

Governor
sump tank
(GST)

2- Oil
Pumps

Pipes
connecting Figure 15Governor Oil Pressurizing Tank (one for each unit)
oil pump
Figure 14 Governor Sump Tank GST with 2 oil pumps
Speed control sensors:-
Fixed on shaft these show signal in case of low shaft speed or high shaft
speed than the rated speed(85.7rpm).and cause alarm indication or tripping in
case of change in speed than rated speed.

Governor oil pressurizing tank:-

Each governor is provided with
welded pressure tanks tested as per
relevant code for pressure vessels.This
receives oil from the governor sump tank
and supply it to the runner blades through
a path passing inside the hollow rotating
shaft. It contains large and small valves.
Pressure range 680-720Mpa
Figure 16 Governor Oil Pressurizing Tank
Governor air compressor:
These are provided to supply air and maintaining automatically the required
pneumatic cushion in the governor pressure oil tank.
Servomotor:-
Servo motors in hydropower plants
normally operate water hydraulically.
Servomotor consists of a piston which moves
due to oil pressure and the movement of
piston is controlled by control valve. The
piston rod is connected to Turbine Guide
mechanism which controls the amount of
water entering the turbine.These servo
motors perform the functions of opening,
closing of wicket gates .it contains a counter
weight attached to it. Figure 17 Hydraulic Servo-motor (supply oil to
Electronic Governor: wicket gates

The electronic governor is the brains of the system and works with
the magnetic pickup sensors and electronic throttle actuators
Proportional valve:-
The function of proportional valves is
to produce a smooth and continuous variation
in flow or pressure in proportion to an
electrical input signal.
Distribution valves:-
Distributing valve is housed inside a cylinder
with a piston and connecting rod connecting
to the rigid fulcrum. And the distributing valve
cylinder consists of two ports P and Q which
controls the supply of oil to the
servomotor.The distributing valve is disposed
such that the direction of movement of a
plunger is horizontal. Figure 18 Proportinal,Distribution and Fc valves, LVTD

FC valves:-
Flow control valves regulate the pressure or flow of fluid. They are designed
to fit for complex pneumatic and hydraulic systems. The control valves respond to
signals generated by devices like temperature gauges or flow meters. The valves
have simple tool orifices with a complex set of electro-hydraulic valves to adjust in
the different variations.To reduce the actual flow rate in a specific area of a
pneumatic circuit, the control valve fittings are used.
Pipes connecting oil pump:
The pipes connecting oil sump is connected to distributing valve and the
distributing cylinder is connected to servomotor.
Oil Pumps:
The function of an oil pump is to pressurize the oil from the sump and send it
to the cylinder of distribution valve.
LVTD (Linear detector voltage trans-meter):
This is a detector that the converts mechanical motion of a object into
electrical signal.

 By opening or closing the wicket gates:

Either by opening or closing the wicket gates the velocity of water striking
the runner blade changes which in return changes the blades rpm(either increase
or decrease) in order to achieve the required rated rpm as constant.
Working principle:
When fluctuations occurs in the rated rpm due to load fluctuation, the
governor speed control sensor sends sense this over-speed and sends command
to the system.
When the load on turbine increases,turbine speed decreases.The
proportional valves(these are 2 in number) receives a signal/pulse MCR(main
control room) this in turn magnetizes the coil which attracts the plunger/Lever
that is placed horizontally and moves the piston(4 holes out of which 2 opens
other 2 close at a time in response either to opening side or closing side according
to signal command) and oil starts passing from here, this activates the
Distribution valves which changes direction of the main piston main path opens
for the oil supply governor tank oil starts flowing in the main line to the
servomotor(placed at 172 floor),this servomotor operated hydraulically to either
open or close the wicket gates.As the speed becomes normal, the piston of
distributing valve, the main lever and servomotor will reach their initial
position.Similarly when the load on the turbine decreases, the speed will increase
(i.e) vice versa.
In case of wicket gate opening:
The oil moves in servomotor from down to up, causes the wicket gates to
open according to governor command.
 In case of wicket gate closing:
The oil moves in servomotor from up to down, causes the wicket gates to
close according to governor command.
Wicket gate opening time 10 sec
Wicket gate closing time 4-5.6 sec
 By changing the position of runner blades:
(-3 to 340 rotation possible, movable blades)
By changing the angle we change the effective area(area facing the
water flow/area directly in contact with striking water) of the runner blade
facing the water flow, and thus changing the amount of energy it extracts from
the water, and maintains the rated rpm.
Working Principle
This is also done by supplying the oil to the runner blades trough
Governor oil pressurizing tank.This pressurizes the oil and send it to runner
hub through path within hollow shaft,this oil goes to servo-motor of the
 runner and then supply it to runner blades causes them to rotate a degree
according to governor command.
Runner opening time 19 sec
Runner closing time 12 sec

Governor speed MCR control room Proportional valve

sensor It receives signal
sends a signal to Coil magnetizes
It detects the governor, to take Attract hori plunger, opens oil
speed variation. action accordingly. path

Servo-motor Distribution valve

It receives oil, It receives signal by proportional
send oil to wicket valve, and moves the piston to
gates and runner open main oil supply to close or
blades open wicket gate, runner

Governor speed controller, speed droop:-

Initially Speed droop +/-5%
Modified speed droop +/-10%
Droop is the decrease in speed that occurs when the governor output shaft
moves from the minimum to the maximum fuel position in response to a load
increase, expressed as a percentage of rated speed. If instead of a decrease in
speed, an increase takes place, the governor shows a negative droop.
 With 5% droop the full-load speed is 100% and the no-load speed is 105%.
Types of faults in governor:
 Wicket gate fault
Failure distribution valve of wicket gate position signal
Failure wicket gate position signal
 Runner blade fault
Failure distribution valve runner position signal
Failure runner position signal
 Speed sensor fault
Speed measurement failure on generator
 Failure of level measurement.
 Oil name Turbo-oil
Oil type T-68
Oil function Coolant as well as lubricant
Thermistors temperature 470C
No. of Purifier discs 80

Purification of turbo-oil:-
1. Dirty-to-Dirty purification cycle
2. Dirty-To-Clean purification cycle
 Dirty-to-Dirty Purification:
The dirty oil from the units collected
in dirty oil tank.This dirty oil is first
cleaned by dirty-to-dirty purification cycle.
 Oil from dirty tank moves into Filter,
filter removes the are size waste
particles.
 Then this oil is pumped to the
purifier through oil pump. In purifier
the small size waste particles and
carbon content present in the oil is
removed by rotating the oil in the
purifier, the centrifugal forces
causes the slug to stick to the sides
of the purifier.
 Then this oil is send to 8-
thermistor where the oil is heated
at 470C in this vapourize the
dissolved organic waste and water
mixed in the oil. This is called
Dehumidification process. Figure 19: Oil purification plant
 After this oil is again send to the dirty oil tank and the same cycle repeats
for 72 hours (3-Days)
  Dirty-to-Clean Purification:-
After re-cycling the oil for 3 days. The same cycle is repeated at last but
this time oil after thermistors stored into cleaned oil tank rather than dirty oil
tank. This oil is fully purified now it can be used again for lubrication purpose
 Transformer oil dehydration plant:-
Removes water from the oil and improves its di-electric strength of the oil
used in the transformer.
Oil Purification Cycle

Dirty Oil tank 8-Thermistors

( filled with (At 470C)
dirty oil) Oil
Dehumidification

Dirty-to-Dirty
Cycle continues
for 72-Hr (3-days)

Clean oil Filter 80 disc-

Dirty-To-Clean (to remove
tank (clean oil Purifier
cycle continues large particles)
filled here after (Removes
After 72-hr.
purification) Slug), small
size waste,C in
oil

After purification the clean oil now can be reused for lubrication and cooling
purpose for bearings, transformer and other parts.
Pumps:
Pump is the device that gives energy to fluid to move from one place to other
usually against gravity. by mechanical action, typically converted from electrical
energy into hydraulic energy.

Ein Eout
PUMP

(
Gives energy
(Ein < Eout)
Types:
there are Basic 2 types
Positive displacement pumps:
A positive displacement (PD)
pump moves a fluid by repeatedly
enclosing a fixed volume and
moving it mechanically through the
system. The pumping action is
cyclic and can be driven by pistons,
screws, gears, rollers, diaphragms
or vanes.
Types of PDP:
The majority can be placed into
2categories:
1) Reciprocating
2) rotary.
Reciprocating positive
displacement pumps:
A Reciprocating Positive Displacement
pump works by the repeated back-and-forth
movement (strokes) of either a piston, plunger
or diaphragm. These cycles are called
reciprocation.

Figure 20 PDP PUMP

Rotary positive displacement pumps:
Rotary positive displacement pumps use the actions of rotating cogs or
gears to transfer fluids, rather than the backwards and
forwards motion of reciprocating pumps.
Dynamic pumps:
A dynamic pump is a form of velocity pump that
uses increased flow velocity to impart kinetic energy to
the fluid. When the velocity of the flow is lowered prior
to or as it departs the pump into the discharge pipe, this
increase in energy is transformed into a gain in potential
energy (pressure).
Types of Dynamic pumps: Figure 21 Dynamic Pumps
Submersible.
Axial.
Centrifugal.

Component of CHP oil and water cooling system.

The oil lubricating system is composed of following main components & devices.
 Two units of lubricating oil pumps driven by electric motor.
 One unit of lubricating oil sump tank.
 One elevated oil tank.
 Two units of oil cooler.
 One solenoid valve.
 Three flow relays.
 Two units of high pressure oil pump driven electric pump.

Lubricating Oil Pump:

Two units of horizontal gear type pump, each

directly coupled with electric motor and
mounted upon the lubricating oil sump tank,
one unit being used as normal lubricating oil
pump and the other as a standby. Each pump
unit is provided with safety relief valve which
is to protect the pump against being exposed
to excessive pressure.

Figure 22Lubrication oil pumps

 Main function Bearing lubrication
Pressure generated 0.588Mpa
Flow rate 300 litter/min
Pump type Dynamic (centrifugal)
The lubricant from lub oil tank is pumped into elevated oil tank with the help
of lub oil pumps.
Lubricating Oil Sump tank:
Total capacity 1000 litters
The lubricating oil sump tank is oil reservoir for the lubricating oil system and
at the same time used as amounting bed for oil pump units. The volumetric
capacity is sufficient to contain 110% of total necessary lubricating oil quantity.
This sump tank is provided with a float type level indicator with level switches
(33QBh, 33QB 11, 33 QB 12).These are micro switches and operated by cams.
Elevated oil tank:
Total capacity 2700 litter
The elevated oil tank is used to feed lubricating oil gravity to the
bearings. Also used when the lubricating oil pumps are in trouble or AC power is
lost. In this case, the stored lubricating oil permits to supply oil to the bearing for
the time required stopping the turbine safely.
Solenoid valve and pilot check valve:
The pilot check valve controlled by the solenoid valve (20QBS) is used to
prevent the oil in elevated tank from flowing into the oil sump tank through the
bearing while the turbine is not operated. When the turbine is not to be operated
for a month or more, the solenoid valve should be periodically opened by hand to
lubricate the bearing with oil
High pressure oil pump:
Operating time Operate at starting and stop.
At 90% of rated rpm.
Pressure generated 14.7Mpa.
Flow rate 40 litter/min.
Main function Shaft lifting.
Pump type Positive displacement pump.
Gear type(PDP)
H-P oil pump are used to do lift of turbine/generator shaft when units stops and
starts.Two units of horizontal gear type pumps,each directly coupled with an
electric motor and installed near side of lubricating
sump tank. One unit used as normal lubrication oil
pump and other as stand-by.
Collers: Figure 23: 2-High pressure pumps
Cooling medium Water.
Cooler type Tube and shell.
A typical oil-to-water (water) cooler is the shell-and- Figure 24 2- High pressure pumps
tube cooler. With this cooler the water flows
through the shell and around the tube bundle that
carries the oil.cooling water to flow essentially
perpendicular to the tube bundle. This provides
efficient temperature gradient than having water flow
parallel to the tube bundle.The rate of the heat flow is
directly proportional to the temperature
difference.The cooler the water at any point in the
heat exchanger, the more effective it will remove the
heat from the hydraulic fluid. Figure 25: 2 shell and tube type oil coolers

Figure 26 Shell and tube coolers for oil

cooling

Oil collers Elevated

Lub oil tank (hot oil exchanges oil tank
1000-litter its heat with cold 2700-litter
capacity water) capacity

Runner
Lubrication of Solenoid
Bulb pressurizin
(bearing, and valve
nose g tank,180L
other parts) 20-QBS
capacity

Oil passage Oil

Runner
Tube within distribution Runner
blades
the shaft tube
 Tap up

Cooling Water Tank

Bearing Transformer Air cooler

Lub Oil Transformer CWP

cooler cooler Compressor
water pump

“Hot water after cooling

Bearings,Transformer and
compressor goes to bulb
nose for exchanging heat
with cool running water”

Water jackets
attached to
bulb nose
Unit Start Sequence:
To start a unit and to join a system specific sequence is followed which is given
below.each step is numbered according to its turn.
 Cooling water pumps on
 Lubrication oil pumps on
 High oil pressure establishes
 Draft tube gate opens(100%)
 Lubrication flow establishes.
 Brakes are release.
 Wicket gates are opened.
 Speed should greater then 90%.
 Fiels circuit brakes closed
 Shaft seal water flow establishes.
 Generator cooling fans opens.
 Dehumifier off.
Unit Stop Sequence:
In order to bring the machine to the complete stop:
Temporary shut down:
 Mostly temporary shut-down is done for preventive, monthly maintenance
 Electrically and mechanically stop the unit.
 Auxiliary is still in running condition.
 RPM becomes zero.
 Wicket gates close completely.
 Lubrication system remains ON.
Permanent Shut-down:
 Only done during annual maintenance.
 Draft tube gate 100% close
 Auxiliary is completely dead,no external supply.,no other unit feeding
suppluy.
 Reduce the machine load to minimum.
 Decrease the active and reactive power.
 Close the excitation input.
 Close the wickets gates to the minimum.
 Decrease the generator output to the minimum.
 This brings the unit to complete stop.
Pipes Used For Different Purpose:
There is a vast piping system, to ensure the supply of oil, water, air, and other
required working fluid.
 Yellow Color pipes:-
These pipes contains oil.The oil is circulated by governer system and tanks to the
required unit parts like transformer and generator.
 Silver Color pipes:-
Silver pipes with white color strips contains air.Air from compressor send to seals
and governer air pressure and other required parts.
 Green Color pipes:-
The green color pipes shows water(For cooling of heated oil) in it.This water is
mainly used for cooling purpose of the oil.
 Red color pipes:-
These pipes linked to fire-fighting system.These in case of emergency tackle with
fire.These contains CO2 gas in it.
 Pink color pipes:-
These pipes contain used oil.
Tripping Relays:-
There are three main tripping relays.
 Mechanical shutdown relay.
 Electrical shutdown relays.
 Safety partial shutdown relays.

In order to drain out water completely from the

turbine casing diring maintenance.The dewatering
system is installed in each unit.There are dewatering
pumps that drain water out of casing.There are
pumps installed at the four corners of the power
house.These pumps are used to drain out water
leaked at the basement of the generator.

Figure 27 Dewatering valve

 Main dewatering systems are;
1) Turbine dewatering system.
To remove water from turbine casing.
2) Generator dewatering system.
To remove water from generator side.

Turbine bulb
casing water,
removed by
dewatering valve
This water drained From pit the water Finally
in dewatering is removed by water is
pit.by dewatering dewatering pumps discharged
valves out
(40-45A)
Generator side
water, removed
by dewatering
valve

In order to given excitation system initial pulse three sources are available
 Wapda public network
 DC-Batteries
 DG-Set

A diesel generator (DG) (also known

as a diesel gen-set) is the combination of
a diesel engine with an electric
generator (often an alternator) to
generate electrical energy. It is the set of
diesel generator. Contains 2 Diesel
generators.One small and one large
generator with different capacities
accordingly.

Figure 28 Diesel Generator

This is a specific case of engine generator. A diesel compression-ignition engine is
usually designed to run on diesel fuel, but some types are adapted for other liquid
fuels or natural gas.
Diesel generating sets are used in places without connection to a power grid, or
as an emergency power supply if the grid fails, as well as for more complex
applications such as peak-lopping, grid support, and export to the power grid.
Diesel generator size is crucial to minimize low load or power shortages. Sizing is
complicated by the characteristics of modern electronics, specifically non-linear
loads.
Large DG power 0.75MW
Small DG power 0.375MW

Important Abbrevations:-
SOP Standard operating procedures
UCC Unit control cubical
MCR Main control room
PTW Permit to work
SP – Tag Self protection tag
DTG Draft tube gate
OTO Order to operate
O&M Operational maintenance
DTD – Valve Draft tube dewatering valve
TUD – Valve Turbine dewatering valve
FC – Valve Flow control valve
DCS Digital control system
CPS Constant pressure system
HVAC Heat ventilation and air conditioning
LSB Left service block
RSB Right service block
GIS Gas insulated switch
DG- Set Diesel generator set
AC Alternating current
ITRE Inspection test and record engineer
EME Electrical maintenance engineer
P & IE Protection instrumentation engineer
MME Mechanical maintenance engineer
TO Turbine operator
CPS Chashma power station
S/D Shut down relay
 It is a device which compresses the gases to higher pressure and then this
high-pressure gas is used for various application like tire inflation, powering a
turbine or used to do some mechanical work. The air compressor is generally
powered by electric motor, diesel or gas Engine.
Types:
Two types of compressors are used in CHP.
1. Station Air compressor
2. Governor Air Compressor
Station Air Compressor
It is positive displacement compressor in which piton with connecting rod
and crankshaft assembly is used to compress the air. the piston does the
reciprocating motion in the cylinder and compress the air .it is medium air
compressor. it Is two stage compressors. It can compress the air to 40 bar or 600
psi but in CHP it compresses the air t0 200 psi or 15 bar. The air compressed by
this compressor is used in maintains seal generator brake spade and for general
use.

Figure 29 Two Stage Air Compressor

\
Governor Air Compressor:-
It is also positive displacement compressor in which piton with connecting
rod and crankshaft assembly is used to compress the air . the piston does the
reciprocating motion in the cylinder and compress the air . it is medium air
compressor. It can compress the air to 800 psi . The air compressed by this
compressor is used in governor system and firing fitting system.

Figure 30 Three Stage Air Compressor

 Lathe Machine
A lathe machine is a machine tool
that removes the undesired material from
a rotating work-piece in the form of chips
with the help of a tool.A lathe machine is
a stationary cutting tool used primarily
for shaping wood and metal, which are
referred to as work-pieces.
The lathe machine removes
unwanted parts of the work-piece to
produce the desired product. The
movements of a traditional lathe machine
are manually controlled by an operator. Figure 31Lathe Machine

Working Principle:
Lathe machine is one of the most important machine tools which is used in the
metal-working industry. It operates on the principle of a rotating work piece and a
fixed cutting tool. The cutting tool is feed into the work piece which rotates about
its own axis causing the work-piece to form the desired shape.

Parts Of lathe machine:

Different Operations performed on Lathe Machine:
1) Facing.
The tool is fed radially into the rotating work on one end to
create a flat surface on the end.
2) Taper turning.
Instead of feeding the tool parallel to the axis of rotation of
the work, the tool is fed at an angle, thus creating a tapered cylinder
or conical shape.
3) Contour turning.
Instead of feeding the tool along a straight line parallel to the
axis of rotation as in turning, the tool follows a contour that is other
than straight, thus creating a contoured form in the turned part.
4) Form turning.
In this operation, sometimes called forming, the tool has a shape
that is imparted to the work by plunging the tool radially into the
work.
5) Chamfering.
The cutting edge of the tool is used to cut an angle on the corner of
the cylinder, forming what is called a ‘‘chamfer.’’
6) Cutoff.
The tool is fed radially into the rotating work at some location
along its length to cut off the end of the part. This operation is
sometimes referred to as parting.
7) Threading.
A pointed tool is fed linearly across the outside surface of the
rotating workpart in a direction parallel to the axis of rotation at a
large effective feed rate, thus creating threads in the cylinder.
8) Boring.
A single-point tool is fed linearly, parallel to the axis of
rotation, on the inside diameter of an existing hole in the part.
9) Drilling.
Drilling can be performed on a lathe by feeding the drill into the
rotating work along its axis. Reaming can be performed in a similar
way.
 Drilling Operation:
Drilling is a machining operation used to create a round
hole in a workpart. This contrasts with boring, which can
only be used to enlarge an existing hole. Drilling is usually
performed with a rotating cylindrical tool that has two
cutting edges on its working end. The tool is called a drill
or drill bit The most common drill bit is the twist drill, The
rotating drill feeds into the stationary workpart to form a
hole whose diameter is equal to the drill diameter.

Operations related to drilling:

(a) Reaming. Reaming is used to slightly enlarge a hole, to provide a

better tolerance on its diameter, and to improve its surface finish.
The tool is called a reamer, and it usually has straight flutes.

(b) Tapping. This operation is performed by a tap and is used to provide

internal screw threads on an existing hole.

(c) Counterboring. Counterboring provides a stepped hole, in which a

larger diameter follows a smaller diameter partially into the hole. A
counterbored hole is used to seat bolt heads into a hole so the heads
do not protrude above the surface.

(d) Countersinking. This is similar to counterboring, except that the

step in the hole is cone-shaped for flat head screws and bolts.

(e) Centering. Also called center drilling, this operation drills a starting
hole to accurately establish its location for subsequent drilling. The tool
is called a center drill.

(f) Spot facing. Spot facing is similar to milling. It is used to provide a

flat machined surface on the workpart in a localized area.
Multiple point cutting tool(Drill Bit):

Milling
Milling operaton:
Milling is a machining operation in which a
workpart is fed past a rotating cylindrical tool
with multiple cutting edges, a tool with one
cutting edge, called a fly-cutter, is used. The axis
of rotation of the cutting tool is perpendicular to
the direction of feed. cutting tool in milling is
called a milling cutter and the cutting edges are
called teeth.

Milling machine:
Milling machines must provide a rotating spindle
for the cutter and a table for fastening,
positioning, and feeding the workpart. Various
machine tool designs satisfy these requirements.
To begin with, milling machines can be classified
as horizontal or vertical. A horizontal milling
machine has a horizontal spindle, and this design
is well suited for performing peripheral milling.A
vertical milling machine has a vertical spindle, and
this orientation is appropriate for face milling.
Cutting Tool(Milling Cutter) Figure 32 Milling Machine

A rotary tool-steel cutter used in a milling machine for shaping and dressing metal
surfaces.
Types of milling:
Peripheral Milling
 In peripheral milling, also called
plain milling, the axis of the tool is
parallel to the surface being
machined,
 The operation is performed by
cutting edges on the outside
periphery of the cutter.
Fcae milling
 In face milling, the axis of the
cutter is perpendicular to the
surface being milled,
 The machining is performed by
cutting edges on both the end and
outside periphery of cutter

Different Milling operations:

1) Face Milling. 2) Plain Milling.
3) Side Milling. 4) Straddle Milling.
5) Gang Milling. 6) Angle Milling.
7) Form Milling. 8) End Milling.
Sawing operation

Sawing is a process in which a

narrow slit is cut into the work by a tool
consisting of a series of narrowly spaced
teeth. Sawing is normally used to separate
a workpart into two pieces, or to cut off an
unwanted portion of a part.
Hacksawing,involves a linear reciprocating
motion of the saw against the work. These
operations are often referred to as cutoff
operations.Cutting is accomplished only on
the forward stroke of the saw blade.

Figure 33 Power Hack-Saw

Power-Hack Saw
Power hacksaws are used to cut large sizes (sections) of metals such as
steel. The hacksaw got its name because historically these saws did not cut
smoothly. Therefore power hacksaws have been developed to carry out the
difficult and time consuming work.The development of the power hacksaw
enhanced the basic hand-held hacksaw's capabilities. It is highly effective at
cutting large pieces of metal Cutting.
Working Principle:
The principle behind the power hacksaw machine is to convert the electrical
energy of the DC motor into horizontal or linear reciprocating motion using a
power hacksaw blade to cut the materials.
Parts of power-hack saw:

Figure 34 Main parts (with HSS blade)

Blade material:
A hacksaw blade is made of either low-alloy steel (LA) or High-speed steel
(HSS) and is available in standard lengths of 250 mm and 300 mm. The selection
of the blade depends on the shape and hardness of the material to be cut.
Flexible blade: Only the teeth are hardened.
Hydraulic press
A hydraulic press is a machine press using a hydraulic cylinder to generate
a compressive force.It uses the hydraulic equivalent of a mechanical lever, and
was also known as a Bramah press after the inventor.A hydraulic press is made up
 of two interconnected cylinders. Each cylinder is filled with hydraulic fluid, and
one is bigger than the other.
Main Parts:

Moveable work head

Double pinned welded allow movement
construction for strength acrossthe entire length
and safety of the top cross bar

Maximum daylight for

large workpiece and
easy loading

Adjustable work bed for

maximum flexibility Rigid frame under full load

Figure 35 Hydraulic Press

Working principle:
A hydraulic press works on the principle of Pascal's law, which states
that when pressure is applied to a confined fluid, the pressure change occurs
throughout the entire fluid. Within the hydraulic press, there is a piston that works as
a pump, that provides a modest mechanical force to a small area of the sample.
Applications:
Hydraulic presses are used in operations;
1) Forging. 2) Molding,
3) Punching. 4) Clinching
5) Blanking. 6) Deep Drawing,
7) Metal Forming Operations.
 They can create intricate shapes while being economical with materials.
 They also take up less space compared to mechanical presses of the same
capability.
 Shearing Machine

A machine with blades or rotary disks for cutting sheets, plates, or bars (as of
metal).Shearing is a metal fabrication
process that's used to trim and
remove unwanted material from
sheet metal. It involves the use of a
machine or tool, such as a bench
shear, to slice through sheet metal
with extreme precision.
 Shearing machines are
multipurpose devices used in
the cutting of alloys and other
sheet metal. Some shearing
machines use a scissor-like,
angular shear action to cut
metal into sheets or strips.
Applications: Figure 36Shearing Machine(To cut metal sheets)

The products are widely used in aviation, light industry, metallurgy,

chemical industry, construction, shipbuilding, automobile, electric power,
electrical appliances, decoration and other industries to provide special
machinery and complete sets of equipment required.
Types of shearing machinese:
According to the operation of the shearing machine, we can be divided into:
 Mechanical shearing machine
 Hydrualic shearing machine
According to the cutting method of the shearing machine, it can be divided into
 linear shearing machine
 circular shearing machine.
 General Question’s answer
1. Emergency Button and their location
Buttons
 Total 3 emergency buttons on each machine

Location
 UCC
 Governor
 Control room mimic board
2. Purpose of synchroscope
Synchroscope is the device that synchronize the generator with national grid

3. 400 auxiliaries required for each machine

Machine own auxiliary
i. Cooling water pump for
 Transformer
 Generator air cooler
 Bearings
ii. Governor oil pump
iii. Draft tube oil pump
iv. Lube oil pumps
v. HP oil pumps
vi. Leakage oil pumps
Common Auxiliaries for Machine
i. Shaft Seal water pump
ii. Station Air Compressor
iii. Governor Air Compressor
iv. Fire Fitting Water Pumps
v. Ground Water Pumps
vi. CPS Pumps
vii. Drainage Pumps
viii. Dewatering Pumps
ix. Sludge waste
x. HVAC Pumps
xi. AHUs
4. What is real, reactive, and apparent power, Power Factor &
Power Triangle?
a) Real power
Real power often denoted as P, is the actual power consumed or produced by a device or system,
measured in watts (W). It represents the actual energy transferred to do useful work, such as
powering appliances or generating mechanical work.
b) Reactive power
Reactive power denoted as Q, is the power that oscillates between the load and the source due to
inductive or capacitive elements in the circuit. It is measured in volt-amperes reactive (VAR).
c) Apparent power
Apparent power denoted as S, is the combination of real and reactive power. It is the total power
that a device or system draws from the source, measured in volt-amperes (VA).
d) The power triangle
Power triangle is a graphical representation of the relationships between real power, reactive
power, and apparent power in an electrical system.
e) Power Factor
The power factor (PF) is the cosine of the angle between the real power and the apparent power
in the power triangle. It quantifies the efficiency of the power transfer and ranges from 0 to 1.

5. Major types of Pumps and their Classification

6. Classification of Compressor

7. Can circuit breaker be used as an insulator?

No circuit breaker can not be used as insulator.
Isolator has only opening and closing contacts, while circuit breaker used to open the circuit
when excessive current flowing is observed. Opening of circuit depend on the type(mechanism)
of breaker

8. Why SF6 is used is used in GIS?

During switching of Circuit breakers an Arc is produced during the operation, in high voltages
this arc creates a path between the contacts due ionization of air.
sf6 gas is used to extinguish the arc as well insulating medium.

9. Is it safe to inhale SF6?

No, it is not safe to inhale sulfur hexafluoride (SF6). It is a colorless, odorless gas and can be
harmful if inhaled in high concentrations, leading to respiratory issues and other health problems.
SF6 is not intended for inhalation and should be used with proper safety measures and in
controlled environments.

10. Why certain country has 50 Hz and some have 60 Hz

frequency?
The difference in frequency (50Hz and 60Hz) of electricity supply across countries is primarily
due to historical reasons and varying infrastructure decisions.
Countries that use 50Hz frequency, such as most of Europe, Africa, and Asia, followed the
standards set by the International Electrotechnical Commission (IEC) in the early 20th century.
On the other hand, countries with a 60Hz frequency, like the United States, Canada, and parts of
South America, adopted the frequency set by the American National Standards Institute (ANSI)
and the Institute of Electrical and Electronics Engineers (IEEE).

11. Working of Reciprocating Air Compressor

It is positive displacement compressor in which the connecting rod and crank shaft assembly is
used to compress the air. The piston does the reciprocating motion in the cylinder and compress

Figure 37 Reciprocating Compressor

the air.

12. Purpose of Multi staged Compressor

The main purpose of a multi-stage compressor is to increase the pressure of a gas or air to a
desired level by passing it through multiple stages of compression. Each stage of compression
helps to achieve higher pressures efficiently, as compared to a single-stage compressor. This
design allows for better performance, reduced work per stage, and increased overall efficiency in
various applications, such as power generation, and air compression systems.

13. Basic Purpose of Buildings Dams and Barrage

The basic purpose of building dams and barrages is to manage water resources effectively.
 Dams are constructed primarily for water storage, flood control, and power generation.
 Barrages are built to regulate water flow, prevent saltwater intrusion, and aid navigation.
These structures play a vital role in providing water supply, generating electricity, and
supporting irrigation for agriculture, among other benefits.
14. Reason why Pumps are Air Locked
Pumps are get air locked due to the presence of air in the pump's suction line or impeller. When
air accumulates in the pump, it disrupts the flow of liquid and prevents the pump from working
efficiently. Factors like leaks, improper priming, or changes in the system's pressure can lead to
air being trapped in the pump

15. Starting Sequence of Unit

To start a unit and join a system a specific sequence is followed which is given below.
 Cooling water pumps on
 Lubrication oil pumps on
 High oil pressure established
 Draft tube gate opens
 Lubrication flow established
 Brakes are released
 Wicket gates are opened
 Speed should greater than 90%
 Field circuit braker closed
 Shaft seal flow established
 Generator cooling fan opens
 Dehumidify off
16. What’s the purpose of Surge Tank?
A surge tank, also known as a surge(waves) vessel or surge drum, is used in fluid systems to
store excess fluid temporarily. Its purpose is to absorb pressure variations and prevent pressure
surges (waves)that may occur due to sudden changes in flow rates or system conditions.it main
purpose is to reduce the waves and uniform distribution of water.

17. Factors that should be consider while choosing the site for
hydro power plant

 Water Availability
Sufficient and reliable water supply is essential for hydropower generation
 Topography
The site's topography plays a crucial role in determining the feasibility of the plant. Steeper
gradients and higher elevation differences often lead to more significant power generation
potential

 Environmental Impact
Assess the potential environmental impacts of the plant on the surrounding ecosystem, wildlife,
and local communities.
 Construction Cost
Evaluate the costs associated with building the plant and related infrastructure
 Transmission Infrastructure
Check the availability and proximity of the power transmission infrastructure to connect the
generated electricity to the grid.

 Regulatory and Legal Considerations

Understand the local regulations, permits, and legal requirements related to hydroelectric power
development.

 Flood Risk
Assess the potential for flooding in the area and incorporate flood management strategies into
the design.

18. Reservoir Capacity

If the project involves a reservoir, consider its capacity, potential impact on land use, and
implications for water management