NHPC LTD.

REPORT
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD OF THE DIPLOMA OF

(Mechanical Engineering)
(MECHATRONICS) SUBMITTED BY

CHANDAN SINGHAL Roll. No.10100240006

HARYANA STATE BOARD OF TECHNICAL EDUCATION PANCHKULA

POLYTECHNIC EDUCATION & TRAINING INSTITUTE

BARNA (KURUKSHETRA)

DECLARATION
I hereby certify that the work which is being presented in the report entitled HYDRO ELECTRIC POWER PLANTS by CHANDAN SINGHAL in partial fulfillment of requirements for the award of DIPLOMA in Mechanical Engineering. submitted in the Department of Mechanical Engineering at POLYTECHNIC EDUCATION & TRAINING INSTITUTE under HSBTE is carried out during a period from July, 2011 to Aug, 2011 under the supervision of A.K. UPADHYAY (A.M) mech.. The matter presented in this report has not been submitted by me in any other Institute for the award of Diploma.

CHANDAN SINGHAL This is to certify that the above statement made by the candidate is correct to the best of my knowledge.

Er. ASHISH KUMAR GUIDE The Diploma VivaVoce Examination of CHANDAN SINGHAL has been held on ____________ and accepted

(Er. N.K.Sikka) H.O.D., Mech. Engg. Signature of External Examiner

ABSTRACT

Hydro power plants in general and hydro turbine in particular like any other real Systems are nonlinear and have time-varying parameters to some extent. The hydrodynamics Of the tunnel, penstock and turbine are complex due to nonlinear relationship, which exists between the water velocity, turbine inlet pressure and developed power. The performance of hydro turbine is strongly influenced by the characteristics of water inertia, water compressibility and penstock-wall elasticity. The dynamic characteristics of a hydro turbine power depend heavily on changes in set point and load disturbances. Thus the hydro turbine exhibits highly nonlinear, non-stationary system whose characteristics vary significantly with the unpredictable load. A key item of any hydro power plant is the governor. Hydro turbine governing system provides a means of controlling power and frequency. The speed governor normally actuates the gates / vanes that regulate the water input to the turbine. The hydro plants being site specific may have different configurations of their layout; however the main motivation of dissertation is confined to a small hydropower scheme, which can be as high head or low head. Small hydro power schemes with high head and thus connected to reservoir with long length penstock experience severe control problems due to occurrence of transients. This is due to pressure wave rise on sudden change of gate position, which in turn is adjusted to meet the load demand. A low head hydro plant Connected as single machine infinite bus system experiences a critical low stability margin. The study for such systems is a useful starting point for designers to evaluate the dynamic performance under alternative / new controller concepts. Subsequently, advanced control techniques are required to realize the full potential of the plant over a wide range of operating conditions to capture full plant characteristics. The mathematical models of various elements of hydro power plant like hydraulic structures / components and electrical systems can be integrated to represent the plant as a single entity. To obtain accurate representation of the integrated system, the plant model can be identified either in open-loop or closed-loop using its input-output data. This will facilitate the implementation of new / alternative control approach to the plant model for effective operation during disturbance. The approach as discussed above may be considered for model identification for real existing hydro power plants using its input-output data only. The model thus developed may be used both in the development and operational stages during the lifetime of the power plant. Design of control system can be facilitated once the model has been validated, against the real system data; a physical interpretation of the model parameters can sometimes be made.

ACKNOWLEDGEMENT
Words are inadequate and out of place at times particularly in the context of expressing sincere feelings in the contribution of this work, is no more than a mere ritual. It is our privilege to acknowledge with respect & gratitude, the keen valuable and ever-available guidance rendered to us by Er. Ashish Tanwar without the wise counsel and able guidance, it would have been impossible to complete the report in this manner. We shall always be highly grateful to Er. Surender Singh, Principal, PETI KKR for providing this opportunity to carry out the present work. The constant guidance and encouragement received from Er. N.K.Sikka, Head of Department of Mechanical Engineering has been of great help in carrying out the present work and is acknowledged with reverential thanks. We express gratitude to other faculty members of Mechanical Engineering Department, PETI, KKR for their intellectual support throughout the course of this work. Finally, we are indebted to our family and for their ever available help in accomplishing this task successfully. Above all we are thankful to the almighty god for giving strength to carry out the present work.

Chandan Singhal

LIST OF FIGURES

S. No. 1. 2 3. 4. 5. 6. 7.

FIGURE No. 1.1 2.1 4.1 5.1 7.1 8.1 9.1,2,3,4,5,6

DESCRIPTION Hydro power plants Catchments area and reservoir Dams Radial gates Trash rack Penstock Turbine classification, Kaplan turbine, Francis turbine, working of Francis turbine, Pelton wheel

PAGE No. 1 2 2 3 3 4 5,6,7,8

8. 9. 10. 11. 12. 13 14

10.1,11.1 12.1, 13.1 14.1, 15.1 16.1 , 17.1 18.1 19.1,20.1 21.1

turbine, working of Pelton wheel turbine Runner, spiral casing Stay ring, Top cover Lower ring, guide vanes Turbine shaft, governor Servomotor Draft tube Shaft seal

10 11,12 13,14 15,16 16 17 18

CONTENTS
Candidate's Declaration Abstract Acknowledgement List of Figures i ii viii xvi Page No. Chapter 1: INTRODUCTION Chapter 2: Company Profile Chapter 3: Training Detail Chapter 4: Conclusions and Personal Experience

INTRODUCTION TO NHPC LTD

The Company
NHPC Limited (Formerly known as National Hydroelectric Power Corporation Ltd.), A Govt. of India Enterprise was incorporated in the year 1975 with an authorized capital of Rs. 2000 million and with an objective to plan, promote and organize an integrated and efficient development of hydroelectric power in all aspects. Later on NHPC expanded its objects to include development of power in all its aspects through conventional and non-conventional sources in India and abroad. At present, NHPC is a Mini Ratna Category-I Enterprise of the Govt. of India with an authorized share capital of Rs. 1,50,000 Million .With an investment base of over Rs. 3, 17,000 Million Approx. NHPC is among the TOP TEN companies in the country in terms of investment. Initially, on incorporation, NHPC took over the execution of Salal Stage-I, Bairasiul and Loktak Hydroelectric Projects from Central Hydroelectric Project Construction and Control Board. Since then, it has executed 13 projects with an installed capacity of 5175 MW on ownership basis including projects taken up in joint venture. NHPC has also executed 5 projects with an installed capacity of 89.35 MW on turnkey basis. Two of these projects have been commissioned in neighboring countries i.e. Nepal and Bhutan, during the financial year 2008-2009. Presently NHPC is engaged in the construction of 11 projects aggregating to a total installed capacity of 4622 MW. NHPC has added 1970 MW during the 10th Plan period and planned to add 5322 MW during 11th Plan period. 9 projects of 8481 MW are awaiting clearances/Govt. approval for their implementation. Detailed Projects reports are being prepared for 7 projects of 5755 MW. Since its inception in 1975, NHPC has grown to become one of the largest organizations in the field of hydro power development in the country. With its present capabilities, NHPC can undertake all activities from concept to commissioning of Hydroelectric Projects.

1.WHAT IS HYDRO POWER?

The objective of a hydropower scheme is to convert the potential energy of a mass of water, flowing in a

stream with a certain fall to the turbine (termed the "head"), into electric energy at the lower end of the scheme, where the powerhouse is located. The power output from the scheme is proportional to the flow and to the head.

Fig.1.1

Selection site of for hydroelectric power plant

Site should be selected at suitable place where water availability will be very high. Site should be provided with convenient place for dam and reservoir erection. Land should be cheep and rocky. The reservoir must have large catchments area. Distance from the load centre should not be very large, otherwise the transmission erection and maintenance costs will be very high. Adequate transportation facilities should be there. There should be stream diversion route during the time of installation.

Purpose of hydro power plants

To generate electric power To control the floods in the rivers To store irrigation water To store drinking water

2. Catchments area and reservoir

The rain water falls on a large area called catchments area, gets collected in the form of streams and flows as runoff to plant site. The area behind dam where water is stored is called the reservoir.

Fig.2.1

3. Intake
A water intake must be able to divert the required amount of water in to a power canal or into a penstock without producing a negative impact on the local environment.

4. Dams
A physical barrier constructed across a river or waterway to control the flow of water or raise the level of water. The purpose of construction may be for flood control, irrigation needs, hydroelectric power production, and/or recreation usage.

Fig.4.1

5. Radial gates

A device used for controlling the flow of water over spillways or into canals by having the upstream face curved in the form of an arc the center of which is at the center of the gate hinge also called Tainter Gate.

Fig.5.1

6. Spillway
A dam failure can have sever effects downstream of the dam. During the lifetime of a dam different flow conditions will be experienced and a dam must be able to safely accommodate high floods that can exceed normal flow conditions in the river. For this reason, carefully passages are corporate in the dams as part of structure. These passages are known as spillways.

7. Trash rack
Almost all small hydroelectric plants have a trash rack cleaning machine, which removes material from water in order to avoid entering plant water ways and damaging electromechanical equipment.

Fig.7.1

8. Penstock

Conveying water from the intake to the power house. The water in the reservoir is considered stored energy when the gate opens the water flowing through the penstock becomes kinetic energy because it is in motion. The movement of water can be used to make electricity. Energy from water is created by the force of water moving from a higher elevation to a lower elevation through a large pipe (penstock). When the water reaches the end of the pipe, it hits and spins a water wheel or turbine. The turbine rotates the connected shaft, which then turns the generator, making electricity.

Fig.8.1

9. TURBINE
Any of various machines in which the kinetic energy of a moving fluid is converted to mechanical power by the impulse or reaction of the fluid with a series of buckets, paddles or blades arrayed about the circumference of wheel or cylinder. OR A turbine is a rotary mechanical device that extracts energy from a fluid flow and converts it into useful works.

Fig.9.1

It requires high head and small quantity of water. Pelton turbine is an IMPULSE turbine. Water head is more than 300m.

Reaction turbine

It requires low or medium head and large quantity of water.

Kaplans turbine
It requires low head and high discharge reaction turbine. Water head is less than 60m. It is adjustable runner blade turbine. This function makes it unique type of turbine.

Fig.9.2

Fig.9.3 It is also a reaction turbine. Water head of Francis turbine varies between 60m to 300m. A water turbine designed to produce high flow from a low head of pressure used in hydro electric power generation .

Fig.9.4

Fig.9.5 A Pelton wheel turbine is a water impulse turbine consisting of a row of double cup shaped buckets arranged around a rim of a wheel and actuated by one or more jets of water playing into the cup ay high velocity.

Fig.9.6

Specification of turbine at Salal power station

Type Rated speed Rated net head Minimum head Maximum net head Rated discharge Turbine rated output At rated head and discharge Maximum output of turbine at Head > maximum head Optimum efficiency of the Turbine at 90% part load Maximum runaway speed Specific speed Direction of rotation from top Maximum axial hydraulic thrust Flywheel effect of turbine Carried by generator Mass of turbine rotating parts Maximum permissible pressure Rise Speed rise at 100% load throw off Pressure rise at 100% load throw off = = = = = = = = = = = = = = = = = = = vertical shaft Francis 187.5 rpm 94.5 m 94.5 m 102 m 137 cumecs 117.5 MW 123.5 MW 92.5% 375 rpm 229.2 m/KW clockwise 382 tonnes 13000 tonnes-m2 382 tonnes 52.4 tonnes 139m (max. water hammer) 55%

Major components of hydro generating set Turbine (Francis type)

1. Draft tube knee lining 2. Draft tube cone 3. Foundation ring assembly 4. Stay ring 5. Spiral casing 6. Turbine pit liner 7. Turbine top cover 8. Lower ring 9. Guide apparatus 10. Servomotor of guide apparatus 11. Turbine shaft 12. Runner assembly 13. Guide bearing 14. Turbine sealing/shaft sealing 15. Guide vanes bush

Turbine auxiliary equipment

1. C.G.L.S.(centralized grease lubrication system) 2. Gravity drain 3. Ejector system 4. Draft tube drain valve 5. Top cover drainage pump 6. Governing system 7. Oil pressure unit 8. Feed back rope 9. Oil leakage unit 10. Emergency slide valve 11. Temperature measuring devices 12. H.p compressor air system 13. L.p compressor air system 14. Cooling water system

10. Runner

The runner is a basically 13 chromium & 4 nickel stainless steel casting. It is a connecting with shaft through bolts and nuts and locking devices .the coupling bolts in runner are line reamed with runner and shaft assembled. The profile of runner is very accurate.

Fig.10.1

Runner of Francis turbine installed at Salal power station

Runner inlet diameter Runner inlet height Discharge diameter Nominal diameter Diameter of runner at Lower rotation labyrinth Nos. of blades Height of runner Material and composition Weight of runner = = = = = = = = = 3347mm 900mm 4092mm 3600mm 3856mm 14 1952mm stainless steel, 13%Cr%Ni 35 tonnes

11. Spiral casing

The spiral casing is valuating type built up from steel plates by welding. The design of spiral casing is such that the hydraulic losses are minimized. The diameter of spiral casing decreases gradually because it is based on principle constant momentum of velocity. There is a drain valve provided in spiral casing to dewater it during inspection and maintenance.

Fig.11.1

Spiral casing of Francis turbine at Salal power station

Inlet or maximum diameter of spiral casing Thickness of plate used Max. Design pressure Test pressure Velocity of water in spiral casing At full load and design Elevation of centerline of spiral casing From sea level Number of stay vanes = = = = = = = 4220mm 40 and 36mm 13.9kg/cm2 21 kg/cm2 99 tones 386 m 12

12. Stay ring

The stay ring is welded plate steel or cast welded construction, heat treated before final machining to relieve locked- up casting or fabrication stresses and sectionalized as necessary for handling and shipment. It has two rings upper and lower ring rigidly held together by stay vanes which guide the water to guide vanes. The stay vanes are designed so that to direct the water flow with a minimum head loss and eliminate vibrations. The surface of stay rings and the welded joints in contact with water are grounded to smooth finish. The stay rings is designed to support all loads superimposing upon it by the concrete, and it is designed so that to transmit the required loads to the concrete based on the design of the generated unit.

Fig.12.1

13. Turbine top cover

The turbine top cover is fabricated steel plants structure. It is heavy construction adequately ribbed and shaped so as to give rigid support to turbine guide bearing, supported ring and the bearings/ bush for upper stems of the guide vanes. The top cover is designed so that it can withstand safely and without detrimental deflection the maximum water pressure, bearing load and all others force acting upon it.

Fig.13.1

TOP COVER OF FRANCIS TURBINE AT SALAL POWER STATION

Maximum diameter of top flange Internal diameter of supporting flange Internal diameter of supporting flange For turbine guide bearing Material = = = = 5100 mm 1560 mm 1735mm 22.5 tonnes

14. Lower ring

The lower ring is made from cast steel or welding steel plates. The lower ring is heavy rugged construction and all necessary anchors and adjusting screws are provided. It has two haves for easy handling. Bronze bushes are provided in it for lower stream of guide vanes. It is bolted and doweled to the stay ring A replaceable stainless steel seal ring, accurately machined to form a water seal with runner band. It is also called lower fixed labyrinth. It is designed to minimize leakage.

Fig.14.1

Lower ring of Francis turbine at Salal power station

Diameter of upper bore Diameter of lower bore Height of lower ring Thickness of curved portion Lower labyrinth clearance Upper labyrinth clearance No. of locating pins Diameter of locating pins No. of lifting bolts Diameter of lifting bolts No of holes connecting lower Ring to stay ring Diameter of connecting holes Pitch circle diameter of connecting holes Material Weight of lower ring = = = = = = = = = = = = = = = 3600 mm 3910 mm 365 mm 25 mm 1.75 to 2.5 mm 1.5 to 2 mm 6 30 mm 4 16 mm 24 48 mm 4260 mm 18% Cr & 10% Ni steel 7.57 tonnes

15. Guide vanes

Fig.15.1 The turbine is equipped with one set of casting stainless steel guide vane or wicket gates. The vanes are uniform in shape and their selection / profile is such that to direct properly and accelerate gradually the water entering the runner with a minimum friction and hydraulic disturbance. The guide vanes regulate the quality of water to vary load of turbine. The governor governs the guide vanes. The number of guide vanes and no of runner blades are considered in design of the turbine to minimize vibrations. The guide vanes are accurately machined and ground to smooth finish and even surface. All guide vanes are interchangeable.

Guide vanes of Francis turbine at Salal power station

Height of guide vanes Maximum opening of guide vanes No. of guide vanes Diameter of location of guide vanes Design clearance, top clearance Bottom clearance Material of guide vanes Leakage through full gate closed Under maximum static head Weight of one guide vanes = = = = = = = = = 899.5 mm 290 mm 24 4200 mm 0.3 to 0.7 mm 0.2 to 0.6 mm stainless steel 1 m3/sec 650 kgs

16. Turbine shaft

It is connected with generator rotor and runner with integrally forced coupling flanges at top bottom respectively. It is designed on basis of runway speed without detrimental vibration or distortion. It is generally hollow in shape.

Fig.16.1

Turbine shaft of Francis turbine at Salal power station

Outer diameter of shaft Inner diameter of shaft Length of turbine shaft Turbine guide bearings journal outer dia. Turbine bearing journal inner diameter Flange diameter PCD of coupling bolts No. of coupling bolts Size of coupling bolts Length of coupling bolts Length of threaded portion of coupling Weight of turbine shaft = = = = = = = = = = = = 1000 mm 700 mm 4150 mm 1350 mm 1150 mm 1570 mm 1350 mm 20 M100 X 4 550 mm 100 mm 17.4 tonnes

17. Governor
Governor is the device, which regulates the quantity of water through guide vanes by sensing the speed of machine through permanent magnetic generator installed at the top of the machine.

Fig.17.1

18. Servomotor
Servomotor is the device, which opens the guide vanes through regulating rings and guide apparatus mechanism by getting signals from governor main slide valve. The signal comes in the form of quantity of oil releasing from main slide valve.

Fig.18.1

19. Draft tube

The draft tube is a conduit, which connects the runner exist to tail pool. It permits a negative suction head by converting the kinetic energy of water after runner exists into pressure energy. It is a welding steel plate pipe or a concrete tunnel, its cross-section gradually increase toward the outlet. Draft tube is connected with runner exit. Its cross- section gradually increases from runner exit to draft tube liner.

Fig.19.1

20. Draft tube drain valve

It is a very critical part of a machine. It is used during machine. It is used for drafting of draft tube when draft tube gates are fully closed. During running machine it is in closed position.

21. Shaft seal

The shaft seal prevents the water form down side of the turbine top cover into turbine guide bearing. Shaft seal arrangement is placed in turbine top cover. All stationary parts are mounted on supporting ring which is mounted on the top cover. And is rotating part of shaft seal arrangement, which is known as revolving sleeve, which is mounted on coupling guide just above the runner.

Fig.21.1

Power station mechanical auxiliary systems

* Centralized grease lubrication system * Hydro static lubrication system * Braking and jacking system * Draining and dewatering system * Drinking water system * Ventilation and air conditioning system * Air services and air compressor * Lift

Centralized grease lubrication system

General aspects:
Guide bearings apparatus is one of the key components of the hydro-turbine; it is used for controlling the water into the turbine depending upon the load requirements. As the entire apparatus has to operate against high water force, high oil pressure is used for operation of the system. To reduce the friction against movement of all the guide vanes in unison, grease is fed into the guide vanes bushes at high pressure. This is done to lubricate the upper, middle and lower bush of the guide vanes. Grease is fed to the brushes by two grease carrying pipe. Distributors installed near the guide vanes push the grease to the upper/middle and lower bushes. A high pressure pump is used to feed grease into the pipes. When the greasing is complete, back pressure builds up in the pipe and switches off the grease pump. Filters are installed in the pipeline to filter the grease before feeding it into the bushes. Both semi-automatic and automatic system can be used for control of the greasing system. Basic components: 1. Grease pump 2. Grease tank 3. Pipeline

4. Distribution 5. Pressure switch and timers

Lubrication system

General aspects
In vertical axis machine, the entire suspended mass of the machine is supported on the thrust bearing assembly. This assembly consists of collar mounted on the shaft, and runner disc fitted below the collar. The disc rests on thrust bearing pads which are supported on pad supports. The pad supports are pivoted on the thrust bearing bolts which ultimately transfer the entire load of the machine brackets, from where the load is passed on top of the civil structures. The surface of the runner disc and the thrust bearing pads move against each other and have to bear entire friction arising due to the motion of the shaft. To facilitate this motion by reducing friction, as well as to cool the surface of the pads and disc, the entire thrust bearing assembly is kept submerged in the lubricating oil bath and runs in it. The pads are pivot supported and during operation of the machine, they move and form a wedge shaped film of lubricating oil on the surface. But during starting and stopping of the machine, this film may not build up leading to high frictional force on the pads surface and consequent temperature rise and damage on the pads. One way to ensure the pressure of oil film on the pads surface during starting of machine is jacking the shaft by 5-6 mm to allow the oil to flush the pads. But this time consuming and may not be always possible. Thus, to ensure the pressure o oil film on the pads surface, hydro- static lubricating is installed in the thrust bearing assembly.

Principal and working

The lubrication system uses a pump- motor set which; (a) (b) (c) (d) Collects the oil from the thrust bearing oil bath itself, Filters the collected oil, Force the oil at a pressure of 80-100 kg/cm2 through the hole provided in the thrust bearing pads Causes the oil to emerge through these holes on to the pad grooves, thereby distributing itself evenly between the pads and disc surface.

This oil after lubricating the surface of the pads and disc mixes back into the thrust bearing oil bath. The lubrication system is switched on automatically before starting and stopping of machine and is switched off when the machine has gained its final speed, using a speed relay mechanism.

Basic component
1. 2. 3. 4. 5. 6. 7. 8. Low pressure pipelines with isolation valve for collection of oil from thrust bearing oil bath. Low pressure oil filter. Pump motor set High pressure oil filter. Pressure gauge and switches for provision of interlock and auto operation High pressure oil pipeline with N.R.V. Flexible high pressure hose pipe assembly for distribution of oil to various pads. Individual N.R.V.s of all thrust bearing pads.

Operational and maintenance features:

1. 2. 3. 4. 5. Starting interlock is provided for safe and automatic operation of the lubrication s System on giving the start command to the machine. N.R.V.s are checked for correct operation during maintenance. Pads oil grooves are checked for thoroughness during maintenance. Filters are cleaned during maintenance.

Machine should show some lift and movement on starting the lubrication system and before opening of guide vanes.

Braking and jacking system

General aspects
Braking system is required for bringing the generator to halt during the stopping operation of the machine. Jacking system in vertical axis hydro generators is required for lifting the entire suspended mass of the machine shaft, comprising of runner, rotor and shaft by desired distance, which is limiting by design features of the machine and the jacking system. This lifting is required for flushing of thrust bearing pads with oil, and for inspection of TB pads without dismantling the generator.

Principal and workings

For the operation of braking system compressed air at the pressure of 6-8 kg/cm2 is used to lift the pistons in the cylinders below the break pads. The cylinders are mounted below the breaking ring provided on the periphery at the base of the rotor. The number of such assemblies installed depends upon the design features of the machine. The break pads when lifted by air pressure touch the breaking rim with a force and bring the machine to a halt. The pistons are spring loaded and come down back to there original position when the air pressure is removed The same assembly as used for the breaking system is also used for the jacking system as well. Pressurized oil at 80-100 kg/cm2 is pumped into the cylinders, instead of air and after isolating the air

source pipeline. The piston lifts up and cause the entire suspended mass of the machine shaft to lift along with. If the machine shaft is to be kept in jacked position for a long time, screw type mechanical locks provided at the periphery of the breaks cylinders are filled and oil pressure released. The screws than take the entire load of the machine shaft, it is first jacked by a very small distance so that the locks can be unscrewed, and then the oil pressure is released. Oil pipeline is than flushed with compressed air for a number of times, to remove any oil present in the pipeline and cylinders.

Basic components
1. Brakes assemblies comprising of cylinders, spring loaded pistons, seals and break pads made of non flammable material. 2. Pressure pipelines for carrying compressed air/ pressurized oil, and connected to all the break assemblies. 3. Manual valves, solenoid valves and pressure gauge for manual and automatic operations 4. Compressed air source pipeline. 5. Jacking pump with oil source and sump. 6. Various limit switches for breaking and jacking control circuits.

Operation and maintenance features

1. Brakes are applied during the stopping operations only when the machine speed has reduced to 30-40% of normal rated speed. To avoid excessive damage to the break pads. 2. Breaks are kept applied for 60-90 s after the machine has attained zero speed. 3. Break applied/ released indication/interlocking is kept in view during starting and stopping the machine. 4. For jacking operation air source pipeline is isolated so that pressurized oil does not go into the air source pipeline. 5. Distance by which the machine shaft is being jacked is monitored with a dial gauge. 6. Suitable limit/ remote switch is used to control jacking or avoid over jacking of the machine.

7. Regular inspection of the break pads height is done. 8. Free downward movements of the break pads on removal of air/oil pressure are ensured. 9. Cleaning and inspection of cylinders and seals is done during overhauling. 10. Cleaning of sump and oil filter of jacking pump is carried out during maintenance.

Drainage and dewatering system

General aspects

In the present day scenario, high capacity hydro power plants are very essential to meet the ever growing demand of electrical power, particularly when we talk of clean power and suitable hydro thermal mix. High capacity hydro power plants invariably high rated heads and semi underground or underground power houses In such kind of semi underground and underground power houses, machine floor level is lower than the level of tailrace. This is where the drainage and dewatering system of power houses gain importance. As the level of tailrace is higher the water from the power house floors has always to be pumped out for drainage and dewatering of the power house. Drainage and dewatering are basically the same things i.e. pumping out of accumulated water from various water sumps in the power houses. The difference is only the purpose for which the pumping system is used.

Drainage system

The drainage system is used to lift seepage and general drain water, or the water leaks from the guide vanes bushes and turbine sealing. This water gets accumulated in the drainage sumps provided at the lower floor of the power house by the way of gravity flow only. From these sumps, it is pumped and thrown into the tail race, using the system of submersible/vertical turbine pumps, pipeline and valves. Stand by pumps are kept ready to avoid the chances of flooding of powerhouse floors due to failure of pumps.

Dewatering system
Dewatering system is used to dewater the accumulated water in the draft tube after closing the penstock and draft tubes gates and opening the penstock and draft tube drain valves. This is done when the unit is taken on shutdown for maintenance of underwater parts.

Basic components
1. 2. 3. 4. Drainage pumps and dewatering pumps Drainage sump and dewatering sumps Drainage pipelines Drainage valves

Operation and maintenance features

1. The drainage water flows into the drainage sumps and can be pumped out 2. Float switch can be used for automatic operation of pumps whenever required. 3. For dewatering of the draft tube or pen stock, the draft tube and penstock gates are closed. Then the valve connecting the same with the dewatering sump is opened up and water made to collect in the dewatering sump 4. The water from the dewatering sump is then pumped out.

Drinking water

General aspects:
To meet the requirement of drinking water system in hydro power station, water can be collected from the two sources, the river itself, or from underground. The river water is collected and stored in over head tanks after adequate filtrations and sedimentation. Than it is treated with bleaching powder to make it fit for drinking If the water is pumped out from the under the ground, it generally does not require filtration. It is bleached and stored in tanks. The storage tanks are regularly cleaned.

Ventilation and air conditioning

General aspects
The air we live and breath consist mainly of nitrogen, oxygen, carbon-dioxide and a mixture of other gases. Apart from this it contains particulate matter and water vapor. Talking about human comfort, the desire level of the comfort for the person to work and breathe efficiently, the quality of air, as well as the temperature, is to be maintained within certain limits. An average person at rest inhales 18 ft 3 of air per hour, of which 5% is absorbed as oxygen. At the same time 63 ft 3 of carbon dioxide is released along with some water vapor and heat.

Ventilation
To describe ventilation, it is the practice to do so by the number of air change per hour, when one change is the volume of the room or space under consideration. The requirement air changes varies from place to place, according to the no. of occupants and type of activity, and are of the order of 6-8 change per hour for a workshop. Modern day power houses are generally of sub-surface or under ground type, and elaborate ventilation system is a must for proper provision of air at various floors. Also, this is required for extraction of working dust/ gases from various floors.

Methods of ventilation
A good ventilation system should evenly distribute the air in whole area, without forming of stale air pocket and without allowing considerable variation in temperature in the area. Pumping in the air to produce a positive pressure, extracting the air to produce a negative pressure, or a combination of both the above can be used for ventilation system. The first method or combination has more advantage as it help s in keeping the inlet air free of dust etc, by provision of filters. A large fan is used to force the air through filters and into the air duct. The air is taken to various points and discharged through louvered outlet. Heating arrangement can be used to heat the air during winters. Ventilations with or without exhaust fans can be provided at the top of the buildings for escape of the stale air.

Air conditioning
This system is used to control the moisture content as well as temperature of the air, even while provided a dust free air. It is required for proper working of the precision relays installed in the control room of the power house. Also, it is installed in office for increasing the comfort and efficiency of the staff. It is of two types: 1. Room air conditioning: - it consist of individual air-conditioning units which are generally window mounted and are suitable for a particular size of room only. 2. Centralized air conditioning: - it is centralized unit which force the clean and conditioned air through duct to the desired areas. The work of both the system is almost same. Air is filtered. This warm air at surrounding temperature is passed over the cooling unit and it gives up heat to cool down. It further undergoes the process of dehumidification. This cool air is then forced out of the unit through the window/ the ducts provided with the air- conditioning unit. The heat dissipated over the cooling unit is picked up by refrigerant which changes from liquid to vapor form. This refrigerant, the temperature is raised to a higher value than the temperature of the outside condenser. The vapor gives up heat to the condenser and changes into liquid. This cycle is repeated. For the provision of warm air during winter season, heating strips or process of heat- pump can be used.

Air services and air compressor

General aspects
In modern days power houses, compressed air is widely used for the following activities: 1. High pressure compressed air of the order of 40 kg/cm2 for the purpose of oil pressure units. 2. Low pressure compressed air of the order of 6-8 kg/cm2 for the purpose of brakes. 3. Low pressure compressed air of the order of 6-8 kg/cm2 for the purpose of general jobs like painting, cleaning and operating of pneumatic tools. 4. Operating of high capacity circuit breaker in switchyard. 5. Fire protection services For the purpose of compression of air, air compressors are used. These can be single stage compressors, for relative low air pressure, or double stage compressor for high air pressure. The cylinders used for air compression are provided with water jacket to bring the air to its original temperature after the process of compression. In double stage compressors, inter cooler is provided to cool down the air after first stage of compression. When dealing with high volume of air, after cooling are used to cool down compressed air and increase the storage capacity of the air receiver tank. The air leaving the compressor contains a certain amount of moisture and oil which can be removed in the after cooler. Compressor air is received and stored in the receiver and used whenever required. Standby receivers are provided to ensure the supply of air. Receivers are fitted with safety valve. Once the pressure of the system is built up to a desired level, a governing device operates and closes the valve at the compressor inlet. Thus the motor unloads and runs without doing any compression. When the pressure of the compressed air falls due to usage, the valve reopens and the motor of the compressor loads and compression begins. This system is useful to avoid frequent starting and stopping of the compressor motor.

Lift
General aspects
Modern day hydro-power stations are build in a number of floors, right from the drainage gallery and turbine floor to the service bay. For the purpose of easy and fast translation of staff between various floors, and to reduce effort and fatigue to them, so that they can use their energy on their work and not on climbing up-down only, lift is very essential in any power house. In fact it is one of the basic services provided in a power house.

The lift service basically comprises of: 1. Lift room for motor and control panel 2. Elevators shaft for movement of the lift cars 3. Call points at various floors

Apart from these, modern days lifts are provided with various safety features like automatic laser based and limits switch based door opening, telephone, fan, fire alarm, emergency light/stop and automatic door opening at the nearest floor in case of power failure.

Monitoring of all parameters of the running machine

1. 2. 3. 4.

Check the pressure of main header of cooling. The pressure should not be less than 5 kg/cm2 Check all the temperature of bearings i.e. thrust bearing, U.G.B, L.G.B, and T.G.B. Check the temperature of stator winding and hot air. The temperature should be in operating range. There should be no excess change in reading in an hour. 5. Check the oil level of bearings. The oil level should lie between the upper limit and lower limit. 6. Check the inlet outlet pressure of all type of cooling. The difference between both inlet and outlet pressure should be minimum. 7. Check the OPU pressure. It should be in operating range(40 kg/cm2) 8. Check the mechanical cabinet of governor, oil pressure, and leakage of oil if any. 9. The pressure of governing oil pressure should be 40 kg/cm2 in manual mode and 20 kg/cm2 in auto mode. 10. Check the thirstier bridge current at AVR panel and check the AVR panel for any indication, 11. Check the stator air cooler. There should not be any type of leakage. 12. Check the generator oil leakage unit. The oil level should be in minimum position. 13. Check the stator cooling 14. All illumination should be proper 15. Check the TGB of the oil level, turbine pit, servomotor stroke and the feedback rope 16. There should not be any leakage in turbine pit if some leakage is observed then check the gravity drain at draft tube drainage gallery 17. Check the turbine oil leakage unit. The oil level should be in minimum position

18. Check the temperature of winding and oil of all transformers 19. Check the oil-circulating pump. One pump should be in running position 20. Check the cooling of transformer pressure of main header of both stages. 21. Check the healthiness of battery bank since it is the heart of power house.

Salal Power Station- A Profile

Salal Power Station located across the river Chenab in the state Jammu and Kashmir is having an installed capacity of 690 MW with six generating units each of 115 MW. It is a run of the river scheme commissioned in two stages. Stage-I with 3 x 115 MW was commissioned in 1987, and stage-II with 3 x 115 MW was added later on during 1993-95 to utilize the surplus inflow available during the months from April to Sept. All the 6 units came into operation as follows: Unit I, II, III Unit IV Unit V Unit VI Nov.87 March93 May94 Feb95

One rock fill dam, 118 meter high and 630 meter long and one concrete dam 113 meter high and 486 meter long have been constructed around a loop of the river at dhyangarh. The spill portion consists of 12 nos. of radial gates of size 9.322m x 15.240m. The water is fed to the hydro turbine through six penstock of diameter 5.23m (one for each machine) and 279m long. After generation, water is discharge to the river through two nos. tail races tunnels of length 2.43km and 2.53km. the voltage level of generated power is 11 KV which is further stepped up to 220 KV through 11/220KV,43.33MVA bank of 3 nos. single phase transformers. 220 KV switchyard is located adjacent to the power house on a filled platform and linked with generator transformer through lines supported on suitable tower structure.

To evacuate power, 6 nos. 220 KV feeders (two nos. 220 KV, single circuit Salal-Jammu lines, 2 nos. 220 KV, double circuit Salal-Kishanpur lines have been constructed from switchyard.

Conclusions and Personal Experience

Hydropower is the cheapest way to generate electricity today. No other energy source, renewable or nonrenewable can match it. Producing electricity from hydro plants is cheap because, once a dam has been built and the equipment installed, the energy source-flowing water is free. Although hydro plants do present a few environmental problems the inherent technical, economic and environmental benefits of hydroelectric power plants make it a important contributor to the future world energy.

It was a great honor for me to have four week training from such a prestigious government undertaking project which is awarded as a mini Ratna class I by government of India. It was a great experience to see the formal work which showed the status of a government profile. Hindi was the language which was mostly preferred for letter work which showed a respect for the constitution and our national language Hindi.

Dams, Power house situated at Dhyangarh helped us to gain the deep knowledge of the different working parts which are responsible for the power generation. Under our training period we come to know about the turbines and why only Francis turbine is preferred in Salal power station. The working of different accessories which is equipped their smooth working of turbine. We come to know about the construction of dams and diverting the water to fall on the turbine for power generation. We are very thankful to General Manager, Manager (HR), Assist Manager for allowing us to make such a wonderful experience which made us to learn a lot.