Version 2

STANDARDS/MANUALS/
GUIDELINES FOR
SMALL HYDRO DEVELOPMENT

Electro-Mechanical Works–
Selection of Turbine And Governing System for Hydroelectric
Project

Sponsor: Lead Organization:

Ministry of New and Renewable Energy Alternate Hydro Energy Center

Govt. of India Indian Institute of Technology Roorkee

May 2011
 CONTENTS

Sl. No. Items Page No.

1.0 OVERVIEW 1
2.0 REFERENCES 1
3.0 SITE DATA 2
3.1 Net Head 2
3.2 Definition of Head 2
4.0 CLASSIFICATION AND TYPES OF TURBINES 5
4.1 Francis Turbines 5
4.2 Axial Flow Turbines 6
4.3 Impulse Turbines 8
4.4 Cross Flow Turbines 17
5.0 SELECTION OF HYDRAULIC TURBINE 21
6.0 SETTING AND CAVITATION OF REACTION TURBINE 44
7.0 TURBINE PERFORMANCE 49
7.1 Pressure Regulation 49
7.2 Speed Regulation 50
7.3 Speed Rise 51
7.4 Pressure Rise and Speed Rise Calculation 52
7.5 Method for Computing Speed Rise 52
8.0 HYDRO TURBINE GOVERNING SYSTEM 56
8.1 Introduction 56
8.2 Type of Governor Control Section 57
8.3 Turbine Control Actuator System 58
8.4 Small Hydro Governor Selection Consideration 59
8.5 Personal Computers (PC)/Programmable Logic Controller (PLC) base Digital 60
Governors
8.6 Governing System used in India 63
8.7 U.S. Practice Regarding Governor and Control 65
8.8 Examples of Typical Governing System 67

ANNEXURES
Annexure – 1 74
Annexure – 2 79
Annexure – 3 80
Annexure – 4.1 81
Annexure – 4.2 82
Annexure – 4.3 83
Annexure – 4.4 84
Annexure – 4.5 85
Annexure – 4.6 86
Annexure – 4.7 87
Annexure – 4.8 88
Annexure – 4.9 89
Annexure – 4.10 90
Annexure – 4.11 91
Annexure – 4.12 92
Annexure – 4.13 93
Annexure – 5 94
 Guide for Selection of Turbine and Governing
System for Hydroelectric Generating Units
Up to 25 MW
1. OVERVIEW

Selecting the type, kind, (within type) configuration, (horizontal or vertical) size, and
number of turbine units that best suit a project is a detailed process. This involves
technical, environmental, financial, and other considerations. The most inexpensive
turbine may not be the best solution to the available head and flow. For small hydro up to
5 MW unit size, selection on the basis of typical turbine data furnished by manufacturers
is recommended. For units above 5 MW size information exchange with turbine
manufacturers is recommended for turbine at project stage. The selection procedure is
prepared for selection of turbine based on the techno economic consideration to permit
rapid selection of proper turbine unit, estimation of its major dimensions and prediction
of its performance.

1.1.1 Purpose

The purpose of this guide is to provide guidance for application of hydroelectric turbines
and governing systems by developers, manufacturers, consultants, regulators and others.
The guide includes, planning, investigation, design and execution, manufacture of
equipment and test at work.

2. REFERENCES

This guide shall be used in conjunction with the following publications. When the
following specification are superseded by an approved revision, the revision shall apply.

IS: 12800 (Part 3) – 1991, Guidelines for selection of hydraulic turbine, preliminary
dimensioning and layout of surface hydroelectric powerhouses.

IS: 12837 – 1989, Hydraulic turbines for medium and large power houses – guidelines
for selection

IEC: 1116 – 1992, Electromechanical equipment guide for small hydroelectric

installations.

IEC: 41 – 1991, Field acceptance tests to determine the hydraulic performance of

hydraulic turbines, storage pumps and pump-turbines
IEC: 193 – 1965, International code for model acceptance tests of hydraulic turbines.

IEC: 60308 – 1970, International code for testing of speed governing system for
hydraulic turbines.

IEC: 545 – 1976, Guide for commissioning, operation and maintenance of hydraulic
turbines.

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 IEC: 609 – 1978, Cavitation pitting evaluation in hydraulic turbines, storage pumps and
pump-turbines.

IEEE: 1207 – 2004, Guide for the application of turbine governing system for
hydroelectric generating units.

IEEE: 125 – 1996, Recommended practice for preparation of equipment specifications

for speed governing of hydraulic turbines intended to drive electric generators

United states department of the - Selecting Hydraulic Reaction Turbine

Interior Bureau of Reclamation
Engineering Monograph No. 20,

Central Board of Irrigation & - Small Hydro Stations Standardization

Power India Publication No.
175 - 1985,

Central Board of Irrigation & - Manual on Planning and Design of Small

Power India Publication No. Hydroelectric Schemes
280 - 2001,

Alternate Hydro Energy Centre – 2005, Micro Hydro Quality Standard

Indian Institute of Technology
Roorkee

ASME – 1996, Guide to Hydropower Mechanical Design (Book)

3. SITE DATA

It is presumed that the data with regard to design head, design discharge, number and
types of units and capacity are known. Departure from these guidelines may be necessary
to meet the special requirements and conditions of individual sites.

3.1 Net Head

The effective head available to the turbine unit for power production is called the net
head. Selection of rated and design head requires special attention. Definition of these
heads are given in Para 1.5 and shown in figure 1.1. The turbine rating is given at rated
head.

Determination of rated head, design head and maximum and minimum net head is
important. Permissible departure from design head for reaction turbines for optimum
efficiency and cavitations characteristics based on experience data is shown in table 1.1.

3.2 Definition of Head

EFFECTIVE HEAD (Net Head) - The effective head is the net head available to the
turbine unit for power production. This head is the static gross head, the difference
between the level of water in the Forebay/impoundment and the tailwater level at the
outlet, less the hydraulic losses of the water passage as shown in Fig. 1.1. The effective

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 head must be used for all power calculations. The hydraulic losses can vary from
essentially zero for flume-type turbine installations to amounts so significant for
undersized outlet conduit that the energy potential of the site is seriously restricted. The
hydraulic losses in closed conduit can be calculated using the principles set out in general
hydraulic textbooks. In addition to conduit losses, an allowance for a loss through the
intake structure should also be included. In general a hydraulic loss of one velocity head
(velocity squared divided by 2 x acceleration due to gravity) or greater would not be
uncommon. The hydraulic losses through the turbine and draft tube are accounted for in
the turbine efficiency.

Gross Head (Hg) – is the difference in elevation between the water levels of the forebay
and the tailrace.

Maximum Head (Hmax) – is the gross head resulting from the difference in elevation
between the maximum forebay level without surcharge and the tailrace level without
spillway discharge, and with one unit operating at speed no-load (turbine discharge of
approximately 5% of rated flow). Under this condition, hydraulic losses are negligible
and nay be disregarded.

Minimum Head (Hmin) – is the net head resulting from the difference in elevation
between the minimum forebay level and the maximum tailrace level minus losses with all
turbines operating at full gate.

Table 1.1

Type of turbine Maximum Minimum

head head
(percent) (percent)
Francis 125 65
Propeller – fixed blade turbine 110 90
Propeller – Adjustable blade turbine 125 65

Weighted Average Head - is the net head determined from reservoir operation
calculations which will produce the same amount of energy in kilowatt-hours between
that head and maximum head as is developed between that same head and minimum
head.

Design Head (hd) – is the net head at which peak efficiency is desired. This head should
preferably approximate the weighted average head, but must be so selected that the
maximum and minimum heads are not beyond the permissible operating range of the
turbine. This is the head which determines the basic dimensions of the turbine and
therefore of the power plant.

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 MAXIMUM WATER SURFACE

SURCHARGE

FOREBAY MAXIMUM HEAD, Hamx

(MUST NOT EXCEED
WEIGHTED AVERAGE WATER LEVEL 125% OF hd)
LOSSES, hl

JOINT USE OR ACTIVE

CONSERVATION CAPACITY RATED HEAD, hr- TURBINE FULL-GATE OUTP
PRODUCES GENERATOR RATED OUTPUT
DESIGN HEAD, hd
LOSSES

REQUIRED
SUBMERGENCE
MINIMUM HEAD, Hmin
(MUST NOT EXCEED 65% OF hd)
INACTIVE AND DEAD
CAPACITY

TAILRACE

ALL UNITS OPERATING FULL GATE

ONE UNIT OPERATING SPEED - NO - LOAD Fig. 1.1

Rated head (hr) – is the net head at which the full-gate output of the turbine produce the generator rated output in kilowatts. The turbine
nameplate rating usually is given at this head. Selection of this head requires foresight and deliberation.

Permissible range of head for reaction turbines for optimum efficiency and cavitations characteristics based on experience data is as follows in
table 1.1.

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4. CLASSIFICATION AND TYPES OF TURBINES

Turbines can be either reaction or impulse types. The turbines type indicates the manner in
which the water causes the turbine runner to rotate. Reaction turbine operates with their
runners fully flooded and develops torque because of the reaction of water pressure against
runner blades. Impulse turbines operate with their runner in air and convert the water’s
pressure energy into kinetic energy of a jet that impinges onto the runner buckets to develop
torque.

Reaction turbines are classified as Francis (mixed flow) or axial flow. Axial flow turbines are
available with both fixed blades (Propeller) and variable pitch blades (Kaplan). Both axial
flow (Propeller & Kaplan) and Francis turbines may be mounted either horizontally or
vertically. Additionally, Propeller turbines may be slant mounted.

4.1 Francis Turbines

A Francis turbine is one having a runner with fixed blades (vanes), usually nine or more, to
which the water enters the turbine in a radial direction, with respect to the shaft, and is
discharged in an axial direction. Principal components consist of the runner, a water supply
case to convey the water to the runner, wicket gates to control the quantity of water and
distribute it equally to the runner and a draft tube to convey the water away from the turbines.

A Francis turbine may be operated over a range of flows approximately 40 to 110% of rated
discharge. Below 40% rated discharge, there can be an area of operation where vibration
and/or power surges occur. The upper limit generally corresponds to the maximum generator
rating. The approximate head range for operation is from 65% to 125% of design head. In
general, peak efficiencies of Francis turbines, within the capacity range of 25 MW, with
modern design tool like CFD (computational fluid dynamics) have enabled to achieve peak
efficiency in the range of 93 to 94%.

The conventional Francis turbine is provided with a wicket gate assembly to permit placing
the unit on line at synchronous speed, to regulate load and speed, and to shutdown the unit.
The mechanisms of large units are actuated by hydraulic servomotors. Small units may be
actuated by electric motor gate operations. It permits operation of the turbine over the full
range of flows. In special cases, where the flow rate is constant, Francis turbines without
wicket gate mechanisms may be used. These units operate in case of generating units in
Micro Hydel range (upto 100 kW) with Electronic Load Controller or Shunt Load
Governors. Start up and shut down of turbines without a wicket gate is normally
accomplished using the shut off valve at the turbine inlet. Synchronising is done by manual
load control to adjust speed.

Francis turbines may be mounted with vertical or horizontal shafts. Vertical mounting allows
a smaller plan area and permits a deeper setting of the turbine with respect to tailwater
elevation locating the turbine below tailwater. Turbine costs for vertical units are higher than
for horizontal units because of the need for a larger thrust bearing. However, the savings on
construction costs for medium and large units generally offset this equipment cost increase.
Horizontal units are more economical for smaller sets with higher speed applications where
standard horizontal generators are available.

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 The water supply case is generally fabricated from steel plate. However open flume and
concrete cases may be used for heads below 15 meters for vertical units.
Francis turbines are generally provided with a 90-degree elbow draft tube, which has a
venturi design to minimize head loss. Conical draft tubes are also available, however the head
loss will be higher and excavation may be more costly.

4.2 Axial Flow Turbines

Axial flow turbines are those in which flow through the runner is aligned with the axis of
rotation. Axial flow hydraulic turbines have been used for net heads up to 60 meters with
power output up to 25 MW. However, they are generally used in head applications below 35
meters Tubular turbine (S-type). S-turbines are used below 30 meters head and 8 MW
capacity. Bulb units can be used for low head if runner diameter is more than 1 meter.
Specific mechanical designs, civil construction, and economic factors must be given full
consideration when selecting among these three axial flow turbine arrangements.

A propeller turbine is one having a runner with four, five or six blades in which the water
passes through the runner in an axial direction with respect to the shaft. The pitch of the
blades may be fixed or movable. Principal components consist of a water supply case,
wicket gates, a runner and a draft tube.

The efficiency curve of a typical fixed blade Propeller turbine forms a sharp peak, more
abrupt than a Francis turbine curve. For variable pitch blade units the peak efficiency occurs
at different outputs depending on the blade setting. An envelope of the efficiency
curves cover the range of blade pitch settings forms the variable pitch efficiency curve. This
efficiency curve is broad and flat. Fixed blade units are less costly than variable pitch blade
turbines; however, the power operating ranges are more limited.

In general, peak efficiencies are approximately the same as for Francis turbines.

Propeller turbines may be operated at power outputs with flow from 40-120% of the rated
flow. Discharge rates above 105% may be obtained; however, the higher rates are generally
above the turbine and generator manufacturers’ guarantees. Many units are in satisfactorily
operation is from 60 to 140% of design head. Efficiency loss at higher heads drops 2 to 5%
points below peak efficiency at the design head and as much as 15% points at lower heads.

The conventional propeller or Kaplan (variable pitch blade) turbines are mounted with a
vertical shaft. Horizontal and slant settings will be discussed separately. The vertical units are
equipped with a wicket gate assembly to permit placing the unit on line at synchronous speed,
to regulate speed and load, and to shutdown the unit. The wicket gate mechanism units are
actuated by hydraulic servomotors. Small units may be actuated by electric motor gate
operators. Variable pitch units are equipped with a cam mechanism to coordinate the pitch of
the blade with gate position and head. Digital control envisages Control of wicket gates and
blade angle by independent servomotors co-ordinated by digital control. The special
condition of constant flow, as previously discussed for Francis turbines, can be applied to
propeller turbines. For this case, elimination of the wicket gate assembly may be acceptable.
Variable pitch propeller turbines without wicket gates are called semi Kaplan turbine.

The draft tube designs discussed for Francis turbines apply also to propeller turbines.

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 4.2.1 Tubular Turbines (S-Type)

Tubular or tube turbines are horizontal or slant mounted units with propeller runners. The
generators are located outside of the water passageway. Tube turbines are available equipped
with fixed or variable pitch runners and with or without wicket gate assemblies.

Performance characteristics of a tube turbine are similar to the performance characteristics

discussed for propeller turbines. The efficiency of a tube turbine will be one to two % higher
than for a vertical propeller turbine of the same size since the water passageway has less
change in direction.

The performance range of the tube turbine with variable pitch blade and without wicket
gates is greater than for a fixed blade propeller turbine but less than for a Kaplan turbine. The
water flow through the turbine is controlled by changing the pitch of the runner blades.

When it is not required to regulate turbine discharge and power output, a fixed blade runner
may be used. This results in a lower cost of both the turbine and governor system. To
estimate the performance of the fixed blade runner, use the maximum rated power and
discharge for the appropriate net head on the variable pitch blade performance curves.

Several items of auxiliary equipments are often necessary for the operation of tube turbines.
All tube turbines without wicket gates should be equipped with a shut off valve automatically
operated to provide shut-off and start-up functions.

Tube turbines can be connected either directly to the generator or through a speed increaser.
The speed increaser would allow the use of a higher speed generator, typically 750 or 1000
r/min, instead of a generator operating at turbine speed. The choice to utilize a speed
increaser is an economic decision. Speed increasers lower the overall plant efficiency by
about 1% for a single gear increaser and about 2% for double gear increaser. (The
manufacturer can supply exact data regarding the efficiency of speed increasers). This loss of
efficiency and the cost of the speed increaser must be compared to the reduction in cost for
the smaller generator. It is recommended that speed increaser option should not be used for
unit sizes above 5 MW capacity.

The required civil features are different for horizontal units than for vertical units.
Horizontally mounted tube turbines require more floor area than vertically mounted units.
The area required may be lessened by slant mounting, however, additional turbine costs are
incurred as a large axial thrust bearing is required. Excavation and powerhouse height for a
horizontal unit is less than that required for a vertical unit. typical Tube turbines of Bharat
Heavy Electricals based on runner diameter is shown in Figure 4.2.1.

4.2.2 Bulb Turbines

Bulb Turbines are horizontal, which have propeller runners directly connected to the
generator. The generator is enclosed in a water-tight enclosure (bulb) located in the turbine
water passageway. The bulb turbine is available with fixed or variable pitch blades and with
or without a wicket gate mechanism. Performance characteristic are similar to the vertical and
Tube type turbines previously discussed. The bulb turbine will have an improved efficiency

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 of approximately 2% over a vertical unit and 1% over a tube unit because of the straight
water passageway.

Due to the compact design, powerhouse floor space and height for Bulb turbine installations
are minimized. Maintenance time due to accessibility, however, may be greater than for
either the vertical or the tube type turbines. Figure 4.2.2 shows transverse section of bulb
turbine installation proposed for Mukerain SHP 2 x 9 MW rated and design head 8.23 m.

4.2.3 Vertical Semi-Kaplan Turbine With Syphon Intake

Low specific speed Vertical semi-Kaplan turbine set above maximum tailrace level with
Syphon intake with adjustable runner blade and fixed guide vane. As the name suggests, the
Vertical Turbine with Syphon Intake operation on the Syphon Principle i.e. the intake flume
chamber valve is closed and made water tight and vacuum is created by a vacuum pump
which enables water to enter flume chamber and energise the runner. Shut down is brought
about by following the reverse procedure i.e. by breaking vacuum. Since turbine operates on
a Syphon Principle, it is not necessary to have Intake and Draft gates thereby reducing the
cost. The Syphon Intake semi Kaplan Vertical Turbine part load efficiency at about 30% load
is about 76%. Turbine is suitable for variable head also. Dewatering and drainage
arrangements are also not requested.

This type of turbine has been found to be most economical for canal drop falls (upto 3-4 m
head). The turbine is set above maximum tailwater level and hence lower specific speed. A
typical installation is shown in fig. 4.2.3.

4.2.4 Pit Type Bulb Turbine

Pit type turbine is a variation of S-type arrangements. Typical pit Turbines coupled to
standard high speeds generator through step up bevel/helical gears are generally used. Overall
efficiency is lower because of gear box. Maximum size depends upon gear box and is
generally limited to 5 MW. Higher sized units upto 10 MW have been recently installed.
Performance data of these units is not available. Typical installation is shown in figure 4.2.4
(a & b).

4.3 Impulse Turbines

An impulse turbine is one having one or more free jets discharging into an aerated space and
impinging on the buckets of a runner. Efficiencies are often 90% and above. In general,
an impulse turbine will not be competitive in cost with a reaction turbine in overlapping range
(Fig. 5.1). However, economic consideration (speed) or surge protection requirements may
warrant investigation into the suitability of an impulse turbine in the overlapping head.

Single nozzle impulse turbine have a very flat efficiency curve and may be operated down to
loads of 20% of rated capacity with good efficiency. For multi-nozzle units, the range is even
broader because the number of operating jets can be varied (figure 4.3.2).

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AHEC/MNRE/SHP Standards/E&M Works – Guidelines for Selection of Turbine and     9 
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 Fig. 4.2.1 Typical Dimension of Tube Turbine (Source: BHEL India)

Fig. 4.2.2 Bulb Turbine for Mukerian SHP 2 x 9 MW

(Source: AHEC Specification)

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 Fig. 4.2.3: Syphon Intake for Tejpura Project
(Source: AHEC Specification)

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 Fig. 4.2.4 (a)

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 Fig. 2.3.4

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 Fig. 4.3.1 Impulse Turbine for Kitpi Project (2 x 1500 KW) –AHEC Project

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 Typical Efficiency Versus Load Curves

Fig. 4.3.2 Francis Versus Pelton Performance. Typical efficiency versus load
characteristics for a low specific speed Francis turbine and a six-jet Pelton turbine with
the optimal number of jets in service are compared

Control of the turbine is maintained by hydraulically operated needle nozzles in each jet.
In addition, a jet deflector is provided for emergency shutdown. The deflector diverts the
water jet from the buckets to the wall of the pit liner. This features provides surge
protection for the penstock without the need for a pressure valve because load can be
rapidly removed from the generator without changing the flow rate.

Control of the turbine may also be accomplished by the deflector alone. On these units
the needle nozzle is manually operated and the deflector diverts a portion of the jet for
lower loads. This method is less efficient and normally used for speed regulation of the
turbine under constant load.

Runners on the modern impulse turbine are a one-piece casting. Runners with
individually attached buckets have proved to be les dependable and, on occasion, have
broken away from the wheel causing severe damage to powerhouse. Integral cast runners
are difficult to cast, costly and require long delivery times. However, maintenance costs
for an impulse turbine are less than for a reaction turbine as they are free of cavitation
problems. Excessive silt or sand in the water however, will cause more wear on the
runner of an impulse turbine than on the runner of most reaction turbines.

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 The runner must be located above maximum tailwater to permit operation at atmospheric
pressure. This requirement exacts an additional head loss for an impulse turbine not
required by a reaction turbine.

Impulse turbines may be mounted horizontally or vertically. The additional floor space
required for the horizontal setting can be compensated for by lower generator costs on
single nozzle units in the lower capacity sizes. Vertical units require less floor space and are
often used for large capacity multi-nozzle units.

Horizontal shaft turbines are suitable for small hydro applications that have less water
available.

Multi-jet turbines are slightly more costly than single jet turbines; however, the more rapid
accumulation of stress cycle alternations justify a more conservative runner design.
Abrasive martial entrained in the water will erode the buckets of a multi-jet turbine more
rapidly than in the case of a single jet per runner.

For the same rated head and flow conditions, increasing the number of jets results in a
smaller runner and a higher operating speed. Therefore, whether vertical or horizontal,
multi-jet turbines tend to be less costly for comparable outputs because the cost of the
runner represents up to 20% of the cost of the entire turbine.

A deflector is normally used to cut into the jet when rapid power reductions are required
such as a complete loss of connected-load. The deflector is mounted close to the runner on
the nozzle assembly and typically is provided with its own servomotor. Cross section of 2
jet pelton turbine of Kitpi project is at figure 4.3.1

4.3.1 Turgo Impulse Turbines

Another type of impulse turbine is the Turgo impulse. This turbine is higher in specific
speed than the typical impulse turbine. The difference between a Pelton unit and a Turgo is
that, on a Turgo unit, the jet enters one side of the runner and exits the other side. The
Turgo unit operates at a higher specific speed, which means for the same runner diameter as
a Pelton runner, the rotational speed can be higher. The application head range for a Turgo
unit is 15 meters to 300 meters. Turgo units have been used for application up to 7,500 kW.
Efficiency of turgid impulse turbine is about 82 to 83 %.

4.4 Cross Flow Turbines

A cross flow turbine is an impulse type turbine with partial air admission.

Performance characteristics of this turbine are similar to an impulse turbine, and consist of a
flat efficiency curve over a wide range of flow and head conditions.

Peak efficiency of the cross flow turbine is less than that of other turbine types previously
discussed. Guaranteed maximum efficiency of indigenous available turbines is about 60-
65%.

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 Fig. 4.4 (i) Cross section view of Jagthana Cross Flow SHP (2 x 50 kW) – AHEC Project

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 Fig. 4.4 (ii) Side view of Jagthana SHP (2 x 50 kW) with cross flow turbine
(AHEC project)

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 Floor space requirements are more than for the other turbine types, but a less complex
structure is required and a savings in cost might be realized. Efficiency of cross flow
turbine of standard 300 MW dia. tested in AHEC testing labs is attached as Annexure 2
and average about 54.5%. Cross section and Side view of cross flow turbine of Jagthana
SHP is at figure 4.4 (i) & (ii).

5. SELECTION OF HYDRAULIC TURBINE

General – The net head available to the turbine dictates the selection of type of turbine
suitable for use at a particular site. The rate of flow determines the capacity of the
turbine. The term specific speed is generally used in classifying types of turbines and
characteristics within type as shown in figure 5.1. This figure is based on ASME guide to
design of hydropower mechanical design 1996 and modified by Indian Projects date
attached as Annexure-1. Exact definition of specific speed is given later. Impulse turbines
have application in high head hydropower installations. Application of impulse turbine in
low head range is limited to very small size units.

Application range of the three types of turbine is overlapping as shown in figure 5.1.
Description & Application of important turbine types is as follows:

Various types of turbines have already been explained in Para 4.0. selection criteria of
hydraulic turbine upto 5 MW units size (including micro hydels) is generally based on
using standard turbines. Hydraulic turbine above 5 MW unit size are generally tailor
made and selection criteria is more specific.

Specification require that the manufacturer be responsible for the mechanical design and
hydraulic efficiency of the turbine. Objective of these guidelines is to prepare designs and
specification so as to obtain a turbine that result in the most economical combination of
turbine, related water passages, and structures. Competitive bidding for the least
expensive turbine that will meet specification requirements is required. In evaluating the
efficiency of a proposed turbine, the performance is estimated on the basis of experience
rather than theoretical turbine design. Relative efficiency of turbine types is shown in
figure 4.3.2 and 5.2. The peak efficiency point of a Francis turbine is established at 90%
of the rated capacity of the turbine. In turn, the peak efficiency at 65% of rated head will
drop to near 75%.

To develop a given power at a specified head for the lowest possible first cost, the turbine
and generator unit should have the highest speed practicable. However, the speed may be
limited by mechanical design, cavitation tendency, vibration, drop in peak efficiency, or
loss of overall efficiency because the best efficiency range of the power efficiency curve
is narrowed. The greater speed also reduces the head range under which the turbine will
satisfactory operate.

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 Note: Details of SHP marked on the chart are attached as Annexure-1 (Based on ASME–Guide to Hydropower Mechanical Design Book)

Fig. 5.1 Ns Versus Head. This figure shows the various turbine type as a function of specific speed (Ns) and head. This figure should be
used a guideline, as there is overlap between the various turbine types with respect to their operating ranges

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 The selection of speed and setting described in these guidelines is satisfactory for
conditions normally found at most sites and will usually result in a balance of factors that
will produce power at the least cost.

5.1 Specific Speed (Ns) – The term specific speed used in classifying types of turbines
and characteristics of turbines within types is generally the basis of selection procedure.
This term is specified as the speed in revolutions per minute at which the given turbine
would rotate, if reduced homologically in size, so that it would develop one metric horse
power at full gate opening under one meter head. Low specific speeds are associated with
high heads and high specific speeds are associated with low heads. Moreover, there is a
wide range of specific speeds which may be suitable for a given head.

Selection of a high specific speed for a given head will result in a smaller turbine and
generator, with savings in capital cost. However, the reaction turbine will have to be
placed lower, for which the cost may offset the savings. The values of electrical energy,
plant factor, interest rate, and period of analysis enter into the selection of an economic
specific speed. Commonly used mathematically expression in India for specific speed is
power based (English System) is as follows:
Nr√Pr
Ns = -------------
Hr (5/4)
Where Nr = revolutions per Minute
Pr = power in metric horse power at full gate opening – (1 kW = 0.86
metric hp)
Hr =rated head in m.

The specific speed value defines the approximate head range application for each turbine
type and size. Low head units tend to have a high specific speed, and high-head units to
have a low specific speed.

Ns, kW Units = 0.86 Ns metric horse power unit

Flow based metric system for specific speed (Nq) used in Europe is given by equitation
below.

NQ 0.5
Nq =
H 0.75
Where Nq = Specific Speed
N = Speed in rpm
Q = Flow in cubic meters/second
H = Net Head in meters

Specific speed (metric HP units) range of different types of turbines is as follows:

Fixed blade propeller turbines - 300 – 1000

Adjustable blade Kaplan turbines - 300 – 1000
Francis turbines – 65 – 445
Impulse turbines –
i) Pelton Turbine per jet 16-20 per jet For multiple jets the power is
proportionally increased
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 ii) Cross flow turbine 12-80

Following standards and monographs are good guides for selection of hydraulic
Turbines.

i) IEC 1116- 1992-10 – Electro-mechanical equipment Guide for small hydro

electric installation

ii) IS 12837 – 1989 – Hydraulic Turbines for Medium and Large Power
Houses – Guidelines for Selection
iii) IS 12800 (Part 3) 1991 – Guide lines for selection of hydraulic turbines,
preliminary dimensioning and Layout of surface Hydro-Part 3 Small Mini and
Micro Hydroelectric Power Houses
Engineering Monograph No. 20 entitled ‘Selection of Hydraulic Reaction turbines’
issued by the US Bureau of Reclamation (USBR) is given below.

5.2 Selection Procedure for small hydro upto 3 MW unit size

5.2.1 General : Selection procedure for small hydro (SHP) including micro hydel unit
size is determined from techno-economic consideration as per Para 1.6.

Preliminary selection for type of small hydro turbine can be made from figure 5.2 which
is based on IEC –1116 – 1992 as modified by actual data (Annexure-3) of large no. of
small hydros installed in the country. Kind (within type) and configuration (horizontal or
vertical) may be based on economic consideration including cost of civil works,
efficiency etc. Standard turbines available for discharge and head in the country as per
data given by some manufacturers (table 5.1) and attached in CBI & P publication No.
175 – 1983 entitled “Small Hydro power Stations standardization are attached as
annexure and listed below for guidance.

These lists provide following information for the turbine.

Rated head; discharge; unit size and runner diameter and configuration. Range of head
and discharge not available in the list may be asked from the manufacturer. Runner
diameter may be used for preliminary layout of the turbine as pre IS 12800 part (3) for
economic evaluation. Relative efficiency of type and configuration is given in Para 2.

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 3. Efficiency of indigenous cross flow turbine is about 60 - 65%.
4. Peak efficiency at design head and rated output is about 2-5% higher.
Fig. 5.2 Turbine Efficiency Curves (Source IS: 12800)

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 Note: Details of SHP marked on the chart are attached as Annexure-2

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 Fig. 5.3.1 Turbine Operating Regimes (Based on IEC:1116)
Table 5.1
Standard Turbine data by some of the manufacturers in India

Annexure – 4.1 BHEL – Standard Tubular Turbines

Annexure – 4.2 BHEL – Standard Kaplan Turbine
Annexure – 4.3 BHEL – Standard Francis Turbine (Horizontal Shaft)
Annexure – 4.4 BHEL – Standard Pelton Turbine (Single Jet – Horizontal Shaft)
Annexure – 4.5 Flovel – Standard Tubular Turbines – Semi Kaplan
Annexure – 4.6 Flovel – Standard Tubular Turbines – Full Kaplan
Annexure – 4.7 Flovel – Standard Pit Type Francis Turbine
Annexure – 4.8 Flovel – Standard Francis Turbine (Spiral Casing Type)
Annexure – 4.9 Jyoti – Standard Tubular Turbines
Annexure – 4.10 Jyoti – Standard Francis Turbines
Annexure – 4.11 Jyoti – Standard Pelton Turbines
Annexure – 4.12 Jyoti – Standard Turgo Impulse Turbine
Annexure – 4.13 HPP – Standard Vertical Kaplan Turbine

5.2.2 Turbine Efficiency

Typical efficiency curves of the various types of turbines are shown for comparison in
Fig 5.2. These curves are shown to illustrate the variation in efficiency of the turbine
through the load range of the design head. Performances of the various types of turbines
when operated at heads above and below design head are discussed. Approximate
efficiency at rated capacity for the reaction turbines are shown for a turbine with a throat
diameter of 300 mm. Rated efficiency will increase as the size of the turbine increases.
The bottom curve shows the relationship of efficiency to throat diameter. The rated
efficiency for turbines with throat diameters larger than one foot may be calculated in
accordance with this curve. This curve was developed from model test comparison to
apply the step-up value throughout the operating range.

The efficiency curves shown are typical expected efficiencies. Actual efficiencies vary
with manufacturer and design.

To find the approximate efficiency for a turbine refer Figure 5.2 determine the
approximate throat diameter from 6.2 or 6.3 and find the size step up factor in the bottom
curve. Add this value to the rated efficiency values given for the approximate turbine
type. Size step up efficiency factors do not apply to impulse or cross flow type turbines.
The values as shown may be used. Note, that these curves can only be used when the
head on the turbine does not vary and less precise results are warranted. In micro hydel
range turbine efficiencies are lower.

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 5.2.3 Turbine Performance Curves – Figures 5.2.3.1 and 5.2.3.2 show performance
characteristics for Francis, Kaplan (variable pitch blade propeller with wicket gates).
Propeller (fixed blades with wicket gates) and Tube (variable pitch blades without wicket
gates) type turbine. These curves were developed from typical performance curves of the
turbines of a special speed that was average for the head range considered in the
guidelines. Comparison of performance curves of various specific speed runners were
made and the average performance values were used. The maximum error occurs at the
lowest Pr and was approximately three percent. These curves may be used to determine
the power output of the turbine and generator when the flow rates and heads are known.
The curves show percent turbine discharge, percent Qr versus percent generator rating,
percent Pr throughout the range of operating heads for the turbine.

Following determination of the selected turbine capacity the power output at heads and
flows above and below rated head (hr) and flow (Qr) may be determined from the curves
as follows:

Calculate the rated discharge Qr using the efficiency values-

Qr = Pr / (rv x hr x nt.r x ng), (m3/s)

Where,

rv = specific density of water in N/m3

nt.r = Turbine efficiency at rated load (%)

Compute the % discharge, % or and find the % Pr on the approximate hr line. Calculate
the power output.

P = % Pr x Pr (kW)

The thick lines at the boarder of the curves represent limits of satisfactory operation
within normal industry guarantee standards. The top boundary line represents maximum
recommended capacity at rated capacity.

The turbine can be operated beyond these gate openings; however, cavitation guarantee
generally do not apply these points. The bottom boundary line represents the limit of
stable operation. The bottom limits vary with manufacturer. Reaction turbines experience
a rough operation somewhere between 20 to 40% of rated discharge with the vibration
and/or power surge. It is difficult to predict the magnitude and range of the rough
operation as the water passageway configuration of the powerhouse effects this condition.
Where operation is required at lower output, strengthening vanes can be placed in the
draft tube below the discharge of the runner to minimize the magnitude of the
disturbance. These modifications reduce the efficiency at higher loads. The right hand
boundary I established from generator guarantees of 115% of rated capacity. The head
operation boundaries are typical, however, they do vary with manufacturer. It is seemed
that these typical performance curves are satisfactory for preliminary feasibility
assessments.

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 Pr = γ w, hr , Q r , η t. r η g (kW)

Where,

Pr = Rated capacity at hr
Hr = Selected Design Head
Qr = Turbine Discharge at h r ε Pr
η t. r = Turbine efficiency at h r ε Pr
η g = Generator efficiency , ( %)

Figure 5.2.3.1 Francis and Kaplan performance curves

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 Pr = γ w, hr , Q r , η t. r η g (kw)

Where,

Pr = Rated capacity at hr
Hr = Selected Design Head
Qr = Turbine Discharge at h r ε Pr
η t. r = Turbine efficiency at h r ε Pr
η g = Generator efficiency , ( %)

Figure 5.2.3.2 Propeller turbine performance curves

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 When the % Pr for a particular selection is beyond the curve boundaries, generation is
limited to the maximum % pr for the hr. The excess water must be bypassed. When the %
Pr is below the boundaries, no power can be generated. When the hr is above or below the
boundaries, no power can be generated.

The optimum number of turbines may be determined by use of these curves for annual
power consumption. If power is being lost because the % Pr is consistently below the
lower boundaries, the annual produced by lowering the kW rating of each unit and adding
a unit should be computed. If the total construction cost of the powerhouse is assumed to
roughly equal the cost of the turbine and generator, the cost per kWh derived above can
be doubled and compared with the financial value of the energy. If the selection of more
turbines seems favorable from this calculation, it should be pursued in further detail with
more accurate studies. Conversely, the first selection of the number of turbines may be
compared with a lesser number of units and compared on a cost per kWh basis as
described above.

Following the establishment of the numbers of units, the rating point of the turbines can
be optimized. This generally is done after an estimate of the total project cost have been
made. Annual power production of turbines having a higher rating and a lower rating
should be calculated and compared to the annual power production of the turbine
selected. With the annual estimate, cost per kWh may be calculated for the selected. With
the annual estimate, cost per kWh may be calculated for the selected turbine. Total
project cost for the lower and higher capacity ratings may be estimated by connecting the
turbine/generator costs from the cost chart and correcting the remaining costs on a basis
of constant cost per kW capacity. Rates of incremental cost divided by incremental
energy generation indicate economic feasibility.

The rated head of the turbine can be further refined by optimization in a similar manner.
The annual power production is computed for higher and lower heads with the same
capacity rating. The rated head yielding the highest annual output should be used. The
boundaries established on these curves are typical. Should energy output of a particular
site curtailed, it is suggested that turbine manufacturers be consulted as these boundaries
can be expanded under certain conditions.

5.2.4 Micro Hydel Range (upto 100 kW): A large number of micro hydel in remote hilly
areas are being installed to supply power to remote villages.

• Electricity for lighting and appliances (fan, radio, TV, computer, etc), in homes and
public buildings such as schools and clinics
• Electrical or mechanical power for local service and cottage industries
• Electrical or mechanical power for agricultural value-adding industries and labour
saving activities
• Electricity for lighting and general uses in public spaces and for collective events

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 The electricity provided is in the form of 415/240-volt AC line connections to users, with
11 kV sub transmission, if required.

These are generally high head schemes. A typical micro hydel scheme is shown in figure
5.2.4. Selected turbine efficiency and speed is of paramount importance for cost effective
installation as illustrated below:

5.2.5 Cost Elements in small and micro hydel power projects as per National Consultants
recommendations UNDP – GEF Hilly Projects is shown in figure 5.2.4.

These cost elements are for type of micro hydel in remote hilly area. Efficiency of indigenous
turbines in the microhydel range is approx. as follows:

Pelton - 90%
Turgo Impulse - 80%
Cross flow - 60%
Francis - 90% (Peak Efficiency at 90%)

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 Fig. 5.4

Fig. 5.2.5 Maximum Civil Features Cost (High Head Scheme)

Minimum weighted average efficiency of turbine and generator set (η Tv) 0.50x ηT100+ 0.5 η
T50 specified in micro hydel standard issued by AHEC (extracts at Annexure 5). Accordingly
weighted average efficiency of different category (size) of micro hydel is as follows:-

Category A Category B Category C

Upto 10 –45 kW Upto 50 kW Upto 100 kW

45% 50% 60%

5.3 Step by step procedure for selection of turbine is detailed below:

1) Obtain Field Data as follows:

a) Discharge data - Q cumecs

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 b) Head - H head in meter
c) Voltage Net work (415 volts or 11 kV)
d) Nearest grid sub-station (optional) – kV and length of interconnecting line

2) Compute kW capacity (P) with available data from site

P = Q x H x 9.804 x 0.8

3) Fix unit size, number and installed capacity based on data collected and requirement.
4) Using kW; H and Q per unit select usable turbine from figure 5.3.
5) In case of turbine in overlapping range determine speed and specific speed relation and
determine synchronous speed based on applicable range of specific as per Para 5.1.
Higher speed machine is cost effective.
6) Review turbine limitation (Para 4) and fix turbine type as per micro hydel standard
(Annexure-5)

5.4 Cost/kW Comparison of 100 kW 60 m head, Run of the river scheme using
different type of turbine based on cost element as per figure 5.2.2 is given in table 5.3.
The civil works i.e. intake weir, settling tank, canal, penstock and power house costs is
dependant upon quantity of water required for generation i.e. proportional to efficiency.
Rough cost comparison between cross flow; Turgo Impulse and Pelton/Francis turbine
is based on indigenous available turbines.

Table 5.3

Item Cross flow Turgo Impulse Francis Remarks

Civil works 45% (For Francis 35100 29700 27000
turbine)

Electro-mechanical 1000/1500 rpm

generator for francis
i) Turbine 3940 4320 4800 and turgo impulse and
ii) Generator 750 rpm gen. For
11220 10200 10200 cross flow
iii)Equipment

Direct cost 50260 44220 42000

Engineering and Indirect cost 21540 18951 18000
Total cost/kW 71800 63172 60000

Francis turbines costs although higher by 20% reduce cost/kW by 20%.

5.5 Examples of Turbine Selection (micro hydel range)

5.5.1 Napalchyo MHP (Uttarakhand)

Site Data Q = 0.674 cumecs

H = 62 m
P = 9.80 x 0.674 x 62 x 0.80

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 = 327.61 kW

Installation proposed based on load survey = 2 x 100 kW

Turbine selection (with following particulars)

Power (P) = 100 kW

Head = 62 m

i) As per IEC 1116- (Fig. 5.3.1), Francis turbine requiring a discharge of 0.2 cumec per
turbine is feasible. Peak efficiency of Francis turbine as per figure 5.2 is 90% (at 90%
gate).

ii) Available standard turbine (CBI & P Annexure- 1.1 to 1.12)

Type Runner dia. Speed Peak Approved

Efficiency
Flovel Francis 450 1000 to 1500 rpm 90%
Jyoti Turgo Impulse 425 1000 rpm 85%

According Francis turbine requiring a discharge of 0.2 cumecs per turbine and 0.4 cumecs for 2
turbines required. Civil work may be designed for 0.45 cumecs (10% + 5% margin). Pumps as
turbine (mixed flow) can also be used. Check for part load efficiency.

5.5.2 Rong Kong MHP (Uttarakhand)

Site Data Q = 0.441

H = 51.0
Power required = 1 x 50 kW

Available power = 9.80 x 0.441 x 51 x 0.8

= 176.32
Installation Proposed –1 x 50 kW

Turbine Selection (with following particulars)

Power (P) = 50 kW
Head = 51 m

i) As per IEC 1116- (Fig. 5.3.1), Francis Turbine requiring a discharge of 0.1 cumec per
turbine is feasible. Peak efficiency of Francis turbine as per figure 5.2 is 90% (at 90%
gate).
ii) Available standard turbine (CBI & P- Annexure 4.1 to 4.12)

Type Runner dia. Speed Peak Approved

Efficiency
Flovel Francis 450 1000 to 1500 rpm 90%
Jyoti Turgo Impulse 350 1000 rpm 85%

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 According Francis turbine requiring a discharge of 0.1 cumecs per turbine. Civil work may be
designed for 0.25 cumecs (10% + 5% margin) for two turbine (one for future). Check for part
load efficiency.

5.6 Mini Hydro in the Range 0.1 MW to 5 MW

Selection Procedure

1) Field Data Required

a) Discharge data - Q cumecs

b) Head - H head in meter
c) Voltage Net work (415 volts or 11 kV)
d) Nearest grid sub-station (optional) – kV and length of interconnecting line

2) Compute kW capacity (P) available from site

P = Q x H x 9.804 x 0.8

3) Fix unit size, number and installed capacity based on data collected.
4) Using kW; H and Q per unit select usable turbine from figure 5.3.
5) In case of turbine in overlapping range determine speed and specific speed relation and
determine synchronous speed based on applicable range of specific as per Para 5.1.
Higher speed machine is cost effective.
6) Select standard available turbine with highest synchronous speed and best efficiency
range (Annexure 1.1 to 1.12).

5.7 Example of turbine selection (mini hydro range)

5.7.1 Sobla Power House (high head)

Site Data

A common penstock bifurcating at the powerhouse into a wye branch for each power unit
is proposed. The length of the penstock system including Y-branch length is 340 meters.

Details of hydraulic system and basic data for design of turbine as extracted from the
specifications is given below :

(1) Full reservoir/max. Forebay level (m) 1935

(2) Minimum draw down level (m) 1934
(3) Maximum gross head (static) (m) 198
(4) Maximum net head (m) 185
(5) Minimum net head (m) 184
(6) Rated head (m) 185
(7) Elevation of centre line (m) 1737
(8) Maximum tail race level (m) 1734
(9) Diameter of each penstock (m) 1200
(10) Length of penstock (m) 340

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 (11) Permissible speed rise 45%
(12) Permissible pressure rise 20%

Discharge Data

Stream discharges available for diversion for generation of power at Sobla are given in
Table 5.7.1 A. There is no storage. Inter connection of power plant implies utilisation of
entire power generated for feeding into the grid besides supplying local loads at Sobla
and Dharchulla. Accordingly, power generation based on minimum in flows and loading
of turbine as percentage of installed capacity is shown in Table-5.7.1 B. It is clear that at
no time the part load operation is below 67%. Average plant factor during water shortage
critical months (December-April) is about 73%.

Inter connection and load characteristics

The powerhouse is proposed to be interconnected by a 33 kV lines to Kanchauti and

Dharchulla in a ring main for interconnection with U.K. Grid sub-station at Dharchulla.

Table –5.7.1 A
SOBLA SMALL HYDEL SCHEME DISCHARGES (m3/sec)

S. Month 1978 1981 1982 1983 1986 1987

No.
1. January 3.00 3.13 3.49 - 3.10
2. February 3.08 - 3.05
3. March 3.00 3.17 - 2.77
2.85
4. April 4.21 4.16 - 3.16
5. May 5.19 4.50 - >5.0
6. June 9.48 - >5.0
7. July 24.00 - 9.10
8.25
8. August 13.65 11.35 11.90
9. September 8.00 ~ ≥.8 12.10
10. October 6.20 7.71 7.90
8.00
11. November 5.20 ≥.4.8 7.05
12. December 3.10 3.40 5.67

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 Table –5.7.1 B

PART LOAD OPERATION OF SOBLA UNITS

Installation = 2 x3 MW ; Rated Head = 185 m
S.No. Month Discharge (Cumecs) Minimum Average
Average Minimum available plant factor
Power = 9.81 during
x Q.HE kW month
1. January 3.18 3.00 4356 71%
2. February 3.06 3.05 4428 73.8%
3. March 3.00 2.77 4022 67%
4. April 3.84 3.16 4588 76.4%
5. May 4.89 4.50 6533 100%
6. June 7.00 5.00 7259 100%
7. July 9.00 8.25 6000 100%
8. August 12.30 11.35 6000 100%
9. September 9.30 8.00 6000 100%
10. October 7.27 6.20 6000 100%
11. November 5.68 4.80 6969 100%
12. December 4.05 3.10 4501 75%

NOTE : Overall Efficiency assumed 80%

A small 250 kVA transformer to feed local loads at Sobla is also proposed.

Accordingly, it is considered essential to design the turbines for stand alone isolated
operation as well as for parallel operation with grid.

Turbine Selection

Rated Head (H) = 185 m

Rated Power (P) per unit = 3000 kW

As per IEC 1116- (Fig. 5.2.1) it is seen that either an impulse or Francis Turbine may be
suitable.

Specific speed (ns) is related to rotational speed (n) by specific speed ns = n√P/H5/4

ns = n√P/H5/4

= n√3000/(185)5/4
n = 12.45 ns

Runner diameter (D) and speed for various possible values of ns are computed and
compared in Table 5.7.1 C.

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 For Pelton Turbine upper practical limit of jet diameter Dj and runner diameter ratio Dj/D
= 0.1, then D is 2.1 m which corresponds to a unit with specific speed ns = 21 for single
jet pelton and about 30 for two jet turbine. Accordingly, synchronous speed of 375 RPM
pelton 2 jet turbine having runner dia of about 1.3 m is possible in case Pelton turbines
are used.
Table 5.7.1 C
S. Type of Ns n(r.p.m.) Runner Setting of Remarks
No. Turbine (metric) =12.4 ns dia (m) runner above
tailrace
10 125 4.11
A. Single Jet 15 187.5 2.74 Above
Pelton 20 250 2.06 maximum Speed nearest
15 187.5 2.74 T.W. level Synchronous
B. Double Jet 20 250 2.06
Pelton 30 375 1.30
60 750 0.675 +5.0 m -do-
C. Francis 80 1000 0.54 +0.7 m -do-
100 1250 Synchronous Speed
Not Possible
120 1500 0.4 –1.1 Speed nearest
Synchronous

Pelton turbines can be coupled directly to 375 r.p.m. (16 pole) generator or 750 r.p.m. (8
pole) generator through speed increasing gears.

For Francis turbine a 6 pole machine 1000 r.p.m. can be set 0.7 m above minimum
tailwater and may be economical to use. Four pole, 1500 r.p.m. generators coupled to 120
(ns) turbines are also feasible and are cavitation free but not recommended due to high
speed low inertia in generators and lower setting.

5.7.2 Comparison of 375 r.p.m. Pelton Turbine and 1000 r.p.m. Francis Turbine

1. Cost of directly coupled pelton turbine generator set will be more (about 2.5
times that of Francis Turbine coupled generators) and those coupled through
speed increasers by about 1.5 – 2 times.
2. Selection of low specific speed Francis turbine (1000 r.p.m.) with a setting of 0.7
m above minimum tailwater level is possible and is liable to be cavitation free.
3. Excessive silt or sand in the water will cause more wear on the runner of an
impulse turbine than on the runners of most reaction turbines.
4. Powerhouse size is liable to be bigger by about 70% for Pelton units. Thereby
increasing Civil Engineering cost.
5. Setting for Pelton turbine nozzle center line is proposed at EL 1737 m and
maximum tail water E.L. is 1734 m. Accordingly, if Francis turbine is used, a
minimum increase in head of 3 meters is possible. Available head will be further
increased during water shortage winter months when tail water is at lower level.
6. Peak efficiency of Pelton turbine is slightly lower than peak efficiency of Rancis
turbine but part load efficiencies of Pelton turbines are higher. The units do not
run below 70% load (Annexure-I) and 80% of the time the units are running

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 above 80-90% load. Accordingly, it is considered that Francis units will generate
more energy.
7. Penstock length (L) is 340 meter and head (H0 is 185 m. According L/H ratio is
about 1.8 indicating no water hammer problem for stable speed regulation for
Francis turbines and no special advantage for pelton turbines.

5.7.3 Conclusion & Recommendations

Proposed Pelton turbines were replaced by Francis Turbines and large economies in cost
(25-30%) were made.

5.8 Low Head Range – Canal power Houses

Cost element in a low head project such as in canal fall projects is shown in figure 5.8.
Accordingly equipment cost predominate. Cost of generators is reduced by providing speed
increasing gears and accordingly selection of turbine in important for cost affective installation.
Accordingly only high specific speed (Axial flow) is possible. Selection procedure is therefore
is to select type and configuration of axial flow turbine as clarified in example. Low Head canal
fall Schemes. Most of the canal falls in the country are below 4 – 5 meter head. Canal schemes
in the range lower that 3 meters are designed as ultra low head schemes.

Fig. 5.8 – Minimum Civil Feature (Low Head Scheme)

5.8.1 Example of Turbine Selection

a) Tejpura SHP (Bihar)

Site Data

Discharge Q = 61.05 cubic meters

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 Net head H = 3.46 meters
Power P = 9.80 x 61.05 x 3.46 x 0.85
= 1759 kW
Installation = 2 x 750 kW

Efficiency SHP range of turbine and generator has been taken as 0.85

Turbine Selection

As per IEC 1116 (Fig. 5.3) only Kaplan Axial flow turbine is feasible.

Available standard turbine CBI & P Publication (Annexure 4.1 to 4.12) is Tubular turbine S
type (Full Kaplan) or Semi Kaplan turbine with runners dia. About 2200 meter is feasible (Fig.
4.2.1). This type of turbines requires intake valve for shut off (emergency) as well as draft tube
gates for dewatering. It also requires dewatering and drainage arrangement.

Semi Kaplan vertical turbines with siphon intake as shown in fig. 4.2.3 was selected as cheapest
and cost effective alternatives (efficient) which does not require intake and draft gates and
dewatering arrangements. Detailed comparison of S type tubular turbine with vertical syphon
intake turbine is given in table 5.8.1.

Table 5.8.1
Comparison of Tubular type and vertical axis siphon intake for ultra low head (below 3 to 4 meter head)

S. No. Tubular turbine Vertical axis Remarks

(semi Kaplan) Siphon intake
1. Inlet valve Required Not required
2. Draft tube gate Required Not required
3. Drainage pump Required Not required
as setting is above
maximum tailrace
4. Dewatering pump Required Not required as setting is
Above tailrace
5. Cost of civil High (setting is low) Low
Work
6. Efficiency Tubular turbine
efficiency is 1% higher

5.8.2 Guaranteed technical Particulars of the Tejpura Mini HP

Turbines ordered is as follows:

Type of turbine – vertical semi Kaplan with siphon intake

Rated Head (H) = 3.24 m

Rated discharge (P) = 845 kW (10% overload)
Rated discharge (Q) = 30.075 Cumecs
(for rated output

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 generator terminal)
Efficiency at rated Head & output = 88.92 %
Synchronous Gen. Efficiency at rated output = 96.4 %

5.9 Selection procedure for Turbines above 5 MW Unit Size

For a small/medium low head power units reaction turbine are used. For high head multiple
jet Pelton turbine are used selection of turbine type is essential based on specific speed
criteria.

Selection of Reaction Turbines as per USBR Monograph No. 20 Criteria

1. Trial Specific speed, n′s

Select trial specific speed from figure 5.1 or from economic analysis. Except for unusual
(
circumstances, the selecting specific speeds is near 2334 / hd metric . )
2. Trial Speed, n′ :

n′s (hd ) n′s hd

5/4
n′ = or
(Pd ) 1/ 2
⎛ Pd ⎞
1/ 2

⎜ 1/ 2 ⎟
⎜h ⎟
⎝ d ⎠
where
n′ = trial rotational speed,
n′s = trial specific speed,
hd = design head, and
Pd = turbine full gate capacity at hd

3. Rotational speed or design speed, n :

The rotational speed nearest the design speed is selected subject to the following
considerations:

a. A multiple of four poles is preferred, but standard generators are available in some
multiples of two poles.
b. If the head is expected to vary less than 10% from design head, the next greater
speed may be chosen. A head varying in excess of 10% from design head suggests
the next lower speed.

120 . frequency
Rotational speed, n =
number of poles
6000
n= at 50 Hz
number of pole

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 4. Design specific speed, ns:

1/ 2
⎛ P ⎞
n⎜⎜ 1d/ 2 ⎟⎟
n(Pd )
1/ 2
or ⎝ d ⎠
h
ns =
(hd )5 / 4 hd

The design specific speed is the basic parameter to which most other factors of the selection are
made.

5.9.1 Example of Turbine Selection above 5 MW Unit Size (Matnar Project,

Chhatisgarh)

1. Turbine Basic Data

I. Rated design head : 57.75 m

II. Rated Turbine Discharge : 41.57 cumecs
III. Total discharge : 124.72 cumecs
IV. Maximum tailrace level : 468.25 m
V. Rated output at rated head and : 20 MW
rated discharge (at generator terminals)

Net design head (hd) = 57.75 m

Turbine full gate capacity at rated load (10% overload on generator 96% generator
efficiency and 5% margin.

Generator rated o/p = 20,000 kW

(10% overload capacity) = 22,000 kW
20000 × 1.10 × 1.05
Turbine rated o/p required = = 27980 MHP
0.96 × 0.86

2334
Trial Specific Speed (n′s ) = (meteric)
hd
2334
= = 307 (Graph 5.1 shows ns = 250)
57.75

n' s ×(hd ) 5 / 4
Trail Rotational Speed (n′) =
Pd

307 × (57.75) 5 / 4
= = 292.2 ≅ 300 or 250
27980

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 Design Speed

Head is expected to vary less than 10% from design head and h the next greater speed
may be chosen.

Accordingly 10 pole (5 pairs pole) generator with design speed of 300 rpm is optimum
choice.

Design Specific Speed (ns)

n Pd
ns =
(hd )5 / 4
300 27980
= = 315.21
(57.75)5 / 4
= 315

Discharge Diameter (D3)

Velocity ratio (φ) = 0.0211 (ns )
2/3

= 0.0211 (315)
2/3
= 0.9768
84.47 × Φ × hd
D3 =
n
84.47 × 0.9768 × 81.37
=
300
= 2.09 m

Manufacturer

M/s BHEL intimated following parameters for the turbine of Matnar project

Design head = 57.75 m

Turbine output = 20000 kW (without 10% overloads)
Rated speed = 300 rpm
Runner dia. = 2.08 m
With 10% overload speed = 272.7 rpm

6. SETTING AND CAVITATION OF REACTION TURBINE

Highest sped practicable at specified head is required for lowest possible cost. In addition
greater speed requires the reaction turbine (Francis and Propeller/Kaplan) to be placed
lower with respect to the tailwater to avoid cavitation. This generally increases
excavation and structural costs.

Cavitation results from sub-atmospheric pressure at places on runner and runner chamber.
To minimize this problem the turbine runner is set at depths below the minimum tail

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 water to obtain a countering pressure. The appropriate value of the depth of setting for
runner of different specific speed is computed using a characteristic ‘cavitation
coefficient’ for the particular specific speed, as follows :

Z = (Ha – Hv) – σH
Where,
Z = Depth of centre line of runner below minimum level of tail water
Ha = Atmospheric pressure in meter water column at plant elevation
Hv = Vapour pressure in metres at plant location temperature
H = head on turbine, meters
σ = Plant sigma or cavitation coefficient for the turbine specific speed
The value for σ may be found from the expression which is as follows :

σ=
(ns )1.64
50.327
The value of σ can also be taken from the curves relating ns and σ shown in fig. 6.1.

The value of σ for Francis turbines are lower than those for Propeller of Kaplan turbines.
The setting level for the latter is consequently lower than for Francis turbine. Many low
ns Francis turbines will yield setting levels above minimum tail water level and same may
be the case with Kaplan/ Propeller turbines of very low heads Pelton turbines are set
above the maximum tailwater level.

Lower setting (below tailwater) results in higher speed and hence smaller runner diameter
fig. 6.2 & 6.3 shows correlation runner diameter and settling for Francis and propeller
turbines.

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Govering System for Hydroelectric Projects
 Fig. 6.1 Reaction Turbine
(Source: USBR Engineering Monograph No. 20)

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 In Meter

NOTES :

1 Estimated turbine runner diameters D are based upon a plant elevation of 600 m. and a
tailwater height (Hs) of zero. Where Hs = distance between minimum tail water level and
exit of runner blades.

2 The estimated runner diameters may be used for both vertical and horizontal Francis
turbines.

3 For plant elevations higher then 600 m add 1% to D for each 300 m. Subtract 1% from D
for each 300 m. slower then the 600 m plant elevation.

Figure 6.2 Francis turbine runner diameters

(Source: Guide manual – us. Army corps of engineers)

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 In Meter

Hs Tailwater Height (m) Hs Distance from

minimum Tailwater to D
NOTES:

1 Estimated turbine runner diameters D are based upon a plant elevation of 600 m.
and a tailwater height (Hs) of zero. Where Hs = distance between minimum tail water
level and exit of runner blades.
2 The estimated runner diameters may be used for both vertical and horizontal Francis
turbines.
3 For plant elevations higher then 600 m add 1% to D for each 300 m. Subtract 1% from D
for each 300 m. lower then the 600 m plant elevation.

Figure 6.3: Propeller turbine runner diameters

(Source: Guide manual – US Army corps of engineers)

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7. TURBINE PERFORMANCE

Turbine performance characteristics required to be provided considerably impact design ands

cost of hydro stations. These characteristics depend upon design of associated water passage from
forebay to tailrace and WR2 of the rotating masses of the unit.. Head loss in penstock and
pressure water system affects direct power loss and optimized by determining economic diameter
of penstock and design of bends etc. Pressure and speed regulating characteristics of turbine are
required to be provided according to performance requirement of the hydroelectric stations by
optimizing pressure water system design and generator inertia WR2/ GD2.

7.1 Pressure regulation

With normal operation i.e. with load accepted or rejected either slowly as the system
requires or rapidly during faults, pressure water system follow slow surge phenomena
and depends upon the rate of closing the guide vanes/nozzle. The wicket gate closing
time is always kept much greater than critical closure time (Tc) i.e. the time of reflection
2l
of the pressure wave, this time, Tc = where l is the length of the pressure water
a
system from tailrace to forebay/ surge tank and a is the velocity of the sound in water
(wave velocity).

Pressure water column inertia is expressed as starting up time (Tw) of water column,

∑ LV
Tw =
gh
Where Tw = starting up time of the water column in seconds

∑ LV = L1 V1 + L2 V2 + ……… Ln Vn + Ld Vd

Ln = length of penstock in whcih the velocity is uniform

Vn = velocity in section Ln at rated turbine capacity,
Ld = draft tube developed length
Vd = average velocity through the draft tube,
h = rated head of the turbine
g = gravitation constant

During preliminary stage of planning simple and short methods of calculating the
pressure regulation as given in following references be adopted.

• Brown, J. Guthrie, Hydro-electric Engineering Practice, Volume 2.

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 • Engineering Monograph No. 20, Selecting Hydraulic Reaction Turbines, United
States Department of the Interior, Bureau of Reclamation USA.

Allievies formula for pressure variation in decimals is given by

∆H
H
=
n
2
{
n ± n2 ÷ 4 }
LV Tw
Where n = = or in case of uniform penstock dia.
gHT T
L - length of penstock + ½ the length if the spiral casing
H – head in meter
T – governor closing time in seconds
V – velocity in m./sec.
4L
This formula is sufficiently accurate only of T > where a is the wave velocity.
a
Note – Use plus for pressure rise and minus for pressure drop.
Pressure rise in percentage is also given by
∆H L × HP × 54
= 2
H D × H 2 ×T
Where T, L & H are same as above;
D – diameter of penstock in meter
HP – rated metric Horsepower

7.2 Speed Regulation

The speed regulation or stability of a hydro-electric unit may be defined as its inherent
property to ensure that changes in external conditions as well as in the turbine and
governing equipment result an a periodic or rapidly damped, periodic return to the new
steady state. Stability over the normal operating range with the machine connected to the
system and stability after disconnection can be considered independently. Most hydro-
electric stations are interconnected and as such their satiability is assisted. The more
important factors upon which the stability of interconnected units depend are the flywheel
effect of the unit, the hydraulic design of the water passages and speed and capacity of
the unit. The GD2 should be sufficient to insure prompt response to power demands and
to restrict speed rise following loss of load. But generator GD2 should be restricted to
avoid excessive power swings. Additional GD2 built into the generator increases the cost,
size and weight of the machines and increasing GD2 more than 50 percent above normal
decreases the efficiency.

Flywheel effect is expressed as starting up time of the unit (Tm). This is the time in
seconds for torque to accelerate the rotating masses from 0 to rotational speed

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 GD 2 × n 2
Tm = (metric units)
3.6 × 105 × P

Where GD2 = Product of weight of rotating parts and square of the diameter

n = rotational speed rpm

P = Turbine full gate capacity in metric horse power

Governor is the main controller and discussed in Para 8.

7.3 Speed Rise

Sudden dropping of load from a unit through opening of the main breaker will cause a
unit to achieve considerable speed rise before the governor can close the gates to the
speed-no-load position. The time required to attain a given over speed is a function of the
flywheel effect and penstock system. The values of speed rise for full load rejection
under governor control is considered an index of speed regulating capability of the unit.
Normally adopted range is from 30 to 60 percent, the former applies to isolated units,
where changes of frequency may be important when sections of distributed load are
rejected by electrical faults. Values from 35 to 60 percent are generally adopted for grid
connected hydro station. Generally units for which length of the penstock is less than five
times the head can be make suitable for stable frequency regulation of the interconnected
system. Also units for which Tm ≥ (Tw)2 can be expected to have good regulating
capacity. This test should be applied over the entire head range. Plants in which more
than one turbine are served from one penstock should be analyzed to determine proper
governor settings and appropriate operating practices. Such plants may be unable to
contribute to system transient speed regulation but adverse effects upon the system may
be avoided by specifying the number of units which may be allowed to operate on free
governor (unblocked) at any one time.

The turbine and generator are designed to withstand runaway speed, but at excessive
speed severe vibrations sometimes develop which snap the shear pins of the gate
mechanism. To minimize vibration, a speed rise not to exceed 60% can be permitted in
contrast to the 35 to 45% desired for satisfactory regulation of independently operated
units.

Considerations for permissible speed rise on full load rejection are as follows:
7.3.1 Small Hydro (grid connected)

Small hydro if grid connected (with no isolated and or islanding provision) cannot take
part in frequency control. Accordingly these should be designed for upto 60% speed rise
on full load rejection. In canal fall or similar units, speed control is required only during
synchronizing. Generator loading should be controlled by level i.e. non speed control
governors can be used and loading on the units is controlled by upstream canal water
level. These are called non speed control governors.

7.3.2 Small Hydro (isolated grid operation)

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 These should be designed as frequency control units for the criteria that speed rise on full
load rejection does not exceed 35%.

7.4 Pressure Rise and Speed Rise Calculation

The penstock pressure rise and unit speed rise may be calculated from the references
given in Para 7.1 entitled ‘pressure regulation’. These could also be calculated as follows,
which is based on USBR design monograph no. 20 referred in Para 7.1. Economic studies
required to be carried out to determine whether more than normal GD2, a larger penstock,
a surge tank or a pressure regulator is required. Some examples follow :

7.5 Method for Computing Speed Rise

Notation :-

Tf = Servomotor minimum closing time, sec.

Pr = Turbine full gate capacity of hr, kW
hr = Rated head, metre
n = Rotational speed: design, r/min.
ns = Design specific speed, metric kW unit
GD2 = Flywheel effect of revolving parts; kgm2
L = Equivalent length of water conduit, m
A = Equivalent area of water conduit, m2
g = Gravitational constant (acceleration), m/s2
P
Qr = = Turbine full gate discharge, m3/s
h r x 9.804 x 0.8
Qr
Vr = = Conduit water velocity for full gate at hr, m/s
A
Tm = Mechanical startup time
Tw = Water startup time

To obtain the speed rise for full load rejection, determine the following values :-

(a) TK = 0.25 + Tf, full closing time of servomotor(s)

GD 2 x n 2
(b) Tm =
3.6 x 10 5 x Pr
TK
(c)
Tm
n ( pr )
1/ 2
(d) ns = At rated condn, metric kW unit
(hr )5/4

TK
(e) Determine SR from fig. 7.5.1 using ns &
Tm
Where,
SR is speed rise in percent of rotational speed,
n1 for full gate load rejection to zero, excluding effect of water hammer.
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 ∑ LV r
(f) TW = (water start up time)
ghr
TW
(g) K=
Tf
(h) S1R = SR (1 + K), speed rise in percent of rotational speed nr for full gate load
rejection to zero, including effect of water hammer.

Fig. 7.5.1 – Turbine Performance

(Based on USBR Design Monograph no. 20)

Example-1

Given :-

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 Tf = 5 sec, Pr = 29851 kW, hr = 24.38 metre
1
Nsr = 94.7, GD2 = WR 2 = 8873333.34 kgm2
6
Vr = 4.199 ≈ 4.2 metre/sec
L = 103.63 metre

(a) TK = 0.25 + 5 sec (0.25 in dead time

= 5.25 sec

GD 2 x n 2 8873333.34 x (94.7) 2 7.957685199 x 1010

(b) Tm = = =
3.6 x 10 5 x Pr 3.6 x 10 5 x 29851 1.074636 x 1010

= 7.40

TK 5.25
(c) = = 0.709
Tm 7.40

n Pr (94.7) 29851 kW
(d) n sr = = = 302.02
(n )
r
5/ 4
(24.38) 5 / 4
= 302 MkW

(e) SR = 28.1% from Chart A (Figure 7.5.1)

103.63 x (4.2)
(f) Tw = = 1.8198
9.81 x 24.38
Tw = 1.82

Tw 1.82
(g) K= = = 0.364
Tf 5

(h) S1R = (28.1) (1 + 0.364) = 38.32

Example-2

Data

Length of Penstock (L) = 153.5 m

Penstock Dia (D) = 1.289 m
Penstock thickness = 0.00889 m = 8.89 mm
Rated unit output = 1750 kW (including 10% over load capacity)
(full gate) (1750 x 1.34 = 2345 HP units)

Rated Head (h) = 46.634 m

(full gate)

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 Maximum pressure rise = 30%
in penstock

First Step:- Fix closing time for 30% speed rise

Assuming governor closing time of 4 seconds

P
Rated Discharge (Qr) =
hr × 9.804 × 0.8
1750
=
46.63 × 9.804 × 0.8

= 4.78 cusecs

Velocity of water (Vr) = Q/A (A – cross sectional area of penstock)

4.78 4.78
= =
π / 4 × (1.289)2
0.7854 × 1.661521

= 3.662 m/sec.

Governor closing time (assumed) = 4 second

Guide vane closing time assuming (t0) = 4 + 0.25 = 4.25 second

(0.25 sec. as dead time)

Gravitational Constant (g) = 9.81 m/sec2

LV
Water starting up time (Tw) =
gH

153.5 × 3.66
=
9.81 × 46.63

= 1.228 second

Pressure rise on full load rejection using Alliivies formula

∆H
H
T
2
{ 2
= w Tw + Tw + 4 }
LV 1.2287
Where Tw = = = 0.2894 = 0.29
gHT 4.25

L = Length of penstock + Length of Spiral Casing = 153.5

H = Head in meter = 46.63

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 T = Governor closing time 4 seconds

V = Velocity in meter/second = 3.66 m/s

g = 9.81 m/s2

∆H
H
=
0.29
2
{
0.29 + 0.292 + 4 }
= 33.50%

Speed Rise and WR2

Normal WR2 of Gen. & Turbine 42000 lb/ft2 (GD2 = 7 Tm2)

GD 2 × n 2 7 × 103 × 7502
Mechanical starting up time Tm = = = 6.25 seconds
3.6 × 102 × Pr 3.6 × 105 × 1750
Closing time of servo motor Tk = 4 seconds (full closing time of servomotor)

Tk 4
= = 0.645
Tm 6.2

n P 750 1750 31374.751

Specific speed nsr = 5/4
= = = 257.48 = 258 ( m units)
h 46.635 / 4 121.48
Speed rise Sr = 26.5% (from figure 7.5.1)
Tw = 1.23

Tw 1.23
k= = = 0.3075
Tf 4
S'R = (26.6) (1 + 0.3075)
= 34.779 = 34.78%

8. HYDRO-TURBINE GOVERNING SYSTEM

8.1 Introduction

Governor control system for Hydro Turbines is basically a feed back control system
which senses the speed and power of the generating unit or the water level of the forebay
of the hydroelectric installation etc. and takes control action for operating the
discharge/load controlling devices in accordance with the deviation of actual set point
from the reference point.

Governor control system of all units suitable for isolated operation are a feed back control
system that controls the speed and power output of the hydroelectric turbine. Water level
controllers can be used for grid connected units. Governing system comprises of
following sections.

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 a) Control section
b) Mechanical hydraulic Actuation section

Speed
Hydraulic
Setpoint Pressure Oil
Power
Water To Turbine Control
Level Turbine Device (Gates,
Governor Control
Unit Speed Controller Blades, Needles, Mechanical Motor
Actuator Deflectors, Load)\

Optional Load
Feedbacks

Fig. 8.1 – Basic Governor Control System

The control section may be mechanical; analogue electronic or digital. Actuator can be
hydraulic controlled, mechanical (motor) or load actuator. Load actuator are used in
micro hydel range; mechanical (motor operated) may be used say upto 1000 kW unit
size. Hydro actuator are mostly used.

8.2 Type of Governor Control Section

8.2.1 Mechanical Controller

By the middle of 20th century, mechanical governors directly driven by prime movers
through belt were used for small machines. The speed of rotation was sensed by fly-ball
type pendulum. In second-generation mechanical governors, permanent magnet generator
and pendulum motor were utilized for sensing the speed of the machine. The isodrome
settings were achieved through mechanical dashpot and droop setting by link mechanism.
These mechanical governors were fully capable of controlling the speed and output of the
generating unit in stable manner. In case of faulty pendulum, manual control of the units
was possible with handles and knobs. This was PI type controller.

8.2.2 Electro-Hydraulic Governor – Analogue Electronics

Next came the third generation Electro-Hydraulic Governors where speed sensing,
speed/output setting and stabilizing parameters were controlled electrically and the use of
mechanical components was reduced considerably. They increased the reliability,
stability and life of the equipment and facilitated more functional requirements. The
design of electrical part of the governors kept changing based on the advancement in
electronics and development work by individual manufacturers. In this type of gov3ernor
analogue circuitry is used to develop set point signal that is used to position the control
actuators of hydroelectric units. An electro hydraulic interface is used to connect the
electronic set point signal into a hydraulic oil flow from a hydraulic servo valve system
which determine the position of the turbine control actuators. This sis a PID controller.

8.2.3 Electro Hydraulic Governor – Digital Governors

In digital governor, digital controller is used in turbine governing system. This is also
PID controller. Digital control hardware running an application programme accomplishes

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 the required control function with this system. Digital controller used for turbine
governing system are very flexible and can be used for functions not directly related to
the turbine governing control function.

Present day trend is to use digital governing control system in hydroelectric units. The
major advantages of microprocessor based system over the earlier analogue governors
(based on solid state electronic circuitry) are higher reliability, self diagnostic feature,
modular design, flexibility of changing control functions via software, stability of set
parameters, reduced wiring and easy remote control through optical fibre cables.
Microprocessor based governor control system are capable of carrying out the following
control functions in addition to speed control during idle run , operating in isolated grid;
interconnected operation and islanding operation.

• Control the power output depending on variation in grid frequency i.e. load
frequency control
• Joint power control of a number of generating units in a power station
• Power control as per water levels in Fore-bay and/or Tail-race
• Automatic Starting / Stopping by single command
• Fast response to transient conditions
• Control from remote place Supervisory Control And Data Acquisition (SCADA)

8.3 Turbine Control Actuator System

Actuator system compares the desired turbine actuator position command with the actual
actuator position. In most of the hydroelectric units it requires positioning of wicket gates
in reaction turbines, spear in pelton turbines and turbine blades in Kaplan turbines. In
load actuators it shunt load bank is adjusted. Pressure oil system with oil servomotor is
most commonly used actuator.

8.3.1 Governor Capacity (oil servomotor)

The size, type, and cost of governors vary with their capacity to perform work which is
measured in (meter-kilograms). Mechanical governor having a capacity of more that
8300 m kg. Are of cabinet actuator type. These having a capacity less than 7000 m kg.
Are gate shaft type.

The capacity is the product of the following factors: turbine gates servomotor area,
governor minimum rated oil pressure, and turbine gates servomotor stroke. For gate shaft
governors, the turbine gates servomotor area is the net area obtained by subtracting the
piston rod area from the gross piston area. For governors controlling two servomotors
mounted directly on the turbine, the effective area is the sum of the net area of the two
servomotors.

Servomotor capacity can be estimated by the formulas:

1. Wicket gates servomotor capacity.

FYM = 34 (hwh Dg.M)1.14(metric)

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 Where
M = wicket gate height
hwh = maximum head, including water hammer, and
Dg = wicket gate circle diameter

2. Blade servomotor capacity (adjustable blade propeller turbine). - The blade

servomotor capacity also varies among manufacturers. This can be roughly estimated
by the formula:

6.17 Pmax (ns )

1/ 4
FYb = metrics
(H max )1 / 2
Where
Hmax = maximum head,
ns = design specific speed, and
Pmax = turbine full-gate capacity at Hmax.

8.4 Small Hydro Governor Selection Consideration

Actuator and Control systems for small hydro units especially in developing countries
have to be selected keeping in view the following:

(a) Traditional flow control governor with mechanical hydraulic actuator is complex
demanding maintenance and high first cost. Further performance requirements of
stability and sensitivity i.e. dead band, dead time and dashpot time especially for
interconnected units may not be met by mechanical governors.
(b) Electronic and Digital flow control governors can be take up plant control
functions.
(c) Cost of speed control and automation with currently installed analog flow
governors, unit control and protection systems is high. These systems require
attended operation and are mostly based on large capacity hydro units. This is
making most of the units very costly and uneconomical to operate.
(d) The manpower as available is unskilled and further adequate supervision is not
feasible.
(e) Load factors for stand-alone micro hydels are usually low affecting economic
viability.
(f) Flow Control Turbine Governors are expensive and not recommended for small
hydro units in micro hydel range. Electronic load control governing system with
water cooled hot water tanks as ballast loads for unit size upto 100 kW are cost
effective. This will make a saving of about 40% on capital cost. The generator
flywheel is not required. If the thyristor control (ELC) is used then the alternator
needs to be oversized upto 2%% on kVA to cope with the higher circulating
current induced. Accordingly, in case of small units upto 100-150 kW size
elimination of flow control governors using load actuator with digital speed

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for Selection of Turbine and     59 

Govering System for Hydroelectric Projects
 controller make these units economically viable and properly designed will
eliminate continuous attendance requirement.
(g) Data storage function can be added to the Digital Governors control system with
hard disk (i.e. PC).
(h) The dummy loads in the Shunt Load Governors (ELC) can be useful load system
or can be used for supplying domestic energy needs.
(i) Digital generation controllers were evolved to take care of speed control, unit
control and automation, unit protection and every generation scheduling and have
been successfully in operation for over ten years.
(j) Programmable logic control (PLC) based systems are with aotmation by personal
computers are reliable and have been in operation in India.
(k) As dedicated PC based systems for complete generation control can be easily
adopted for data acquisition and storage at a nominal cost and can also be
adopted to SCADA system.
(l) Manual back up and or redundant control system are provided.

8.4.1 Application of Governor Control System to SHP

Selection of the type of controller to be used in SHP may be based on the

recommendations of the American, European and Indian consultants for the UNDP-GEF
project for Himalayan range. These recommendations are given in table 8.1 with
following aspects.

(a) Ease of adoption

(b) Sustainability
(c) Cost saving potential
(d) Over all rating

8.5 Personnel Computers (PC) /Programmable Logic Controller (PLC) based

Digital Governors

Modern control schemes also utilise personal computers (PCs) in conjunction with PLC
control systems. The PCs are utilized with man-machine interface (MMI) software for
control display graphics, historical data and trend displays, computerized maintenance
management systems (CMMS), and remote communication and control. In addition, the
PLC programming software is usually resident on the PC, eliminating the need for a
separate programming terminal implement or change the PLC software coding.

A PC also can be used for graphical displays of plant data, greatly enchancing operational
control. Standard Microsoft-based graphical display software packages are available for
installation on a standard PC. The software package can be utilized on the PC to create
specific powerhouse graphical displays based upon real-time PLC inputs. These displays
typically include control displays with select-before-execute logical, informational
displays for plant RTD temperatures, or historical trending plots of headwater, tailwater,
and flow data.

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Govering System for Hydroelectric Projects
 Modems with both dial-out and dial-in capabilities can be located in either the PC, the
PLC, or both to provide off-site access to plant information. These modems may also be
utilised to control the plant operation from a remote location.

Programmable Logic Controller (PLC) type plant controllers with a manually operated
back up system combined with PC based SCADA system are used as Governors and for
Plant control and data acquisition. This makes the system costly but reliability is stated to
be good and can be used for small hydro generation control. It is considered that
dedicated digital control systems which is digital P.C. based can perform all functions of
governing, unit control and protection as well as for data storage and can be more
economical, dependable and are being manufactured in U.S.A., Europe, India and other
countries. These dedicated systems with back up manual control facility of speed control
in emergency by dedicated semi automatic digital controllers can be an option and is also
recommended for UNDP-GEF projects in India.

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Govering System for Hydroelectric Projects
 Table 8.1: GOVERNORS, CONTROLS AND MONITORING SYSTEMS, TECHNOLOGY

Rating by MHPG (European Consultant) Comments

Concept Ease of Sustainability Cost saving Overall MHPG Mead & Hunt AHEC
adoption potential rating
Load Control 3 2 3 2.7 Most useful on non-grid Not considered Most useful on
connect sites, upto 500 kW. unit size upto 200
Could save more than 20% kW on both grid
due to spin effects. & non grid
connected.
Analogue integrated 3 2 2 2.3 Low cost solution for upto Not considered Not recommended
governor and plant 500 kW grid connect. cost high.
control.
Digital integrated 3 2 2 2.3 Preferred solution for large Not considered Preferred solution
governor and plant grid connect schemes. for schemes with
controller Savings where optimisation unit size above
or complex operation 250 kW.
needed.
PLC controller 3 2 1 2 Useful for larger schemes Recommended Recommended
with separate governors.
Data Logger 3 3 2 2.7 Available in India, suitable Data storage Data storage and
for isolated schemes using and retrieval retrieval as part of
analogue or flow control recommended Digital Gov.
governing. by P.C. system.

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Govering System for Hydroelectric Projects
 Monitoring and control and data acquisition system (SCADA system) can be a part of the
P.C. based digital governor and generation control equipment. Provision of data storage
of one month with 16 MB of Ram memory and a 540 to 850 MB Hard Drive as part of
the PC based governing and control system should be provided. This data could be
retrieved on a floppy drive after one month for examination. As the communication links
develop the data can also be transmitted via a Modem to a remote point for examination
and supervisory control.

Auxiliary control normally forms a part of digital governor. It is further recommended

that water jet diverters of emergency closure of inlet valves be provided to avoid
overspeeding to runaway in case of governor failure emergency.

8.6 Governing System used in India

Basically there is no difference in governors used for large generating units and small
units except for sizes, operating pressure and control features as per requirement of
individual project. Also for smaller units, hydro-mechanical part of governor is built on
the sump of oil pressure plant for compactness. Higher operating pressure is used to
reduce sizes of control elements and pipelines. Nitrogen cylinders are used in place of
pressure air to avoid use of high-pressure air compressors. Oil pipelines of sizes upto 50
mm are used in stainless steel with ermeto (dismantlable) couplings to reduce welding
and maintain cleanliness.

Following types of governing system are used:

Micro Hydel - Digital speed control system will load actuator is used.
(upto 100 kW)
Small Hydros - Flow control governing system with hydraulic actuator
Upto 3 MW and digital PID speed and power control system. Mechanical
motor type actuator have also been, used upto 1000 kW unit size
with microprocessor based level control PI Controller
Small Hydro - Flow control PID governor with hydraulic actuator
Above 3 MW

Governing system including controller and actuator used for different capacity
powerhouses designed by AHEC and consultants is given in Table 8.2.

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Govering System for Hydroelectric Projects
 Table – 8.2

Sl. Project Name Controller Actuator Remarks

No.
Arunachal Pradesh Energy Development Agency
1. Pein Small Hydro Power Digital governor Oil pressure
Project (Phase I) (2 x 1500 PLC based servomotor
kW), District Lower Subansiri alongwith plant
control capability
with PC (SCADA)
2. Pareng Small Hydro Power Digital governor Oil pressure
Project (2 x 3000 kW), District PLC based servomotor
Papumpare alongwith plant
control capability
with PC (SCADA)
3. Sie Small Hydro Power Project Digital governor Oil pressure
(2 x 2800 kW), District West PLC based servomotor
Siang alongwith plant
control capability
with PC (SCADA)
Uttarakhand Renewable Energy Development Agency
1. Nagling Micro Hydro Power Digital controller Load Actuator
Project (2 x 25 kW), District (Electronic Load
Pithoragarh Controller)
2. Dugtu Micro Hydro Power Digital controller Load Actuator
Project (1 x 25 kW), District (Electronic Load
Pithoragarh Controller)
3. Kuti Micro Hydro Power Digital controller Load Actuator
Project (1 x 50 kW Phase I), (Electronic Load
District Pithoragarh Controller)
4. Rong Kong Micro Hydro Digital controller Load Actuator
Power Project (1 x 50 kW (Electronic Load
Phase I), District Pithoragarh Controller)
5. Sela Micro Hydro Power Digital controller Load Actuator
Project (2 x 25 kW), District (Electronic Load
Pithoragarh Controller)
6. Borbadala Micro Hydro Power Digital controller Load Actuator
Project (1 x 25 kW), District (Electronic Load
Bageshwar Controller)
7. Chillud Gad Micro Hydro Digital controller Load Actuator
Power Project (2 x 50 kW), (Electronic Load
Uttarkashi Controller)
8. Nepalchyo Mini Hydro Power Digital controller Load Actuator
Project (2 x 100 kW), District (Electronic Load
Pithoragarh Controller)
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Govering System for Hydroelectric Projects
Bihar State Hydro Electric Power Corporation Ltd.
1. Rajapur Small Hydro Power PLC based digital Oil pressure
Project (2 x 350 kW), District electronic governor servomotor
Supaul
2. Natwar SHP Project Digital Controller Oil pressure
(2 x 250 kW), District Rohtas servomotor
3. Jainagara SHP Project Digital Controller Oil pressure
(2 x 500 kW), District Rohtas servomotor
4. Belsar SHP Project Digital Controller Oil pressure
(2 x 500 kW), District servomotor
Jehanabad
5. Rajapur Small Hydro Power Digital Controller Oil pressure
Project (1 x 700 kW), District servomotor
Supaul
6. Shirkhinda SHP Project Digital Controller Oil pressure
(2 x 550 kW) servomotor
7. Walidad SHP Project Digital Controller Oil pressure
(1 x 700 kW), District servomotor
Jehanabad
8. Arwal SHP Project Digital Controller Oil pressure
(1 x 500 kW), District servomotor
Jehanabad
NTPC Ltd., Singrauli (U.P.)
Singrauli SHP Project Digital Governor Oil pressure
(2 x 4000 kW), District with integrated plant servomotor
Sonebhadra control with PC
(SCADA)

8.7 U.S. Practice Regarding Governor and Control

Type of Scheme

Two basic control schemes utilized for small and medium hydro stations are (1) a single
PLC with a manually operated back-up system, and (2) a redundant.

PLC system. There are various modifications of these two basic schemes, which depend
upon the individual plant requirements and owner preference. The single PLC offers the
advantages of low cost and simplicity, and is typically based up by a hardwired system.
With a redundant PLC system, backup control and memory are provided by a second
PLC. Advantages and disadvantages of the two schemes are summarized in Table 8.3 and
8.4.

Table 8.3 : Advantages and Disadvantages of the Redundant PLC Control Scheme

Advantages Disadvantages
• 100 percent backup for the central processing unit • Cost. The cost of a second PLC exceeds the
(CPU). The CPU includes the processor, system cost of a manual backup system.
memory, and system power supply.

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Govering System for Hydroelectric Projects
• Continued automatic control of the nit under • Complexity. Most small hydro plant operators
headwater level or discharge control with one PLC are not technically trained for troubleshooting
out of service. This ability allows continued PLCs (some of this complexity is offset by the
maximizing unit revenue when a PLC fails. PLC and I/O card self-diagnostics now
available.

• Uniform spare parts. Only one set of I/O cards • Failure of both systems simultaneously.
needs to be maintained. Items such as spare relays Although redundant PLCs do enhance system
and control switches associated with a hard-wired reliability, they can be prone to simultaneous
failure caused by surge. Owners should insist
system are not required. on good surge protection engineering.
• Software problems. If software is non-
standard, software problems will be common
to both PLCs.

Table 8.4 : Advantages and Disadvantages of a Single PLC with Manually Operated
Backup System

Advantages Disadvantages
• Less expensive than a redundant PLC • Headwater level or discharge control (if
system. performed by the PLC) is disabled whenever
the PLC is disabled. When utilizing the
manually.

• Less chance of a common mode failure • Operated backup system for control, the
because the hardwired system is less prone unit’s output is set a the operator’s
to surge-induced failures and more tolerant discretion. An operator will usually allow a
of inadequate grounds. safety margin of approximately 10 percent in
headwater or discharge level to avoid
problems such as drawing air into the
penstock. As a result, maximum possible
revenue for the unit is usually not realized
during manual operation.

• Operator familiarity with trouble shooting • Nonuniform spare parts. Spare parts would
hardwired relay systems. have to provided for both the PLC system
and the manually operated backup system.
However, it should be noted that relatively
few spare parts would be needed for the
manual backup system, due to its simplicity.

In either unit control scheme, all unit protective relays should be independent from the
programmable controllers. This independence will allow the protective relays to function

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Govering System for Hydroelectric Projects
 even if the PLC fails, ensuring the safety of unit equipment and personnel. For the single
PLC scheme with a manually operated back-up system, it is usually best to have an
independent resistance temperature detector (RTD) monitor and annunicator panel
functionally operative during manual operation of the unit. These additional panels will
provide the operator vital information which will facilitate operation of the plant in the
manual mode.

8.8 Examples of Typical Governing Systems

i) 2 x 30 kW Microhydel with Synchronizing, Assam Project (isolated

operation) – Fig. 8.2 & 8.3

Digital controller and load actuator (Electronic Load Controller) – Project by

Prof. O. D. THAPAR Consultant, AHEC

ii) 2 x 500 kW – Satpura SHP project - (Fig. 8.4)

Electronic Digital Level Controller with induction generator – grid connected –

Project by Prof. O. D. THAPAR Consultant, AHEC

iii) 2 x 1000 kW –SHP project Newzeland -(Fig. 8.4)

Electronic Digital Level Controller with synchronous generator – grid connected

with motor operated mechanical actuator, for peak load operation with a limited
storage pool Project by Prof. O. D. THAPAR Consultant, AHEC for M/s Jyoti
Ltd.

iv) 2 x 3000 kW – Sobla SHP project (Fig. 8.5)

PC based a digital PID controller with oil pressure servomotor actuator with
synchronous generator suitable for isolated/grid connected operation with back
up manual control and integrated plant control and off site control facility -
Project by Prof. O. D. THAPAR Consultant, AHEC for M/s Jal Viduyat Nigam
Ltd. UP..

v) 2 x 9 MW – Mukerain Stage –II canal fall SHP project (Fig. 8.6)

PLC Digital PID Controller with oil pressure servomotor actuator with
Synchronous Bulb generator – grid connected with redundancy and redundant PC
based automation (AHEC Project)

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Govering System for Hydroelectric Projects
 Fig. 8.2

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for Selection of Turbine and     68 

Govering System for Hydroelectric Projects
 Fig. 8.3

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for Selection of Turbine and     69 

Govering System for Hydroelectric Projects
 Fig. 8.4- Water Level Controllers

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for Selection of Turbine and     70 

Govering System for Hydroelectric Projects
 Fig. 8.5 (a) PC Base Sobla Projects Governing System with Plant Control

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for Selection of Turbine and     71 

Govering System for Hydroelectric Projects
 Fig. 8.5 (b)

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Govering System for Hydroelectric Projects
 LEGEND

12-X OVERSPEED,SYNCHRONOUS SPEED,

AND UNDERSPEED SWITCHES
13-X
14-X
65SF SPEED SIGNAL FAILURE
39C CREEP DETECTOR OPERATION
15FM -LS SPEED REFERENCE M OTOR DRIVE
SPEED & POWER CONTROL SECTION MECHANICAL/HYDRAULIC IC ACTUATOR LIM IT SWITCHES
65PM -LS POWER REFERENCE INDICATION

SPEED 52 UNIT ON-LINE

SETPOINT 15FM LS
ADJUSTM ENT 27PS GOVERNOR POWER SUPPLY FAILURE
M ANUAL 65SS START-STOP SOLEM OID AUXILIARY
GATE GATE ACTUATOR CONTACTS COM PLETE SHUTDOWN
LIM IT CONTROL LOCK
65SNL PARTIAL SHUTDOWN (SPEED-NO-LOAD)
POWER AM P SOLENOID AUXILIARY CONTACTS
13-X 12-X P & ELECTRIC-
HYDRAULIC
TRANSDUCER OPEN WICKET 26QS GOVERNOR HYDRAULIC SYSTEM SUM P
GATE SERVOM OTORS TANK FLUID TEM PERATURE HIGH

HYDRAULIC AMLIFICATION CLOSE WICKET 63Q

14-X

SPEED GOVERNOR HYDRAULIC SYSTEM

SENSING I GATE SERVOM OTORS PRESSURE SWITCHES

WICKET GATE 71QP GOVERNOR HYDRAULIC SYSTEM

POSITION PRESSURE TANK LEVEL SWITCHES
PILOT SERVOM OTOR SWITCHES
D 71QS GOVERNOR HYDRAULIC SYSTEM SUM P
65SF 39C POS FDB TANK LEVEL SWITCHES
WICKET
GATE 63AR GOVERNOR HYDRAULIC SYSTEM AIR RELIEF
POSITION WICKET GATE VALVE OPERATION
SPEED SHUTDOWN POSITION
REGULATION R SENSING 33WGL WICKET GATE AUTOM ATIC LOCK
& START-UP
(DROP) AUXILIARIES APPLIED/RELEASED
V 65WGLF WICKET GATE AUTOM ATIC LOCK FAILURE
63AB GENERATOR AIR BRAKES APPLIED
65SS 65SNL
63ABS GENERATOR AIR BRAKE SUPPLY
POWER 26QS 63AR PRESSURE LOW
I
TDCR FIRE DETECTION SYSTEM OPERATION/TROUBLE
49F

GATE
POSIN
TRANSDUCER TILT BLADES

71QP
GATE POWER GOVERNOR UNIT BLADE ON
SETPOINT SETPOINT HIGH PRESS (HYDRAULIC FLATTEN BLADES
ADJUSTER ADJUSTM ENT OIL SYSTEM AM PLIFICATION)

63Q
BLADE POSITION

BLADE OIL LKG

65PM -LS 6Q 71QS
63ABS 63AB 65WGLF 33WGL

APPLY GATE S
WICKET GATE ERVO LOCK
SERVOM OTOR
ON-LINE/ GOVERNOR LOCK CONTROLS RELEASE GATE
OFF-LINE POWER SERVO LOCK
SENSING SUPPLY

APPLY GEN
GENERATOR BRAKES
AIR BRAKE
52 27PS CONTROLS SUPPLY AIR

FIRE
DETECTION &
49F

EXTINGUISHING

Fig. 8.6 Electric Hydraulic Turbine Governor Control & Monitoring System
(Mukerian Stage-II canal fall project 2 x 9 MW Bulb turbine)

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Govering System for Hydroelectric Projects
 Annexure-1
Indian Project Data
Source: - Bharat Heavy Electrical Ltd. India Publication Entitled “Hydro-Electric
Installation”

Sl. POWER CUSTOME NO. OF HEA SPEE YEAR SPECI TYPE OF REMARK
N STATION R UNITS× D D OF FIC TURBIN
o. SIZE(M (M) (RPM COMM’I SPEED E
W) ) NG (Ns)
1. Parbati NHPC 4×200 789.0 375.0 2006 48.57
Stage-II
2. Varahi KPCL 2×115 460.0 250.0 1989 48.20 Generatin
3. Sharavathy KPCL 2×89.1 439.5 300.0 1976 56.55 g
4. Chukha Chukha 4×84 435.0 300.0 1986 53.00
Sets
project
Authority,
with
Bhutan
5. Tillari GOM 1×60 628.8 500.0 1986 47.11
Pelton
6. Bihai Taiwan 1×62.5 416.8 495.0 2005 79.58
Power Co.
Turbine
Taiwan
7. Kuttiyadi KSEB 2×50 625.0 500.0 2005 43.33
AES
8. Pykara TNEB 3×50 1027. 600.0 2005 27.95
Ultimate 0
9. Malana MPCL 2×43 480.0 500.0 2001 55.89
10 Lower National 2×27.68 400.0 428.6 1993 48.28
. Sungai piah Electricity
Board,
Malaysia
11 Bassi HPSEB 4×15 335.7 500.0 1970 51.61
.

12 Khandong NEEPCO 2×25 99.0 333.3 1984 204.37

. Generatin
13 Kakkad KSEB 2×25 123.5 428.6 1999 199.34 g
.
14 Mahi Stage-I RSEB 2×25 40.0 150.0 1986 285.53
. Sets
15 Doyang NEEPCO 3×25 67.0 250.0 2000 249.74
.
16 Khara UPSEB 3×24 42.6 187.0 1992 322.37 with
.
17 Pattani EGA 3×24 58.0 214.3 1981 251.19 Turbine
. Thailand Francis only
18 Tenom Pangi SEB 3×22 66.6 300.0 1983 283.24
. Malaysia

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Govering System for Hydroelectric Projects
19 Kundah-V TNEB 1×21.6 259.1 750.0 1988 128.42 Turbine
.
20 Madhikheda MPEB 3×20 52.75 250.0 2005 301.19
.
21 Rangit NHPC 3×20 129.6 428.6 2000 167.76
. 7
22 Birsinghpur MPEB 1×20 40.0 200.0 1991 340.51
.
23 Poringal KSEB 1×16 165.3 600.0 1999 155.07
. Kuthu
24 Bhatsa GOM 1×15 70.0 375.0 1991 274.71
.
25 Sumbal Govt. of J&K 2×11.3 149.0 500.0 1973 123.65
. Sindh
26 Gumma HPSEB 2×1.5 176.7 1500. 2000 109.17
. 5 0
27 Karnah Govt. of J&K 2×1.0 36.0 750.0 1991 325.72
.

28 Balimela APSEB 2×30 35.8 187.5 2008 449.13 Generatin

. Dam g
29 Donkarai APSEB 1×25 21.0 136.4 1983 580.99
. sets
30 Mukerian PSEB 6×19.5 22.0 166.7 1989 591.68
. Phase-III & with
IV
31 SYL Phase-I PSEB 2×18 15.3 136.4 2010 732.41 Kaplan Likely
. Year of
Turbine Comm’ing
32 UBDC PSEB 3×15 17.1 166.7 1989 711.05
. Stage-II
33 UBDC PSEB 3×15 17.1 150.0 1971 639.82
.
34 Mukerian PSEB 6×15 16.8 150.0 1983 654.13
. Phase-I & II
35 Bansagar MPEB 2×15 21.0 166.7 2002 550.01
. Phase-II
36 Kabini SP&ML 2×10 18.0 200.0 2003 653.29
.
37 Pochampad APSEB 3×9 21.4 250.0 1987 624.04
.
38 Mukerian PSEB 2×9 8.23 125.0 2006 1030.26
. Stage-II Generatin
39 Singur APSEB 2×7.5 18.29 250.0 1999 693.22 g
.
40 Teesta Canal WBSEB 4×7.5 8.0 142.9 1999 1113.95
. sets

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Govering System for Hydroelectric Projects
 41 Bhadra R.B. KPCL 1×6 17.0 214.0 1998 581.56
.
42 Narayanpur MPCL 2×5.8 6.5 111.1 1999 987.31 with
.
43 Suratgarh RSEB 2×2 8.66 187.5 1992 683.57
. Kaplan
44 Mangrol RSEB 3×2 7.27 166.7 1992 756.31
.
45 Sone BSHPC 4×1.65 3.7 120.0 1993 1150.37 Turbine
. Western
Canal
46 Dhupdal FORBES 2×1.4 4.8 158.0 1997 1107.71
. Gokak Mills
47 Nidampur PSEB 2×0.5 3.0 136.4 1985 935.54
.
48 Dauhar PSEB 3×0.5 3.5 136.4 1987 771.58
.
49 Ganekal KPCL 1×0.35 3.69 136.4 1994 604.27
.
50 Kakatiya APSEB 3×0.23 3.3 166.7 1987 688.37
. (19th Mile)
51 Kakroi University of 1×0.1 1.9 125.0 1988 678.63
. Roorkee

Source: Project Design by Alternate Hydro Energy Centre (AHEC), I.I.T. Roorkee

Sl. Power Sponsorer/ No. of Head Speed Year/ Likely Specifi Type of Type of
No. Station Manufactur Units x (M) (RPM year of c Turbine Generator
er Size ) Commissioni Speed
(MW) ng (Ns)

BIHAR
1. Triveni Jyoti Ltd. 2x1.50 4.94 155 1056.7 Horizontal Synchronou
SHP 0 6 Kaplan s Generator
Vertical
2. Nasarganj VA Tech. 2x0.50 3.99 166.66 28.06.2007 759.25 Vertical Synchronou
SHP 0 Semi s Generator
Kaplan Vertical
3. Jainagra VA Tech. 2x0.50 4.18 187.5 783.78 Vertical Synchronou
SHP 0 Semi s Generator
Kaplan Vertical
4. Sebari HPP Energy 2x0.50 3.66 150 745.96 Vertical Synchronou
SHP (India) Pvt. 0 Semi s Generator
Ltd. Kaplan Vertical
5. Shirkhind HPP Energy 2x0.35 3.186 135 744.89 Vertical Synchronou
a SHP (India) Pvt. 0 Semi s Generator
Ltd. Kaplan with Vertical

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Govering System for Hydroelectric Projects
 Syphon
Intake
6. Belsar HPP Energy 2x0.50 3.22 129 763.22 Vertical Synchronou
SHP (India) Pvt. 0 Semi s Generator
Ltd. Kaplan with Vertical
Syphon
Intake
7. Tejpura HPP Energy 2x0.75 3.46 107 770.77 Vertical Synchronou
SHP (India) Pvt. 0 Semi s Generator
Ltd. Kaplan with Vertical
Syphon
Intake
8. Rajapur HPP Energy 2x0.35 4.78 190 798.55 Vertical Synchronou
SHP (India) Pvt. 0 Semi s Generator
Ltd. Kaplan with Vertical
Intake Gate
9. Amethi HPP Energy 1x0.50 3.218 114 745.97 Vertical Synchronou
SHP (India) Pvt. 0 Semi s Generator
Ltd. Kaplan with Vertical
Syphon
Intake
10. Arwal HPP Energy 1x0.50 2.926 103 757.83 Vertical Synchronou
SHP (India) Pvt. 0 Semi s Generator
Ltd. Kaplan with Vertical
Syphon
Intake
11. Walidad HPP Energy 1x0.70 3.44 116 751.36 Vertical Synchronou
SHP (India) Pvt. 0 Semi s Generator
Ltd. Kaplan with Vertical
Syphon
Intake
12. Paharma City Hunan 2x0.50 3.36 166.7 1009.0 Fixed Blade Synchronou
SHP of China 0 0 Tubular s Generator
Turbine Horizontal

UTTARAKHAND

13. Dokti Nepal Hydro 1x0.02 62.0 1575 Cross Flow Synchronou
& Electric s Generator
Pvt. Ltd. Horizontal,
Kirloskar
14. Kanolgod Nepal Hydro 2x0.05 24.5 990 Cross Flow Synchronou
& Electric s Generator
Pvt. Ltd. Horizontal,
Kirloskar
15. Karmi-II Nepal Hydro 2x0.02 70 1673 Cross Flow Synchronou
& Electric 5 s Generator
Pvt. Ltd. Horizontal,
Kirloskar
AHEC/MNRE/SHP Standards/E&M Works – Guidelines for Selection of Turbine and     77 
Govering System for Hydroelectric Projects
16. Ramgarh Jyoti Ltd. 2x0.05 50 750 Cross Flow Horizontal
Jyoti Ltd.
17. Ratmoli Nepal Hydro 2x0.02 39 1250 Cross Flow Synchronou
& Electric 5 s Generator
Pvt. Ltd. Horizontal,
Kirloskar
18. Gangotri-I Vodini 2x0.05 23.6 836 Cross Flow AVK
Check 0
Republic

ARUNACHAL PRADESH
19. Kitpi-II Guglor 2x1.5 200 600 Pelton 2 Jet Synchronou
Hydro Horizontal s Generator
Energy gmbh Horizontal

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Govering System for Hydroelectric Projects
 Anexure-2
List of the Cross Flow Turbines Tested at AHEC, IIT Roorkee for UREDA

S.No. Name of Manufacturer/ Type of water mill Type of runner Runner dia Range of Testing Parameters Maximum Remarks
Supplier (mm) Head range Discharge Power Efficiency
(m) rage (lps) output
(kW)
1. M/s Gita Flopumps India Horizontal shaft Cross flow 300 9.0-12.0 28-125 0.6-8.4 56.00 Accepted
Pvt. Ltd., Saharanpur
(U.P.)
2. M/s Standard Electronic Horizontal shaft Cross flow 300 3.0-14.0 76-135 0.5-8.5 53.00 Accepted
Instruments Corpn., (open type)
Roorkee (UA)
3. M/s SBA Hydro Systems Horizontal shaft Cross flow 300 4.0-12.0 80-132 1.1-6.6 54.00 Accepted
(Pvt) Ltd. New Delhi
4. M/s Gopal Engineering Horizontal shaft Cross flow 300 3.0-8.0 75-117 2.5-9.0 55.00 Accepted
Works, Dharanaula,
Almora (UA)

Average efficiency = 54.50

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Govering System for Hydroelectric Projects
 Annexure-3

List of points showing in Fig. 5.3 (Indian Projects)

Sl. Power No. Of Head Discharge Year Of Specific

No Station Units×Size (M) (M/s) Coming Speed Ns
(MW) in (MHP)
Axial Turbine (Kaplan Turbine)
1. Nidampur 2x0.500 3.000 - 1985 935.54
2. Dauhar 3x0.500 3.500 - 1987 771.58
3. Ganekal 1x0.350 3.690 - 1994 604.27
4. Kakatiya 3x0.230 3.300 - 1987 688.37
5. Kakroi 1x0.100 1.900 - 1988 678.63
6. Jainagra SHP 2x0.500 4.180 29.62 -
7. Shirkhinda SHP 2x0.350 3.186 31.40 739.37
8. Rajapur SHP 2x0.350 4.780 23.00 791.80
9. Amethi SHP 1x0.500 3.218 2.17 Under 740.44
10. Arwal SHP 1x0.500 2.926 24.40 Construction 752.21
11. Rampur SHP 1x0.250 2.940 11.97 -
12. Natwar SHP 1x0.250 3.569 9.87 -
13. Mautholi SHP 1x0.400 2.350 25.94 -
14. Katanya SHP 4x0.250 1.780 81.12 -
15. Agnoor SHP 2x0.500 2.744 41.90 2005 -
16. Dhelabagh SHP 2x0.500 2.400 51.80 2006 -
17. Triveni SHP 2x1.500 4.940 72.52 Under -
Construction
Francis Turbine
18. Gumti 3x5.000 40.00 - 1976 283.73
19. Devighat
(ThroughNHPC) 3x4.800 40.00 - 1983 278.00
20. Gumma 2x1.500 176.75 - 2000 109.17
21. Karnah 2x1.000 36.00 - 1991 325.72
Pelton Turbine
22. Chenani 2x4.600 365.8 - 1975 30.81
23. Thirot 3x1.500 245.0 - 1995 36.29
24. Yazali 3x1.500 277.0 - 1991 31.13

MHP: - Metric hoarse power units.

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Govering System for Hydroelectric Projects
 Annexure-4.1
BHEL – Standard Tubular Turbines

Runner Dia. 1200 1500 1800 2000 2200 2500

(mm)
Head (m) Unit Output Pt (kW) and Discharge Q m3/sec.
Pt 75 to 150 150 to 225 225 to 325 325 to 400 400 to 500 500 to 625
3.0
Q 3.18 to 6.36 6.36 to 9.54 9.54 to 13.78 13.78 to 16.96 16.96 to 21.20 21.20 to 26.50
Pt 120 to 250 250 to 375 375 to 525 525 to 650 650 to 825 825 to 1050
4.0
Q 3.82 to 7.95 7.95 to 11.92 11.92 to 16.69 16.69 to 20.67 20.67 to 26.23 26.23 to 33.38
Pt 175 to 335 335 to 525 525 to 750 750 to 925 925 to 1125 1125 to 1450
5.0
Q 4.45 to 8.52 8.52 to 13.35 13.35 to 19.08 19.08 to 23.53 23.53 to 28.62 28.62 to 36.88
Pt 225 to 425 425 to 650 650 to 950 950 to 1175 1175 to 1450 1450 to 1875
6.0
Q 4.77 to 9.00 9.00 to 13.78 13.78 to 20.14 20.14 to 24.91 24.91 to 30.73 30.73 to 39.74
Pt 280 to 525 525 to 800 800 to 1175 1175 to 1450 1450 to 1775 1775 to 2300
7.0
Q 5.09 to 9.54 9.54 to 14.53 14.53 to 21.35 21.35 to 26.34 26.34 to 32.25 32.25 to 41.79
Pt 310 to 525 525 to 825 825 to 1200 1200 to 1450 1450 to 1800 1800 to 2300
8.0
Q 4.93 to 8.35 8.35 to 13.12 13.12 to 19.08 19.08 to 23.05 23.05 to 28.62 28.62 to 36.56
Pt 370 to 625 625 to 1000 1000 to 1450 1450 to 1775 1775 to 2150 –
9.0
Q 5.23 to 8.83 8.83 to 14.13 14.13 to 20.49 20.49 to 25.08 25.08 to 30.38 –
Pt 425 to 740 740 to 1175 1175 to 1675 1675 to 2050 – –
10.0
Q 5.41 to 9.41 9.41 to 14.94 14.94 to 21.30 21.30 to 26.07 – –
Pt 565 to 850 850 to 1350 1350 to 1950 1950 to 2400 – –
12.0
Q 5.99 to 9.01 9.01 to 14.31 14.31 to 20.67 20.67 to 25.44 – –
Pt 675 to 1100 1100 to 1700 1700 to 2475 – – –
14.0
Q 6.13 to 9.99 9.99 to 15.44 15.44 to 22.48 – – –
Pt 800 to 1250 1250 to 2000 – – – –
16.0
Q 6.36 to 9.94 9.94 to 15.90 – – – –

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Govering System for Hydroelectric Projects
 Annexure – 4.2

BHEL – Standard Kaplan Turbine

Runner dia. 1200 1500 1800 2000 2200 2500

(mm)
Head (m) Unit Output Pt (kW) and discharge Q (m3/sec.)

Pt 875-1250 1250-1950 1950-2800 2800-3500 3500-4200 4200-5000

16
Q 6.8-9.7 9.7-15.2 15.2-21.8 21.8-27.3 27.3-32.7 32.7-39.0

Pt 1050-1500 1500-2350 2350-3375 3375-4200 4200-5000

18 -
Q 7.3-10.4 10.4-16.3 16.3-23.4 23.4-29.1 29.1-34.6

Pt 1240-1750 1750-2750 2750-3950 3950-4875 4875-5000

20 -
Q 7.7-10.9 10.9-17.7 17.7-24.6 24.6-30.4 30.4-31.2

Pt 1350-1850 1850-2900 2900-4175 4175-5000

22.5 - -
Q 7.5-10.25 10.25-16.1 16.1-23.1 23.1-27.7

Pt 1600-2175 2175-3375 3375-4875 4875-5000

25 - -
Q 8.0-10.8 10.8-16.8 16.8-24.3 24.3-25.0

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Govering System for Hydroelectric Projects
 Annexure – 4.3

BHEL – Standard Francis Turbine (Horizontal Shaft)

Runner dia. 450 500 560 640

(mm)
Head (m) Unit Output Pt (kW) and discharge Q (m3/sec.)

Pt 400-500 500-620 620-775 775-1000

45
Q 1.00-1.30 1.30-1.65 1.65-2.05 2.05-2.65

Pt 600-775 775-950 950-1200 1200-1550

60
Q 1.20-1.55 1.55-1.88 1.88-2.40 2.40-3.10

Pt 850-1075 1075-1300 1300-1700 1700-2000

75
Q 1.35-1.70 1.70-2.10 2.10-2.70 2.70-3.17

Pt 875-1100 1100-1350 1350-1700 1700-2000

90
Q 1.25-1.55 1.55-1.90 1.90-2.40 2.40-2.80

Pt 825-1050 1050-1300 1300-1600 1600-2000

120
Q 0.80-1.05 1.05-1.30 1.30-1.6 1.6-2.00

Pt 750-950 950-1150 1150-1450 1450-1900

150
Q 0.6-0.75 0.75-0.90 0.90-1.15 1.15-1.50

Pt 950-1150 1150-1450 1450-1800 1800-2000

180
Q 0.65-0.75 0.75-0.95 0.95-1.20 1.20-1.35

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for Selection of Turbine and     83 

Govering System for Hydroelectric Projects
 Annexure – 4.4
BHEL – Standard Pelton Turbine (Single Jet – Horizontal Shaft)

Runner dia. A B C D E F G
(mm)
Head (m) Unit Output Pt (kW) and discharge Q (m3/sec.)

Pt 140-170 170-215 215-265 265-320 320-380 380-450 450-500

150
Q 0.08-0.1 0.1-0.117 0.117-0.13 0.13-0.145 0.145-0.157 0.157-0.17 0.17-0.176

Pt 210-260 260-325 325-400 400-500 500-580 580-680 680-800

200
Q 0.13-0.16 0.16-0.178 0.178-0.20 0.20-0.225 0.225-0.240 0.240-0.26 0.26-0.28

Pt 290-360 360-460 460-565 565-685 685-825 825-950 950-1100

250
Q 0.175-0.22 0.22-0.25 0.25-0.28 0.28-0.31 0.31-0.34 0.34-0.36 0.36-0.39

Pt 380-475 475-600 600-750 750-900 900-1075 1075-1250 1250-1450

300
Q 0.23-0.29 0.29-0.325 0.325-0.37 0.37-0.405 0.405-0.44 0.44-0.48 0.48-0.51

Pt 480-600 600-760 760-940 940-1150 1150-1350 1350-1580 1580-1850

350
Q 0.30-0.37 0.37-0.42 0.42-0.46 0.46-0.515 0.515-0.555 0.555-0.60 0.60-0.65

Pt 600-730 730-925 925-1150 1150-1400 1400-1650 1650-1930 1930-2000

400
Q 0.36-0.45 0.45-0.50 0.50-0.57 0.57-0.625 0.625-0.680 0.680-0.73 0.73-0.70

Pt 700-875 875-1100 1100-1350 1350-1650 1650-1975 1975-2000

450 -
Q 0.43-0.54 0.54-0.60 0.60-0.67 0.67-0.74 0.74-0.81 0.81-0.76

Pt 820-1025 1025-1300 1300-1600 1600-1950 1950-2000

500 - -
Q 0.50-0.63 0.63-0.715 0.715-0.79 0.79-0.875 0.875-0.820

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 Annexure–4.5

Flovel – Standard Tubular Turbines – Semi Kaplan

Runner 900 1150 1400 1650 1900 2150 2400 2650 2900 3200
Dia. (mm)
Head (m) Turbine/Generator Output (kW)
3 100 125 175 280 350 425 550 650 800 1000
4 100 175 275 380 500 650 800 1000 1250 1500
5 150 225 350 500 650 825 1100 1350 1600 1900
6 200 320 450 625 875 1200 1450 1700 2000 2400
7 240 380 550 800 1100 1400 1750 2000 2400 3000
8 275 420 700 950 1250 1650 2000 2375 2900 3500
9 320 520 800 1150 1500 1900 2250 2750 3400 4000
10 380 600 850 1250 1650 2100 2600 3250 3800 4500
12 420 750 1100 1450 1850 2600 3200 4000 4800 6000
14 500 800 1200 1600 2100 3000 3700 4600 5600 6500
16 500 800 1200 1700 2750 3150 4100 4600 5600 6700

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Govering System for Hydroelectric Projects
 Annexure–4.6

Flovel – Standard Tubular Turbines – Full Kaplan

Runner 1450 1650 1900 2150 2400 2650 2900 3200

Dia. (mm)
Head (m) Turbine/Generator Output (kW)
3 200 300 400 500 650 800 1000 1200

4 300 420 550 725 900 1050 1300 1500

5 400 550 750 925 1160 1450 1700 2000

6 500 700 950 1200 1500 1800 2150 2500

7 600 850 1200 1500 1750 2150 2500 3200

8 750 1000 1400 1725 2050 2500 3000 3600

9 800 1200 1600 1950 2400 3050 3600 4300

10 1000 1300 1700 2250 2750 3400 4000 4900

12 1150 1500 1900 2750 3400 4200 5000 6200

14 1200 1650 2100 3200 3850 4600 5650 7000

16 1200 1650 2220 3300 4200 4900 6200 7500

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Govering System for Hydroelectric Projects
 Annexure-4.7

Flovel – Standard Pit Type Francis Turbine

Runner dia. (mm) 800 1100 1400

Head (m) Turbine/generator output P (kW) and Turbine Speed N (rpm)

P 36 75 125
3
N 170 120 100

P 60 100 200
4
N 220 170 120

P 100 175 350

6
N 280 210 150

P 175 300 500

8
N 300 230 180

P 250 450 750

10
N 350 250 200

Note: Recommended generator speed – 1000 to 1500 rpm

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Govering System for Hydroelectric Projects
 Annexure–4.8
Flovel – Standard Francis Turbine (Spiral Casing Type)

Runner 450 650 800 1000 1200 1400 1600

dia. (mm)
Head range 15 to 250 15 to 300 20 to 200 20 to 150 20 to 90 20 to 70 20 to 50
(m)
Output 100 to 200 to 500 to 1000 to 1500 to 2000 to 3000 to
(kW) 1500 3000 6000 7000 8000 8000 8000
Range of 1000 500 400 375 300 250 200
speeds 1500 750 500 420 375 300 250
(rpm) 1000 600 500 428 333 300
750 600 500

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for Selection of Turbine and     88 

Govering System for Hydroelectric Projects
 Annexure – 4.9

Jyoti – Standard Tubular Turbines

Runner 260 600 750 1000 1200 1400 1650 1900 2200 2500
dia.
(mm)
Head Turbine output Pt (kW)
(m)
3 5 28 45 75 125 175 240 330 430 550
4 8 45 80 130 200 280 380 520 730 925
5 11 65 115 190 300 400 560 800 1050 1350
6 15 90 150 250 400 540 750 1000 1400 1800
7 17 115 190 300 460 700 900 1200 1650 2150
8 19 130 210 340 525 750 1000 1400 1900 2500
9 150 240 400 600 825 1150 1600 2150 2900
10 165 270 450 650 920 1250 1750 2350 3200
12.5 205 320 545 800 1200 1600 2200 3100 4000
15 240 380 650 1000 1400 1850 2750 3700 4700
20 320 480 830 1300 1800 2450 3550 4600 6000
25 400 560 900 1450 2250 3150 4200 5900 7200

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for Selection of Turbine and     89 

Govering System for Hydroelectric Projects
 Annexure-4.10
Jyoti – Standard Francis

Runner 350 425 500 650 800 1000

dia. (mm)
Head (m) Turbine Output in Kilowatts
10 25 35 95 160 245 385
20 70 105 270 457 695 1085
30 130 190 495 840 1270 1990
40 200 290 560 955 1450 2265
50 270 400 640 1080 1950 2530
60 360 550 840 1415 2560 4000
70 460 675 940 1580 2400 3750
80 550 825 1150 1930 2900 4530
90 670 985 1370 2300 3485 5445
100 785 1150 1600 2700 4090 6390
110 690 1015 1410 2380 3605 -
120 - 1150 1600 2710 4105 -
130 - 1300 1810 3060 4635 -
140 - 1455 2025 3465 5245 -
150 - 1615 2250 3800 5760 -
160 - 1780 2475 4180 6335 -
170 - 1950 2700 4565 - -

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for Selection of Turbine and     90 

Govering System for Hydroelectric Projects
 Annexure-4.11

Jyoti – Standard Pelton Turbines

Runner dia. 300 425 600 750 900 1100

(mm)
Head (m) Turbine Output in Kilowatts
100 20 40 90 120 190 275
110 25 50 105 140 215 320
120 30 55 120 160 250 366
130 32 60 130 180 285 410
140 35 70 150 205 320 465
150 40 80 165 225 355 515
160 45 85 180 245 390 570
170 50 95 200 270 435 625
180 55 100 215 295 460 675
190 60 110 235 325 510 740
200 - 120 255 345 550 790
225 - 140 300 415 645 940
250 - 165 355 485 760 1100
275 - 190 410 560 880 1275
300 - 215 465 635 1005 1450
325 - 245 525 715 1125 1635
350 - 275 585 800 1255 1825
375 - 305 650 890 1395 2030
400 - - - 975 1535 2235
425 - - - 1080 1695 2465
450 - - - 1165 1830 2660

Note : Pelton will be double of above figures for two jet pelton

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for Selection of Turbine and     91 

Govering System for Hydroelectric Projects
 Annexure–4.12
Jyoti – Standard Turgo Impulse Turbine

Runner dia. 225 275 350 425 450 525 600 675 750
(mm)
Head (m) Turbine Output in Kilowatt
40 17 26 41 61 68 100 131 168 207
50 23 35 57 86 96 140 184 233 290
60 31 48 75 113 126 185 241 308 382
70 40 62 94 141 158 232 304 388 481
80 47 73 115 174 195 284 373 473 587
90 56 87 137 207 232 338 444 564 702
100 - 109 161 242 271 397 521 622 822
110 - 126 186 279 312 458 601 764 948
120 - 144 212 319 357 521 684 868 1078
130 - 161 239 359 402 589 772 982 1217
140 - 180 267 404 450 658 862 1097 1360
150 - - 295 446 500 727 956 1212 1509
160 - - 325 491 549 801 1053 1336 1636
170 - - 356 537 602 878 1152 1465 1822
180 - - 388 585 655 957 1255 1596 1986
190 - - 421 635 711 1038 1367 1731 2153
200 - - 455 687 770 1126 1475 1879 2327

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for Selection of Turbine and     92 

Govering System for Hydroelectric Projects
 Annexure-4.13
HPP - STANDARD VERTICAL KAPLAN TURBINE
RUNNER DIA 1200 1400 1700 1850 2000 2100 2300 2700 2900 3000 3600
(mm)
HEAD (m) TURBINE / GENERATOR OUTPUT (KW)

1.75 60 80 120 145 170 185 225 300 350 380 550

2 80 110 160 200 225 250 300 400 475 500 725

3 160 200 300 360 420 465 560 770 885 950 1350

4 225 300 450 535 625 690 825 1140 1315 1400 2025

5 325 440 650 770 900 990 1190 1640 1900 2025 2915

6 400 550 815 965 1130 1245 1500 2050 2375 2550 3660

7 500 685 1015 1200 1400 1550 1850 2550 2950 3160 4550

8 550 750 1100 1300 1500 1675 2000 2770 3200 3420 4925

9 675 920 1350 1600 1875 2060 2480 3420 3950 4225 6080

10 775 1050 1550 1850 2150 2375 2850 3925 4530 4850 7000

12 850 1165 1715 2030 2375 2620 3140 4325 5000 5350 7700

14 1120 1520 2240 2650 3100 3420 4100 5650 6520 6980 10050

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for Selection of Turbine and     93 

Govering System for Hydroelectric Projects
 Annexure-5
Power Generation Equipment Special Requirement

Description Category (Installed Capacity in kW)

Category A Category B Category C
(Upto 10 kW) (Above10kW and upto (Above 50 kW and
50 kW) upto 100 kW)
Types • Cross Flow • Cross Flow • Cross Flow
• Pump as turbine • Pelton • Pelton
• Pelton • Turgo Impulse • Turgo Impulse
• Turgo • Axial Flow • Axial Flow
• Axial Flow Turbine Turbine
• Turbine • Francis • Francis
• Any other turbine • Pump as Turbine • Any other turbine
meeting the technical • Any other turbine meeting the technical
requirement meeting the technical requirement
requirement
Turbine
Rated Output at rated Upto 10 kW (Above10kw and upto 50 (Above 50 kW and upto
head (at Generator kW) as specified 100 kW) as specified
output)
Bid evaluation – Each 3% for every 1 Each 3% by which rated
equalization for percent difference by average efficiency
shortfall in overall NIL which rated average (computed) is lower than
weighted average efficiency (computed) is the highest weighted
efficiency lower than the highest average efficiency
weighted average
efficiency
Synchronous/ Induction - Synchronous/ Induction Synchronous
Types Single Phase/3 phase 3 Phase 3 Phase

Terminal Voltage, 240 V, 1 –phase, 415 V 3 phase, 415 V, 3 phase,

Generator frequency 50 Hz 50 Hz 50 Hz
Make and Runaway Standard / Special generators designed to withstand against continuous runaway
withstand condition.
Insulation and Class F/H insulation and Class B Temperature rise
Temperature Rise
Overall Minimum required
Efficiency Weighted Average
Efficiency of the 45% 50% 60%
turbine Generator set
(ηT Av)
0.50 x ηT100+0.50
ηT50

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for Selection of Turbine and     94 

Govering System for Hydroelectric Projects
 Version 2

STANDARDS/MANUALS/
GUIDELINES FOR
SMALL HYDRO DEVELOPMENT

Electro-Mechanical Works–
Selection of Hydro Generator for SHP

Sponsor: Lead Organization:

Ministry of New and Renewable Energy Alternate Hydro Energy Center

Govt. of India Indian Institute of Technology Roorkee

May 2011
 CONTENTS

Sl. No. Items Page No.

1.0 GENERAL 1
1.1 References and Codes 1
2.0 HYDRO GENERATOR ABOVE 5 MVA 2
2.1 General 2
2.2 Site Operating Conditions 2
2.3 Transient Event and Emergency Duty requirements 4
2.4 Rotor Surface Heating 6
2.5 Types of Generators and Configuration 7
2.6 Capacity and Rating 7

2 

 
 3.0 ELECTRICAL CHARATERISTICS 8
3.1 Generator Terminal Voltage 8
3.2 Insulation and Temperature Rise 8
3.3 Short Circuit Ratio 8
3.4 Line Charging and Synchronous Condensing Capacity 9
3.5 Reactance 9
3.6 Damper Winding 9
3.7 Efficiency 10
3.8 Total Harmonic (TH) 10
4.0 MECHANICAL CHARACTERISTICS 10
4.1 Direction of Rotation 10
4.2 Rotor Assembly Critical Speeds 10
4.3 Phase Sequence 11
4.4 Noise Level and Vibration 11
4.5 Over Speed with Stand 11
4.6 Flywheel Effect 11
4.7 Cooling 12
4.8 Thrust Bearing Lubrication 12
4.9 Fire Extinguishing System 13
5.0 SMALL HYDRO GENERATOR UPTO & BELOW 5 MVA 13
5.1 General 13
5.2 Classification of Generators 13
5.3 Selection and Characteristics 17
5.4 Vertical/Horizontal Configuration 18
5.5 Speed 18
5.6 Dimension 18
5.7 Over Speed Withstand 18
5.8 Ratings and Electrical Characteristics 18
5.9 Synchronous Generators 19
5.10 Asynchronous (Induction) Generator 20
5.11 Guide and Thrust Bearings 20
5.12 Generation Efficiencies 21
5.13 Testing of Generator 21
6.0 EXCITATION SYSTEM 22
6.1 General 22
6.2 Excitation System Type 22

3 

 
 6.3 Steady State Excitation System Requirement 25
6.4 Transient Requirements 25
6.5 Power System Stabilizer 26
6.6 Under Excitation Limiter 27
6.7 Over Excitation Limiter 27
6.8 Volts per Hertz (V/Hz) Limiter 27
6.9 VAR or PF Control System 27
6.10 Redundancy of Equipment 28
6.11 Environmental Considerations 28
6.12 Equipment Tests 28
7. EXAMPLES 29

ANNEXURES

Annexure – 1 30
Annexure – 2 35
Annexure – 3 36
Annexure – 4 39
Annexure – 5 40

4 

 
 Guide for Selection of Hydro-Generators
and Excitation System Upto 25MW
1. GENERAL

The electric generator converts the mechanical energy of the turbine into electrical energy. The
two major components of the generator are the rotor and the stator. The rotor is the rotating
assembly to which the mechanical torque of the turbine shaft is applied. By magnetizing or
“exciting” the rotor, a voltage is induced in the stationary component, the stator. The principal
control mechanism of the generator is the exciter-regulator which sets and stabilizes the output
voltage. The speed of the generator is determined by the turbine selection, except when geared
with a speed increaser. In general, for a fixed value of power, a decrease in speed will increase
the physical size and cost of the generator.

The location and orientation of the generator is influenced by factors such as turbine type and
turbine orientation. For example, the generator for a bulb type turbine is located within the bulb
itself. A horizontal generator is usually required for a tube turbine and a vertical shaft generator
with a thrust bearing is appropriate for vertical turbine installations.

Conventional cooling on a generator is accomplished by passing air through the stator and rotor
coils. Fan blades on the rotating rotor assist in the air flow. For larger generator (generally above
5 MW capacity) and depending on the temperature rise limitations of the winding insulation of
the machine, the cooling may be assisted by passing air through surface air coolers, which have
circulated water as the cooling medium.

The Generators interconnected with the grid should need grid standards issued by CEA Relevant
extracts – Schedule for operation and maintenance are enclosed as annexure-1)

1.1 References and Codes

Latest edition of the following standards are applicable.

IEC-1116: 1992 – Electro-Mechanical Equipment Guide for Small Hydro-electric

Installation
IEC-60034-1: 2004 – Rotating Electrical Machines, Rating and Performance
IEC-34-2A-1972 – Rotating Electrical Machines Methods for determining losses and
efficiency of electrical machinery from tests (excluding machines for
traction vehicles
IEC-34-5-1991 – Classification of degrees of protection provided by enclosures for
rotating electrical machines (IP Code)
IEC-85-1987 – Classification of materials for the insulation of electrical machines
IS-4722 –1992 – Rotating electrical machines
IS-325 –1996 – Three phase induction motor
IS-8789 –1996 – Values of performance characteristics for three phase induction
motors
ANSI/IEEE 1010-197–American National Standard IEEE Guide for Control of Hydro
Power Plants
Micro Hydel Std. AHEC IIT Roorkee

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 1 

2. HYDRO GENERATOR ABOVE 5 MVA

2.1 General

Hydraulic turbine driven generators for hydro plants are salient pole synchronous alternating
current machines. Large salient pole generators are relatively slow speed machines in the range
80-375 rpm with large number of rotor poles. These generators are normally specifically designed
and generally interconnected with grid.

2.2 Site Operating Conditions (as per IEC: 60034 & IEEE C-50-12)

Rated operation condition specified in the standards are as follows: Site operating conditions if
deviating from these value, correction have to be applied as per table 2.2.1.

Maximum Ambient Temperature Steady State duty: Salient-pole open ventilated air-cooled
synchronous generators operate successfully when and where the temperature of the cooling air
does not exceed 400C.

Salient-pole totally enclosed water to air cooled (water) synchronous generators operate
successfully when and where the secondary coolant temperature at the inlet to the machine or
heat exchanger do not exceed 250C.

If the cooling air temperature (ambient) exceeds 400C, or cooling water temperature exceeds 250C
then maximum allowable temperature based on temperature rise on reference temperature
(400/250C) of the insulation class be specified instead of temperature rise. Correction as pre IEC
are shown in table 2.2.1.

The minimum temperature of the air at the operating site is – 150C, the machine being installed
and in operation or at rest and de-energized.

Note: If temperatures different from above are expected. The manufacturer should be informed of
actual site conditions.

Generators: Generators should operate successfully at rated MVA, frequency, power factor, and
terminal voltage. Generators at other service conditions should be specified with the standards of
performance established at rated conditions.
Altitude: Height above sea level not exceeding 1000 m. For machines intended for operation on a
site where the altitude is in excess of 1000 m. correctly should be made asp er table 2.2.1.
Number of starts and application of load: The purchaser should specify the anticipated no. of
starts and maximum MVA, power, and reactive power loading rate of change requirements for
the manufacturer to take into account in the machine design. The method of starting must be
identified in the case of peaking stations.
Variation from rated voltage and frequency: Generators should be thermally capable of
continuous operation within the capability of their reactive capability curves over the ranges of ±
5 % in voltage and ± 2 % in frequency, as defined by the shaded area of figure 2.2.

a) As the operating point moves away from rated values of voltage and frequency, the
temperature rise of total temperatures of components may progressively increase.
Continuous operation near certain parts of the boundary of the shaded area in figure 2.2
(a) at outputs near the limits of the generator’s reactive capability curve may (figure 2.2

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 2 

 b) cause insulation to age thermally at approximately two times to six times its normal
rate.
b) Generators will also be capable of operation within the confines of their reactive
capability curves within the ranges of ± 3 %/ -5 % in frequency as defined by the outer
boundary (zone B) in figure 2.2 (a) with further reduction of insulation life.
c) To minimize the reduction of the generator’s lifetime due to the effect of temperature and
temperature differentials, operation outside the shaded area should be limited in extent,
duration, and frequency of occurrence. The output should be reduced or other corrective
measures taken as soon as practicable.
d) The boundaries of figure 2.2 (a) result in the magnetic circuits of the generator to be over
fluxed under fluxed by no more than 5%. The sloped boundaries in figure (2.2 (a)
correspond to constant voltz per hertz.
e) The machine may be unstable or margins of stability may be reduced under some of the
operating conditions shown in fig. 2.2 (a). Excitation margins may also be reduced under
some of the operating conditions shown in figure 2.2 (a).
f) As the operating frequency moves away from the rated frequency, effects outside the
generator may become important and need to be considered. For example, the turbine
manufacturer will specify ranges of frequency and corresponding periods during which
the turbine can operate, and the ability of the auxiliary equipment to operate over a range
of voltage and frequency should be considered.
g) Operation over a still wider range of voltage and frequency, if required, should be subject
to agreement between the purchaser and the manufacturer and need to be specifically
brought out in tender specification.

Key 1 zone A
X axis frequency p. u. 2 zone B (outside zone A)
Y axis voltage p. u. 3 rating point
Fig. 2.2 (a) Voltage and Frequency Limits for Generators
(As per IEC: 60034)

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 3 

 2.3 Transient event and emergency duty requirements

A generator confirming to these guidelines will be suitable for withstanding exposure to transient
event and emergency duty imposed on a generator because of power system faults.

Sudden short circuit at the generator terminals: A generator will be capable of withstanding,
without injury, a 30 second, 3 phase short circuit at its terminals when operating at rated MVA
and power factor and at 5% over voltage, with fixed excitation. The machine shall also be capable
of withstanding, without injury, any other short circuit at its terminals of 30 s duration or less in
accordance with IEEE C 50. 12-2005. Generator circuit breaker need to be selected accordingly.

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 4 

 LIMITED BY FIELD HEATING

OVEREXCITED
(LAGGING)
POWER FACTOR

RATED MVA LIMITED BY

CAVITATION STATOR HEATING
LIMIT
MEGAVARS

MEGAWATTS

SHAFT STRESS OR
HYDRAULIC LIMIT

SEE NOTE-1
UNDEREXCITED

MINIMUM
EXCITATION
(LEADING)

LIMIT

SYSTEM STABILITY
LIMIT

LINE CHARGING LIMIT

SEE NOTE-2

Fig. 2.2 (b) Typical Hydro-Generator capability Curve

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 5 

 Synchronizing

a. Generators are designed to be fit for service without inspection or repair after
synchronizing that is within the limits given below:

i) Breaker closing angle ±10%

ii) Generator side voltage relative to system0% to +5%
iii) Frequency difference ±0.067 Hz

Additional information on synchronizing practices can be found in IEEE std. C37. 102TM-
1995.

b. Faulty synchronizing is that which is outside the limits given above. Under some system
conditions, faulty synchronizing can cause intense, short duration currents and torques
that exceed those experienced during sudden short circuits. These currents and torques
may cause damage to the generator.
c. Generators shall be designed so that they are capable of coasting down from synchronous
speed to a stop after being immediately tripped off-line following a faulty
synchronization. Any generator that has been subject to a faulty synchronization shall be
inspected for damage and repaired as necessary before being judged fit for service after
the incident. Any loosening for stator winding bracing and blocking and any deformation
of coupling bolts, couplings, and rotor shafts should be corrected before returning the
generator to service. Even if repairs are made after a severe out-of-phase synchronization,
it should also be expected that repetition of less severe faulty synchronizations might lead
to further deterioration of the components.
d. It should be that the most severe faulty synchronizations, such as 1800 or 1200 out-of-
phase synchronizing to a system with low system reactance to the infinite bus, might
require partial or total rewind of the stator, or extensive or replacement of the rotor, or
both.

Check synchronizing relay and auto synchronizing equipment need to be set accordingly.
Normally synchronizing closing angle is kept ±7%.

Short-time volts/hertz variations: The manufacturer shall provide a curve of safe short-time
volts/hertz capability. Identify the level of overflux above which the machine should never be
operated, to avoid possible machine failure. Unless otherwise specified, the curve apply for time
intervals of less than 10 min.

2.4 Rotor Surface Heating

Continuous phase current unbalance: Generator above 5 MVA are normally capable of
withstanding, without injury, the effects of a continuous phase current unbalance corresponding
to a negative current of the values in table 1, providing the rated MVA is not exceeded and the
maximum as expressed as a percentage of rated stator current.

Table –2.2.4 Continuous negative sequence current capability

Type of generator or generator/motor Permissible I2 (%)

Non-connected amortisseur winding 5

Connected amortisseur winding 10

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 6 

 These values also express the negative-sequence current capability at reduced generator MVA
capabilities, as a percentage of the stator current corresponding to the reduced capability.

Continuous performance with nonconnected amortisseur windings is not readily predictable.

Therefore, if unbalanced conditions are anticipated, machines with connected amortisseur
windings should be specified. Negative sequence relays (phase unbalance) be set accordingly.

2.5 Types of Generators and Configuration (Vertical or Horizontal)

Vertical shaft generators are generally used. There are two types of vertical shaft hydro
generators distinguished by bearing arrangements.

Umbrella type generators: These generators have combined bottom thrust and guide bearings and
confined to low operating speeds (upto 200 rpm) and is the least expensive generator design. In
semi umbrella type generators a top guide bearing is added. Umbrella/Semi Umbrella design is
being increasingly used for slow speed vertical generator.

Conventional generators: Prior to introduction of umbrella and semi umbrella designs

conventional design comprised of top-mounted thrust and guide bearing supported on heavy
brackets, capable of supporting total weight of generator. A bottom guide bearing combined
with turbine shaft is usually provided. This conventional design is used for high speeds (upto
1000 rpm) generators. Some medium size low flow turbine and tube turbine generators are
horizontal shaft. Direct driven bulb turbine generators are also horizontal shaft generators located
in the bulb. Pelton turbine coupled generators are mostly horizontal shaft.

2.6 Capacity and Rating

kW Rating: kW capacity is fixed by turbine rated output. In a variable head power plant the
turbine output may vary depending upon available head. In general the generator is rated for
turbine output at rated head. In peaking power plant higher generator kW rating could be
specified to take care of possible higher turbine output. Economic analysis is required for this
purpose as the cost will increase and generator capacity remains unutilized when heads are low.

The kilowatt rating of the generator should be compatible with the kW rating of the turbine. The
most common turbine types are Francis, fixed blade propeller, and adjustable blade propeller
(Kaplan). Each turbine type has different operating characteristics and impose a different set of
generator design criteria to correctly match the generator to the turbine. For any turbine type,
however, the generator should have sufficient continuous capacity to handle the maximum kW
available from the turbine at 100-percent gate without the generator exceeding its rated nameplate
temperature rise. In determining generator capacity, any possible future changes to the project,
such as raising the forebay (draw down) level and increasing turbine output capability, should be
considered. Typical hydro generator capability curve is shown in figure 2.2 (b).

kVA Rating and power factor: kVA and power factor is fixed by consideration of
interconnected transmission system and location of the power plant with respect to load centre.
These requirements include a consideration of the anticipated load, the electrical location of the
plant relative to the power system load centers, the transmission lines, substations, and
distribution facilities involved. A load flow study for different operating condition would indicate
operating power factor, which could be specified.

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 7 

 (Turbine output in MW) x (Generator efficiency)
Generator MVA =
Generator power factor

3 ELECTRICAL CHARACTERISTICS

Electrical Characteristics e.g. voltage, short circuit ratio, reactance’s, line charging capacity etc.
must conform to the interconnected transmission system. Large water wheel generators are
custom designed to match hydraulic turbine prime over. Deviation from normal generator
design parameters to meet system stability needs can have a significant effect on cost. The system
stability and other needs can be met by modern state excitation high response systems and it is a
practice to specify normal characteristics for generators and achieve stability requirements if any
by adjusting excitation system parameter (ceiling voltage/exciter response). Generally these
special requirements do not arise in the range under discussion.

3.1 Generator Terminal Voltage

Generator terminal voltage should be as high as economically feasible. Standard voltage of 11 kV is

generally specified for hydro generator in the range under considerations.

3.2 Insulation and Temperature Rise

Modern hydro units are subjected to a wide variety of operating conditions but specifications
should be prepared with the intention of achieving a winding life expectancy of 35 years or more
under anticipated operating conditions. Class B insulation with organic binding material was
specified with conservative temperature rise for stator and rotor winding insulations in the
machines upto 1965. Present practice is to specified class F insulation system for the stator and
rotor winding with class B temperature rise over the ambient. Ambient temperature rise should be
determined carefully from the temperature of the cooling water etc.

If may be noted that as per IS the temperature rise specified over an ambient of 400C.
Accordingly maximum temperature for the insulation class under site conditions should be
specified.

Thermosetting insulation systems materials are hard and do not readily conform to the stator slot
surface, so special techniques and careful installation procedures must be used in applying these
materials to avoid possible slot discharges. Special coil fabrication techniques, installation,
acceptance and maintenance procedure are required to ensure long, trouble-free winding life.

3.3 Short Circuit Ratio

The short circuit ratio of a generator is the ratio of field current required to produce rated open
circuit voltage to the field current required to produce rated stator current when the generator
terminals are short circuited and is the reciprocal of saturated synchronous reactance. Normal
short circuit ratios around 1.0 at 0.9 pf. Higher than normal short circuit ratio will increase cost
and decrease efficiency.

In general, the requirement for other than nominal short-circuit ratios can be determined only
from a stability study of the system on which the generator is to operate. The generator
parameters which have a bearing on stability are the flywheel effect, transient reactance and short
circuit ratio. Present practice is to specify generators with normal short circuit ratio and other

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 8 

 characteristics and achieve requirements of stability by optimizing parameters of excitation
system.

3.4 Line Charging and Synchronous Condensing Capacity

This is the capacity required to charge an unloaded line. Line charging capacity of a generation
having normal characteristics can be assumed to equal 0.75 of its normal rating multiplied by its
short circuit ratio. If the generator is to be designed to operate as synchronous condenser. The
capacity when operating over excited as condensers can be as follows:

Power Factor Condenser Capacity

0.80 65%
0.90 55%
0.95 45%

3.5 Reactance

The eight different reactances of a salient-pole generator are of interest in machine design,
machine testing, and in system stability model studies. Lower than normal reactances of the
generator and step-up transformer for system stability will increase cost and is not recommended.

Both rated voltage values of transient and subtransient reactances should be used in computations
for determining momentary rating and the interrupting ratings of circuit breakers.

Typical values of transient reactances for large water wheel generators are given below.
Guaranteed values of transient reactances will be approximately 10% higher.

Rated Sub-transient Reactance - xd′′

MVA Rating Speed RPM
100 150 300
10 - 25 0.27 0.26 0.25

3.6 Damper Winding

A short circuit grid copper conductor in face of each of the salient poles is required to prevent
pulling out of step the generator interconnected to large grid. Two types of damper windings may
be connected with each other, except through contact with the rotor metal. In the second, the pole
face windings are connected at the top and bottom to the adjacent damper windings.

The damper winding is of major importance to the stable operation of the generator.
While the generator is operating in exact synchronism with the power system, rotating field and
rotor speed exactly matched, there is no current in the damper winding and it essentially has no
effect on the generator operation. If there is a small disturbance in the power system, and the
frequency tends to change slightly, the rotor speed and the rotating field speed will be slightly
different. This may result in oscillation, which can result in generator pulling out of step with
possible consequential damage.

The damper winding is of importance in all power systems, but more important to systems
that tend toward instability, i. e. systems with large loads distant from generation resources,
and large intertie loads.

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 9 

 In all cases, connected damper windings are recommended. If the windings are not
interconnected, the current path between adjacent windings is through the field pole and
the rotor rim. This tends to be a high impedance path, and reduce the effectiveness of the
winding, as well as resulting in heating in the current path. Lack of interconnection leads to
uneven heating of the damper windings, their deterioration, and ultimately damage to the damper
bars.

The damper winding also indirectly aids in reducing generator voltage swings under some faults
conditions. It does this by contributing to the reduction of the ratio of the quadrature reactance
and the direct axis reactance, X q′′ / X d′′ . This ratio can be as greater than 2.0 for a salient pole
generator with no damper winding, and can be as low as 1.1 if the salient pole generator has a
fully interconnected winding practice is to provide X q′′ / X d′′ > 1.3.

3.7 Efficiency

As high an efficiency as possible which can be guaranteed by manufacturer should be specified.

Calculated values should be obtained from the manufacturer.

For a generator of any given speed and power factor rating, design efficiencies are reduced
by the following:

i. Higher Short-Circuit Ratio

ii. Higher WR2
iii. Above-Normal Thrust

3.8 Total Harmonic (TH)

This is required only for synchronous machines having rated outputs of 300 kW (or kVA) or
more with a view minimizing interface caused by the machine.

Limits: When tested on open circuit and at rated speed and voltage, the total harmonic (TH) of
the line-to-line terminal voltage, as measured according to the methods laid down in IEC: 60034
should not exceed 5%.

4 MECHANICAL CHARACTERISTICS

4.1 Direction of Rotation

The direction of he rotation of the generator should suit the prime mover requirements.

4.2 Rotor Assembly Critical Speeds

A rotor dynamic analysis of the entire shaft system should be performed. This analysis should
include the prime mover, generator, and any other rotating components. This analysis should
include lateral and torsional shaft system response to the various excitation that are possible
within the operational duties allowed by the standards. When the turbine generator is purchased
as a set, it would be typical that the manufacturer should perform this analysis. When shaft
components are purchased from different manufacturers, the purchaser should arrange to have
this analysis. Critical speeds of the generator rotor assembly should not cause unsatisfactory

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 10 

 operation within the speed range corresponding to the frequency range and should be above
runaway speed. The generator rotor assembly shall also operate satisfactorily for a reasonable
period of time at speeds between standstill and rated speed upon by the prime mover and
generator designers. The turbine generator set shaft vibration at operating speed should be within
limits specified by ISO 7919-52 for machine sets in hydraulic power generating and pumping
plants.

4.3 Phase Sequence

Phase sequence defines the rotor in which the phase voltages reach their positive maximum at the
terminals of the machine, and shall be agreed upon the manufacturer and purchaser. Typically this
is given as a three letter sequence, R, C, L, (right, center, left) or L, C, R (left, center, right), as
defined by an observer looking at the terminals from outside the machine. In the case of terminals
on the top or bottom of the machine, the sequence is defined looking from the end of the machine
nearest the terminals toward the centerline of the machine.

Care must be exercised to ensure that the defined phase sequence of the machine is consistent
with that of the connected equipment, particularly in situations where the plant layout requires
otherwise identical machines to have different phase sequence.

4.4 Noise Level and Vibration

Under all operating conditions, the noise level of generator should be in the range 85-95 dB (A) at
a distance of 1 meter radialy & 1.5 m from floor of operating. In order to prevent undue and
harmful vibrations, all motors shall be statically and dynamically balanced.

4.5 Over speed withstand

It is general practice in India to specify all hydro generators to be designed for full turbine
runaway conditions. The stresses during design runaway speed should not exceed two-thirds of
the yield point.

American practice as per Army Corps Engineers Design Manual is as follows;

Generators below 360 rpm and 50,000 kVA and smaller are normally designed for 100% over
speed.

4.6 Flywheel Effect

The flywheel effect (GD2) of a machine is expressed as the weight of the rotating parts multiplied
by the square of the radius of gyration. The WR2 of the generator can be increased by adding
weight in the rim of the rotor or by increasing the rotor diameter. Increasing the GD2 increases the
generator cost, size and weight, and lowers the efficiency. The need for above-normal WR2
should be analyzed from two standpoints, the effect on power system stability, and the effect on
speed regulation of the unit. Speed regulation and governor calculation are discussed in
guidelines for turbine selection.

Electrical system stability considerations may in special cases require a high GD2 is only
one of several adjustable factors affecting system stability, all factors in the system design should
be considered in arriving at the minimum overall cost. Sufficient WR2 must be provided to
prevent hunting and afford stability in operation under sudden load changes. The index of the

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 11 

 relative stability of generators used in electrical system calculations is the inertia constant, H,
which is expressed in terms of stored energy per kVA of capacity. It is computed as:

kW • s 0.0385 (GD 2 ) (r / min) 2 ×10 −6 ⎛ 0.231(GD 2 )(r / min) 2 × 10 −6 ⎞

H= = ⎜⎜ ⎟⎟
kVA kVA ⎝ kVA ⎠

The inertia constant will range from 2 to 4 for slow-speed (under 200 rpm) water wheel generators.
Transient hydraulic studies of system requirements furnish the best information concerning the
optimum inertia constant, but if data from studies are not available, the necessary GD2 can be
computed or may be estimated from aknowledge of the behavior of other units on the system.
Increased in normal GD2 will increase generator cost.

Mechanical characteristics of the generator are based on the hydraulic turbine data to which the
generator will be coupled. Characteristics regarding speed, flywheel effect have been discussed in
guidelines of tubular selection. Special characteristics are discussed below.

4.7 Cooling

Losses in a generator appear as heat which is dissipated through radiation and ventilation. The
generator rotor is normally constructed to function as an axial flow blower, or is equipped with
fan blades, to circulate air through the windings. Small-generators up to 5 MW may be partially
enclosed, and heated generator air is discharged into the generator hall, or ducted to the outside.
Adequate ventilation of the generator hall preferably thermostatically should be provided in this
case.

Water to air coolers normally are provided for all modern hydro generators rated greater than 5
MVA. The coolers are situated around the outside periphery of the stator core. Generators
equipped with water-t-air coolers can be designed with smaller physical dimensions, reducing the
cost of the generator. Automatic regulation of the cooling water flow in direct relation to the
generator loading results in more uniform machine operating temperatures, increasing the
insulation life of the stator windings. Cooling of the generator can be more easily controlled with
such a system, and the stator windings and ventilating slots in the core kept cleaner, reducing the
rate of deterioration of the stator winding insulation system. The closed system also permits the
addition of automatic fire protection systems, attenuates generator noise, and reduce heat gains
that must be accommodated by the powerhouse HVAC system.

Normally, generators should be furnished with one more cooler than the number required for
operation at rated MVA. This allows one cooler to be removed for maintenance without affecting
the unit output.

The generator cooling water normally is supplied from the penstock via a pressure reducing
station or pumped from the tailrace. In either case, automatic self-cleaning filters must be
provided in the cooling water supply lines to avoid frequent fouling or plugging of the water-to-
air coolers.

4.8 Thrust Bearing Lubrication

Specifications for generators above 5 MW, and for generators in unmanned plants, should require
provisions for automatically pumping oil under high pressure between the shoes and the runner
plate of the thrust just prior to and during machine startup, and when stopping the machine.

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 12 

 4.9 Fire Extinguishing System

All hydroelectric generators greater than 25 MVA should be furnished with either a water deluge
or carbon dioxide (CO2) fire extinguishing system, to minimize the damage caused by a fire
inside the machine. Generators 25 MVA or below should be evaluated individually to ensure
installation on cost effective system.

5 SMALL HYDRO GENERATOR UPTO & BELOW 5 MVA

5.1 General

Standardized or upgraded mass-produced machine should be used where possible. Most “off-the-
shelf” or mass-produced machines are designed for lower over speed values (typically 1,25 to
1,50 times rated speed) than are experienced with hydraulic turbines. Therefore, such generator
designs should be checked for turbine runaway conditions.

Special Design Features as per IEC 1116 for these generators is as follows:

i) Designed to mechanically withstand continuous over speed of 200 to 300% of rated

speed of the turbine.
ii) These generators should be factory assembled that are shipped to the field as two integral
component parts, rotor and stator. So that assembled work at site is minimize.
iii) Class F insulation with class B temperature rise
iv) Self lubricated journal type maintenance -free pedestal bearing
v) Open ventilation
vi) Fully assembled and dynamically balanced

Standard BHEL generators confirming to the IEC standards are given in table 5.1.

5.2 Classification Of Generators

There are basically two types of alternating current generator: synchronous and asynchronous (or
induction) generators. The choice of the type to be used depends on the characteristics of the grid to
which the generator will be connected and also on the generator’s operational requirements.

Salient pole Synchronous generators are used in the case of stand alone schemes (isolated
networks). In case of weak grids where the unit may have significant influence on the network
synchronous generator are used.

For grid connected schemes both types of generator can be used. In case grid is weak; Induction
generators be used if there are two units, one of the unit can be synchronous so that in case of grid
failure; supply could still be maintained. Unit size be limited to 250 kW. In case of stronger grids
induction generators upto a 2001 kW or even higher can be used.

In case of isolated units, small capacity Induction generators with variable capacitor bank may be
used upto a capacity of about 20 kW especially if there is no or insignificant Induction motor load
i.e. less than about 20%.

Before making a decision on the type of generator to be used, it is important to take the following
points into consideration:

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 13 

 - A synchronous generator can regulate the voltage and supply reactive power to the
network. It can therefore be connected to any type of network.
- An induction generator has a simpler operation, requiring only the use of a tachometer to
couple it to the grid as the machine is coupled to the grid there is a transient voltage drop,
and once coupled to the grid the generator absorbs reactive power from it. Where the
power factor needs to be improved, a capacitor bank will be necessary. The efficiency of
an asynchronous generator is generally lower than that of a synchronous one.

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 14 

Table 5.1 STANDARD SHP GENERATORS MANUFACTURED BY M/S BHEL INDIA Ltd. (*)

A. SHP

S. Rating Speed in RPM

No. in kW 300 333.3 375 426 500 600 750 1000 1500

1. 500 230M20 230M20 183M20 183M20 145M20 145M20 145M20 145M20 132M25
2. 1000 230M25 230M25 183M25 183M25 183M25 145M50 145M38 145M38 132M50
3. 1500 230M35 230M35 183M50 183M50 183M50 145M75 145M57 145M57 132M50
4. 2000 230M45 230M45 183M70 183M70 183M60 145M75 145M57 145M75 132M50
5. 2500 230M70 230M70 230M60 183M70 183M60 203M70 145M75 145M75 132M100
6. 3000 230M70 230M70 230M50 254M50 254M40 203M70 203M50 145M100 132M100
7. 3500 230M90 230M70 230M60 254M50 254M50 203M70 203M50 145M100 132M100
8. 4000 230M90 230M90 230M80 254M65 254M50 203M95 203M70 145M100 -
9. 4500 230M90 230M90 230M80 230M65 254M50 203M95 203M70 - -
10. 5000 230M90 230M90 230M80 230M65 254M50 203M95 203M70 - -

B. Mini Micro: generators 200-500 kW; speed 300 to 1500 RPM; power factor 0.67 lag.; Voltage 415 to 11 kV

(*)
A. M. Gupta BHEL, Bhopal - Small Hydro Generators – International course on technology selection for small hydro power development at
Alternate Hydro Energy Centre (AHEC) during Feb. 18-28, 2003

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 16 

Merits and demerits of synchronous and induction is given in table 5.2.

Table 5.2 MERITS & DEMERITS SYNCHRONOUOS V/S INDUCTION ENERATORS

S. No. Item Syn. Generator Ind. Generator

1 Rotor construction Salient pole type Squirrel cage type
2 Excitation Required Not required
3 Isolated operation Possible Not possible
4 Stability To be maintained by excitation No problem
control
5 Maintenance More because of excitation & Less because of squirrel case
control equipments rotor
6 Efficiency High Low
7 Inertia High Low
8 Cost High Low
9 Power factor Adjustable by excitation Not adjustable determined by
control load
10 Suitability for highly Ideal Not suitable
fluctuating loads
11 Loads Highly capacitive Only inductive
12 Voltage variation Possible Not possible

Climatic conditions (ambient temperature, altitude, humidity) can affect the choice of the class of
insulation level and temperature rises.

The cooling system of the generator should be evaluated. In the case where heat from the
generator is expelled into the powerhouse sufficient power house ventilation shall be provided.

If necessary, a braking system (either air or oil operated) should be considered.

5.3 Selection and Characteristics

Small hydro upto 5000 kW may be further sub classified as follows:

Micro hydel upto 100 kVA

Small hydro upto 5000 kVA

h) Microhydel generators may be selected in accordance with quality standard issued by

AHEC extracts enclosed as Annexure 2. These generators are generally factory
assembled and classified as category-1 generator in American Practice. They are shipped
to site completely assembled depending on the rpm selected, unit speed/weights and
method of transportation to site.
i) Small hydro upto 5 MVA are generally category-2 generators. These generators are
factory assembled that are shipped to the field as two integral component parts, rotor and
stator.

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 17 

 5.4 Vertical/Horizontal Configuration

With all turbines, a vertical or horizontal configuration is possible. The orientation becomes a
function of the turbine selection and of the power plant structural and equipment costs for a
specific layout. As an example, the Francis vertical unit will require a deeper excavation and
higher power plant structure. A horizontal machine will increase the width of the power plant
structure yet decrease the excavation and overall height of the unit. It becomes apparent that
generator orientation and setting are governed by compatibility with turbine selection and an
analysis of overall plant costs.

5.5 Speed (rpm) : The speed of a generator is established by the turbine speed. The
hydraulic turbines should determine the turbine speed for maximum efficiency corresponding to
an even number of generator poles. Generator dimensions and weights vary inversely with the
speed. For a fixed value of power a decrease in speed will increase the physical size and cost of
generators. Low head turbine can be connected either directly to the generator or through to a
speed increaser. The speed increaser would allow the use of a higher speed generator, typically
500, 750 or 1000 (1500) r/min, instead of a generator operating at turbine speed. The choice to
utilize a speed increaser is an economic decision. Speed incresers lower the overall plant
efficiency by about 1% for a single gear increaser and about 2% for double gear increaser. (The
manufacturer can supply exact data regarding the efficiency of speed increasers). This loss of
efficiency and the cost of the speed increaser must be compared to the reduction in cost for the
smaller generator. It is recommended that speed increaser option should not be used for unit sizes
above 3 MW capacity.

5.6 Dimension

Three factors affect the size of generator. These are orientation, kVA requirements and speed. The
turbine choice will dictate all three of these factors for the generator.

The size of the generator for a fixed kVA varies inversely with unit speed. This is due to the
requirements for more rotor field poles to achieve synchronous speed at lower rpm.

5.7 Overspeed Withstand

In the interest of safety, units with synchronous generators should be designed to withstand
continuous runaway conditions.

5.8 Ratings and Electrical Characteristics

5.8.1 kW Rating: The kilowatt rating of the generator should be compatible with the kW
rating of the turbine. The most common turbine types are Francis, fixed blade propeller, and
adjustable blade propeller (Kaplan). Each turbine type has different operating characteristics and
imposes a different set of generator design criteria to correctly match the generator to the turbine.
For any turbine type, however, the generator should have sufficient continuous capacity to handle
the maximum kW available from the turbine at 100-percent gate without the generator exceeding
its rated nameplate temperature rise. In determining generator capacity, any possible future
changes to the project, such as raising the forebay (draw down) level and increasing turbine
output capability, should be considered.

In a variable head power plant the turbine output may vary depending upon available head. In
general the generator is rated for turbine output at rated head.

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 18 

 5.8.2 kVA Rating and power factor: kVA and power factor is fixed by consideration of
location of the power plant with respect to load centre. These requirements include a
consideration of the anticipated load, the electrical location of the plant relative to the power
system load centers, the transmission lines, substations, and distribution facilities involve.

5.8.3 Frequency and Number of Phases: In India standard frequency is 50 cycle, 3 phase
power supply.

5.8.4 Generator Terminal Voltage: Generator terminal voltage should be as high as

economically feasible. Generator of less than 5000 kVA should be designed for 6.6 kV, 3.3 kV or
415 volts depending upon requirement of generator WR2 or generator reactance. Economical
terminal voltage for small hydro generators recommended by CBI & P (publication no. 280 –
2001) is as follows:

Upto 750 kVA – 415 volts

751 – 2500 kVA – 3.3 kV
2501 – 5000 kVA – 6.6 kV
Above 5000 kVA – 11 kV

Preferred voltage rating of generator as per IEC 60034-1 is as follows:

3.3 kV – Above 150 kW (or kVA)

6.6 kV – Above 800 kW (or kVA)
11 V – Above 2500 kW (or kVA)

5.8.5 Stator Winding Connection: Star, stator winding connection are providing for both
grounded or ungrounded operation and six terminal (3 on line side and 3 on neutral side) are
brought out, except for small generators below 100 kW unit size when only one neutral is brought
for ground connections.

5.8.6. Excitation Voltage: Rated generator rotor voltage is specified by the manufacturer,
based on the rotor winding resistance and the excitation current required for full load operation at
rated voltage and power factor, including suitable margin. Ceiling voltage is as agreed upon by
the manufacturer and purchaser. Voltage of excitation system should be less than 250 V DC.

5.8.7 Short Circuit Ratio, Line Charging and synchronous condenser capacity and damper
windings considerations are discussed in Para 3.6.

5.9 Synchronous Generators

a) Stator:

Class F insulation level and Class B temperature rises are recommended.

b) Rotor :

The insulation level should normally be Class-F and temperature rises Class-B.

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 19 

 c) Excitation equipment :

It is recommended that a system requiring the least maintenance be chosen (e.g. static
brushless excitation). Coupled excitation armature with rotating rectifier assembly and
stationary excitation field suitable for voltage and power factor control is recommended.

d) Voltage regulating equipment :

The aim should be simplicity with a view to maintenance. This equipment could be
included in the control system.

e) Synchronising equipment :

May be manual and/or automatic. The synchronization should cover the voltage,
frequency and phase. Normally this equipment is included in the automatic control
system.

f) Power Factor :

Between 0.8 and 1.0 depending on the reactive power requirements.

5.10 Asynchronous (Induction) Generator

a) Stator

Class F insulation level and Class B temperature rises are recommended.

b) Rotor

Squirrel cage construction, Class F insulation and Class B temperature rises are
recommended.

These units should be designed to withstand continuous runaway conditions.

c) Voltage and Speed

The selection of voltage and speed affects the possibility of using a standard machine.

5.11 Guide and Thrust Bearings

The shaft system should be designed to minimize the number of bearings. It is essential to study
the turbine and generator bearings as a systems is the choice between journal, ball or roller
bearings, attention should be given to their ability to withstand vibrations, eddy currents and
runaway conditions including critical speed.

If the unit size is small and for reasons of simplicity, the use of self-lubricating bearings should be
preferred.

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 20 

 5.12 Generator Efficiencies

The efficiency of an electrical generator is defined as the ratio of output power to input power.
Efficiency values for commercially available generators are included in section 3. There are five
major losses associated with an electrical generator. Various test procedures are used to
determine the magnitude of each loss. Two classes of losses are fixed and therefore independent
of load. These losses are 91) windage and friction and (2) core loss. The variable losses are (3)
field copper loss, (4) armature copper loss and (5) stray loss or load loss.

Windage and friction loss is affected by the size and shape of rotating parts, fan design, bearing
design and the nature of the enclosure. Core loss is associated with power needed to magnetize
the steel core parts of the rotor and stator. Field copper loss represents the power losses through
the dc resistance of the field. Similarly, the armature copper loss is calculated from the dc
resistance of the armature winding. Stray loss for load loss is related to armature current and its
associated flux. Typical values for efficiency range from 90 to 97% depending upon speed and
capacity of machine. This efficiency value is representing throughout the whole loading range of
a particular machine; i.e., the efficiency is approximately the same at ¼ load or at ¾ load.

5.13 Testing of Generator

There are usually 2 categories of generators for this purpose.

a. Category –1 Factory assembled generators supplied to site completely assembled. These

are generally below 3 MW unit size.
b. Category – 2 Factory assembled generators supplied at site as two integral component
parts, rotor and stator. These are generally between 3 MW and 15 MW unit size.

5.13.1 Factory Assembly Test

Following factory and final acceptance tests are recommended to ensure proper performance and
guarantees for category 1 & 2 types of generators.

a. Resistance test of armature and field windings.

b. Dielectric test of armature and field windings.
c. Insulation resistance of armature and field windings.

This should include the polarization index values for both armature and field windings.

d. Stator core loop test at rated flux for one hour.

e. Phase rotation check
f. No load saturation test
g. Short circuit saturation test
h. Mechanical balance of rotor
i. Dynamic balancing of rotor at 125% rated speed
j. Current transformer test
k. Efficiency test
l. Non Destructive Test of rotor tests of rotor shaft and shaft coupling bolts
m. Material test certificates of various component parts.
n. Temperature rise test

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 21 

 5.13.2 Field Acceptance Test

Field acceptance tests (all units). These tests consist of:

a. Stator dielectric tests. These tests consist of: Insulation resistance and polarization index,
Corona probe test, Corona visibility test, Final AC high potential test, Partial discharge
analysis (PDA) test, and Ozone detection (optional).
b. Rotor dielectric tests.
c. Stator and rotor resistance tests.

Special field test (one unit of series). These tests consist of:

a. Efficiency tests.
b. Heat run tests.
c. Machine parameter tests.
d. Excitation test.
e. Overspeed tests (optional)

6 EXCITATION SYSTEM

6.1 General

Excitation systems supply and regulate the amount of D. C. current required by generator field
windings and include all power regulating control and protective elements. The excitation system
should be specified to meet the power requirements and required response characteristics to meet
the power system to which generator will be connected. Overall performance and capacity of the
excitation system represented earlier by excitation response and response ratio is now expressed
as nominal system response (ANSI/IEEE std. 421-1-1996). Standard excitation system voltages
are 62.5, 125, 250.

6.2 Excitation System Type

Modern static excitation have completely replaced older shaft mounted rotating exciters with DC
filed current controlled by motor operated field rheostat. Brushless excitation system and static
excitation systems are being used in modern systems.

Brushless Exciter: An alternator-rectifier exciter employing rotating rectifiers with a direct

connection to the synchronous machine field thus eliminating the need for field brushes, is
typically shown in Fig 6.2 (a). Brushless system may be used for small hydro generators upto
about 10 MVA where large DC current Capacity is not required. A provision for field flashing the
field of the rotating exciter for startup purposes is required.

Static Excitation System: The static excitation system is the most commonly used excitation
system for hydro generators. It is typically shown in figure 6.2 (b). Static excitation systems
consist of two basic types depending upon the speed of generator field suppression required. The
full inverting bridge type uses six thyristor connected in a three-phase full wave bridge
arrangement. It allows reversed DC voltage to be applied to the generator filed to force faster
field suppression, thereby quickly reducing the generator terminal overvoltage during a full load
rejection. The semi-inverting type uses three thyristor and three diodes connected in a three-phase
full wave bridge. The semi-inverting type drives the positive DC voltage to zero during a full load
rejection, but does not allow negative filed forcing. Potential excitation source systems (from

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 22 

 generator leads) are common for new generators and requires slip ring for supplying power to the
field winding. Field flashing equipments is necessary for potential source excitation system
which obtain power from machine terminals. in such cases, adequate self-cooling may be
specified for startup without the need for auxiliary cooling power.

Digital controllers have proved to be more reliable and should be preferred.

Fig. 6.2(a)

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 23 

 Fig. 6.2 (b)

A comparison of the characteristics of two-excitation system is given in table 6.2.

TABLE 6.2

Features Exciter performance characteristics

Potential controlled rectifier Brush less exciter (rotating
rectifier exciter)

High initial response Yes No (see note 1)

Sustained fault current No No (see note 1)
support
Online rectifier maintenance Yes No
possible
Spare exciter user Yes No
Field monitoring ground Yes Yes, if Aux. Slip rings, or
relaying opto/EM/RF coupling is used
Rapid de-excitation Yes, for half wave control, field No
breaker discharge resistor is required
General maintenance Brushes and collectors Exciter diode check

Note 1: may be possible with special provisions (refer IEEE std. 421.4-2004)

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 24 

 6.3 Steady State Excitation System Requirement

6.3.1 Rated Field Current: The direct current in the field winding of the generator when
operating at rated voltage, current, power factor and speed.

6.3.2 Exciter Rated Current: Continuous current rating should be specified to equal or
exceed the maximum required by the synchronous generator field under any allowed continuous
operating condition including continuous overload rating.

6.3.3. Exciter rated Voltage: Exciter voltage rating should be sufficient to supply necessary
continuous current to generator field at its maximum under rated load conditions.

6.3.4 Rated Field Voltage: The voltage required across the terminals of the field winding of
the synchronous machine under rated continuous load conditions of the synchronous machine
with its filed winding at (1) 750C for field windings designed to operate at rating with a
temperature rise of 600C or less; or (2) 1000C for field windings designed to operate at rating with
a temperature rise greater than 600C.

6.4 Transient Requirements

6.4.1 Transient requirements excitation system of generator is determined from following

considerations.

The stability of a hydro turbine generator set while connected to its power system is critically
important. However, the designer must also consider the unit’s characteristics when operating
alone, or in an isolated “island” much smaller than the normal power system.

One example of a unit operating is a main unit serving as the station service source in a plant that
becomes separated from its power distribution system. The unit will have to accept motor starting
loads, and other station service demands such as gate and valve operation, while maintaining a
safe and stable output voltage and frequency. All this will be accomplished while operating at a
fraction of its rated output.

When operating in an “island” the unit may be required to operate in parallel with other units
while running at speed-no-load in order to provide enough capacity to pick up blocks of load
without tripping off line. In this case, stable operation without the stabilizing effect of a very large
system is critically important to restoring service, and putting the system back together.

6.4.2 Ceiling Voltage

The maximum direct voltage, which the excitation system is able to supply from its terminals
under following conditions.

(1) No-load conditions

(2) The ceiling voltage under load with the excitation system-supplying ceiling current.
(3) Under power system disturbance conditions: System studies are normally required
for fixing excitation system parameters for large generators from stability
considerations. For small generators under consideration producing energy for a very
large system, stability is not so critical since system voltage support will be beyond
the small unit’s capability. Nonetheless, for its own safe operation, good voltage

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 25 

 control is important. An extremely high response system is not necessary, but the
system should respond rapidly enough to prevent dangerous voltage changes.
(4) For excitation systems employing a rotating exciter, the ceiling voltage is determined
at rated speed.

The ceiling voltage of high initial response static excitation system is normally specified directly
after system studies as the ceiling voltage is reached in less than 0.1 second. Ceiling voltage for
potentials source (from generator bus) static excitation system with high initial response for the
generator under considerations may be specified 1.5 – minimum recommended by IEEE Std.

For brushless system, it may be considered a function of the nominal response, which could be
specified.

6.4.3 Excitation System Nominal Response

The excitation system nominal response is defined as the rate of increase of the excitation system
output voltage determined from the excitation system voltage response curve, divided by the rated
field voltage (formerly called exciter response ratio). The rate, if maintained constant, would
develop the same voltage time area as obtained from the actual curve over the first half-second
interval. This may be specified for brushless excitation system only.

Excitation systems response based on a ceiling voltage for high initial response static excitation
system and for the brushless system is compared in 6.4.3.

6.5 Power System Stabilizer

The excitation system stabilizer is used for fast acting high initial excitation system to stabilize
oscillations that may occur between the machine and the systems by providing damping at power
system frequency to control oscillation in the post fault period. IEEE std. 421.4-2004 requires
power system stabilizer for grid connection at 66 kV and above so as to avoid oscillations in post
fault period.

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 26 

 high initial response
static excitation system brushless excitation system

h c
be = ceiling voltage for
b brushless excitation system
g'h = ceiling voltage of high initial
response static excitation syste

AREA acd = AREA abd

d
a g

ce-ao
EXCITER VOLTAGE E FD

NOMINAL VOLTAGE=
(ao) (oe)

WHERE
oe = 0.5 seconds
ao = synchronous machine
rated field voltage

e
0 g' SECONDS

less than
0.1 seconds
Fig. 6.4.3

6.6 Under Excitation Limiter

Under excitation limiter should be provided on all small hydro generators which are normally
equipped with VAR (power factor control) and disconnected form the system on system
disturbances to feed local loads/station service systems.

6.7 Over excitation limiter

Over excitation limiter should be provided on all generators to avoid overheating of the generator
field winding in case of faults.

6.8 Volts-per Hertz (V/Hz) Limiter

The Volts-per Hertz (V/Hz) Limiter may be provided to prevent overheating that may arise from
excessive magnetic flux due to under frequency operation or overvoltage operation, or both.

6.9 VAR or PF Control System

The generators under consideration cannot follow the changes in the system voltage and therefore
must be equipped with power factor control regulators. These Grid connected power units require
a power factor regulator as well as field current regulator with automatic change over from

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 27 

 voltage control mode to power factor control mode after synchronizing with the grid. Further
minimum and maximum field exciter limit are also required.

6.10 Redundancy of Equipment

Manual control is a back up to excitation controller failure is generally adequate.

Power rectifier bridge redundancy is generally provided by providing parallel rectifiers of which
at least one is redundant. Redundant cooler should also be provided to ensure adequate cooling.
This may be provided for generators above 5 MVA.

6.11 Environmental Considerations

Environmental considerations to be specified include electrical transients, radio interference,

temperature extremes, humidity, altitude, vibration, corrosive atmosphere etc.

Special requirement include tropicalization, seismic considerations etc.

6.12 Equipment Tests

Complete factory assembly of the excitation system is generally not required. Routine, type and
special tests may be carried out as per IEEE std. 421.4-2004. In addition factory tests and type
tests for the excitation system recommended are given below:

6.12.1 Static Excitation (potential source rectifier exciter) system

a) Excitation transformer - factory tests

Factory tests may be carried out as per relevant IS: std. Routine tests should include measurement
of following.

i) Winding resistance
ii) Ratio
iii) Polarity and phase relationships
iv) No-load loss 9if capable)
v) Magnetizing current at rated voltage
vi) High potential test in accordance with IEEE std. 421.3-1997
vii) Induced potential

b) Type Tests (certified test report if type test is performed)

i) Impedance, load loss, and regulation

ii) Temperature rise, i.e., heat run
iii) Impulse test (s)

6.12.2 Rectifier Assembly

a) Excitation transformer - factory tests

Factory tests may be carried out as per relevant IS: std. Or IEEE std. C57.12.91-2001 Routine
tests should include measurement of following.

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 28 

 i) Continuity of rectifier fuses
ii) Polarity and phase relationships
iii) Range and stability of rectifier phase control
iv) High potential test in accordance with IEEE std. 421.3 - 1997

b) Type Tests (certified test report if type test is performed)

i) Rated current, watt losses

ii) Temperature rise, i.e. heat run
iii) Burn in, 48 hours unless otherwise specified (designate if current or voltage burn in is
required)
iv) Verify current balance between parallel bridge

6.12.3 Brushless Excitation System

a) Factory tests

i) Insulation resistance
ii) Resistance of all windings at a specified temperature
iii) Resistance of all external current limiting resistors and field rheostats, where applicable
iv) Air gap
v) No-load saturation curve, from residual voltage to exciter ceiling voltage
vi) Phase rotation
vii) Continuity of rectifier fuses
viii) Rectifier leakage
ix) Range and stability of rectifier phase control, where applicable
x) High potential test
xi) Operation at anticipated overspeed

b) Type tests

i) Audible noise
ii) Load saturation curve, up to 110% of nominal ceiling voltage
iii) Main exciter regulation
iv) Heat run
v) Exciter time constant
vi) Excitation system voltage response time and response
vii) Operation at anticipated overspeed, at the anticipated maximum

7 EXAMPLE

7.1 Type and rating, electrical characteristics, mechanical characteristics, insulation and
temperature rise and speed rise and run away speed specified for a 10 MVA grid
connected powerhouse is enclosed as Annexure-3.
7.2 Brush less excitation system for 1.5 MW Pacha project in Arunchal Project (grid
connected) is attached Annexure 4.
7.3 Static excitation system – Block diagram for 9 MW, 11 kV, 0.9 PF is at Annexure 5.

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 29 

 Annexure-1

Grid standard for operation and maintenance of transmission

lines as per CEA (grid Standard) Regulation –2006

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 30 

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 31 
AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 32 
AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 33 
AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 34 
 Annexure-2
Generator for Micro Hydel
(as per AHEC Micro Hydro Quality Std.)

A. Synchronous Generators and Induction Motors as Generators

1. Brand. The brand and power rating of the generator or motor should be approved by the
manufacturer of the turbines and by the purchaser.
2. Nameplate. The original manufacturer’s nameplate for the generator or motor must be
retained. New nameplates can be added but must not replace the originals.
3. Over-rating. The power rating given on the original nameplate must be at least 10%
more than the scheme rated power.
4. Generator voltage. The “power house voltage” is the voltage at the generator terminals
with powerhouse-consumer isolation switch in off position. This must be between the
nominal national voltage (415 V) and +10% of 415 V.
5. Generator rotational speeds to be selected shall be 1500 rpm (+slip) or lower. In cases of
direct coupling 750 rpm or 1000 rpm generators should be preferred.

B. Synchronous Generators

1. Frequency. The operating frequency should be between 47.5and 52.5 Hz.

2. Pf. The power factor rating should be 0.8 when an ELC is in use except where all loads
and the ELC present a unity power factor.
3. Brushless generators shall be supplied with regulator (AVR). The unit proposed for
interconnection with grid shall have in addition automatic power factor Regulator
(APFR) with automatic change over from AVR to APFR when grid interconnection
circuit breaker.
4. The generator shall be capable of continuous withstand against runaway speed.

C. Induction Motors as Generators

1. Frequency. The frequency should be between 50 and 52.5 Hz. The frequency should be
within this range under all operating conditions, including minimum and maximum
power output, zero consumer load and worst-case consumer load power factor.
2. The induction generator must be over-voltage protected to avoid excessive currents to
flow through the excitation capacitors and induction machine. A protection system is
required that disconnects all or some of the capacitors, to limit the currents flowing to
below the limits for the induction machine windings and the capacitors. Provide MCBs of
suitable current rating in the series with excitation capacitors.
The generator shall be capable of continuous withstand against runaway speed.

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 35 

 Annexure-3

TECHNICAL SPECIFICATION OF GENERATORS

A. CAPACITY AND RATING (Large)

A net capacity of ---------- kVA at rated conditions is required. The generator nameplate rating
shall reflect the necessary additional capacity to supply the excitation equipment. The generator
shall be capable of 10% continuous overload capacity.

(a) Power factor 0.9 lagging

(b) Frequency 50 cycles
(c) Number of phases 3
(d) Voltage between phases, rated (kV) 11
(e) Speed (RPM) To match turbine speed
(f) Stator winding connections Star, (suitable both for grounded
or ungrounded operation)
(h) Excitation voltage, not to exceed 250 VDC
(g) Guaranteed unsaturated (rated current)
Direct axis transient reactance not more than

B. ELECTRICAL CHARACTERISTICS

Each generator shall have the following principle characteristics.

1. Rated continuous rating at ----------

0.9 lagging power factor and at
normal rated terminal voltage
2. Continuous overload capacity 10 %
3. Terminal voltage at which the maximum 11 kV
Continuous rating must be achieved
4. Minimum terminal voltage under 10 % lower then the
Operating continuous with unloaded system normal rated voltage
5. Excitation at maximum leading KVA Not less then 10 %
expressed as percentage of that required
at rated output and power factor
6. Terminal voltage at which the maximum 5 % higher then the
Continuous rating must be achieved normal rated voltage
7. Short circuit ratio on rated KVA 1.0
Base, not less then
8. Total Harmonic Distortion (THD) Not to exceed 5%
9. Deviation factor of wave form, measured 5
in percent of open circuit at rated voltage
and frequency, not more then
10. Efficiency at 10,000 kVA 0.9 power factor 97 %
lagging at normal rated voltage
and frequency not less then percent
11. Normal exciter response for the To suit above ratio

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 36 

 exciter, not less then
12. Ceiling voltage of exciter when connected 2
to the generator field and with rated
exciter current delivered (80 degree C)
8. Line charging capacity of the generator, ----------- kVA
when charging a transmission line, at rated
speed and voltage, without being completely
self excited or unstable not less then KVA
9. Maximum ambient air temperature ----------
degrees centigrade

C. MECHANICAL CHARACTERISTICS

1. Flywheel effect (WR2) of rotating Normal

parts of the generator and exciter
2. Direction of rotation To match turbine
3. Maximum runway speed r.p.m. To match turbine
4. Maximum temperature of inlet cooling 36oC
water for air cooling system
5. Design mechanically to withstand --------- kW
Continuously. Without exceeding the
specified normal operating stress,
a load of kW (1.0 pf)
6. Design mechanically to withstand --------- kW
temporary overloads, with stress not
exceeding one – half the yield point
corresponding to turbine output of
not less then (provided that the duration
of such overload is not sufficient to
cause injurious heating) kW.
7. Designed for operation with a turbine -----------
having the following rated output kW.

D. INSULATION AND TEMPERATURE RISE

a. Insulation shall be provided as follows:

(i) Stator Winding Material corresponding to class F

(ii) Rotor Winding Material corresponding to class F

b. The generator shall be capable of delivering rated output at any voltage and frequency in
the operating range at rated power factor without exceeding the following values of
temperature rise over ambient temp. Cooling air entering the generator at not more than
400C (Cooling water maximum temperature 360C).

(i) Stator Winding 70oC

(ii) Rotor Winding 70oC
(iii) Stator core 750C

c. The maximum temperature rise when the generator is delivering maximum output
corresponding to continuous overload capacity for conditions rated above shall not

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 37 

 exceed 90oC for both for stator and rotor winding respectively. Temperature rise shall be
guaranteed in the tender and shall be measured on site in accordance with IEC 340 or
relevant IS.

E. SPEED RISE AND RUNAWAY SPEED

The moment of Inertia of the generator together with the moment of inertia of the turbine shall be
such that the maximum momentary speed rise under Governor Control on full load rejection
shall not exceed 45% of rated speed for the grid connected generator as station power is supplied
from main generator and adverse effect of this speed rise on motor driven station auxiliaries is
not desirable. Additional flywheel required shall be built in the rotor. Separate flywheel shall not
be permitted.

The maximum runaway speed shall be stated and guaranteed by the supplier. All rotating parts
and bearings shall be capable of withstanding the forces and stresses occurring during runaway
speed for at least 30 minutes without any damage to any part. The guide bearing and guide cum
thrust bearing shall be capable to withstand runaway speed for 30 minutes without supply of
cooling water and continuously with cooling water without abnormal increase of vibrations and
temperature.

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 38 

 Annexure-4

Brushless Excitation System for 1.5 MW, 3.3 kV, 750 RPM, 50 Hz, 0.8 PF, 8 poles Generators (Pacha Project)

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 39 

 Annexure-5

Static Excitation System - Block Diagram for 9 MW, 11 kV, 0.9 PF, 125 RPM Generators

AHEC/MNRE/SHP Standards/Guidelines for selection of Hydro Generator for SHP   Page 40 

 Version 2

STANDARDS/MANUALS/
GUIDELINES FOR
SMALL HYDRO DEVELOPMENT

Electro-Mechanical Works–
Selection of Switchyard Equipment for SHP
(Including Power Transformer and Circuit Breaker)

Sponsor: Lead Organization:

Ministry of New and Renewable Energy Alternate Hydro Energy Center

Govt. of India Indian Institute of Technology Roorkee

May 2011
 CONTENTS

Sl. No. Items Page No.

Section – 1
Guide for Design of Outdoor Step up Sub-Station
And Selection of Equipment
1.0 INTRODUCTION 1
2.0 DESIGN REQUIREMENTS 1
2.1 General 1
2.2 Seismic Consideration 2
2.3 Basic Insulation Level and Insulation Co-ordination 2
2.4 Electrical Clearances for Installing Equipment in the Field 8
2.5 Insulators – Creepage Distance 11
2.6 Insulator Type 12

2 

 
 2.7 Switchyard Structures 12
2.8 GIS Substations 15
2.9 Power Line Carrier Equipment 16
2.10 Substation Auxiliary Facilities 17
2.11 Bus Bar Schemes 17
2.12 Inspection and Maintenance 17
ANNEXURE – 1.1 18
ANNEXURE – 1.2 19
Section – 2
Selection of Switchyard Equipment
1.0 BUS BAR 20
2.0 CIRCUIT BREAKERS 21
3.0 ISOLATORS 21
3.1 Temperature Rise 21
3.2 Rating 22
3.3 Isolator Insulation 22
3.4 Arcing Horn & Arcing Contacts 23
3.5 Load Break Switches 23
3.6 Terminal Connectors 23
3.7 Interlocks 23
3.8 Supporting Structures 24
3.9 Fire Extinguishing System 24
4.0 CURRENT TRANSFORMERS 24
4.1 Type and Rating 25
4.2 Details of Current Transformer 25
4.3 General Requirements 26
4.4 Terminal Connectors 33 kV and Above 27
4.5 Type of Mounting 27
4.6 Tests 28
4.7 External Insulation (12 kV & Above) 28
4.8 Fittings and Accessories (12 kV & Above) 28
5.0 POTENTIAL TRANSFORMER AND COUPLING VOLTAGE
TRANSFORMER 28

3 

 
 5.1 Type and Rating of Potential Transformer 29
5.2 Temperature Rise 30
5.3 11 kV Voltage Transformer 30
5.4 Coupling Voltage Transformer (36 kV & Above) 31
6.0 TRANSFORMERS 31
7.0 LIGHTNING ARRESTORS 31
8.0 EQUIPMENT FOR CUMMUNICATION, RELAYING AND TELE
METERING AND OFF-SITE CONTROL 35
9.0 AUXILIARIES 35
10.0 REPAIR / INSPECTION FACILITIES 35
11.0 PALE FENCING 36
12.0 SWITCHYARD LAYOUT 36
Section – 3
Selection of Power Transformer
1.0 GENERAL 51
2.0 GENERATOR TRANSFORMERS 52
3.0 TRANSFORMER RATING 52
4.0 STANDARD RATING 53
5.0 COOLING 54
6.0 TEMPERATURE RISE, OVERLOAD CAPACITY AND
CONTINUOUS RATING 55
7.0 TRANSFORMER STUDIES 55
8.0 ELECTRICAL CHARACTERISTICS 55
8.1 Type of Transformer and Operating Conditions 55
8.2 Continuous Maximum Rating and Overloads 56
8.3 Voltage Ratio 56
8.4 Duty Under Fault Condition 56
8.5 Electrical Connections 57
8.6 Flux Density 57
8.7 Current Density 57
8.8 Short Circuit Strength 57
8.9 Frequency and System Voltage 58
8.10 Parallel Operation 58

4 

 
 8.11 Vibration and Noise 58
8.12 Basic Insulation Levels (BIL) 58
9. IMPEDANCE 58
10. TRANSFORMER EFFICIENCY 59
11. TERMINAL BUSHINGS 60
12. TANKS 61
13. PRESSURE RELIEF DEVICE 61
14. ANTI EARTHQUAKE CLAMPING DEVICE 61
15. FITTINGS AND ACCESSORIES 61
16. DIELECTRIC TESTS 63
17. ACCESSORIES 63
18. OIL CONTAINMENT AND FIRE PROTECTION SYSTEM 63
19. FACTORY AND FIELD TESTING 64
20. ERECTION, MAINTENANCE TESTING AND COMMISSIONING 64
21. TYPICAL TRANSFORMER RATING AND CHARACTERISTICS 64
ANNEXURE – 3.1 65
ANNEXURE – 3.2 67
ANNEXURE – 3.3 69
ANNEXURE – 3.4 70
Section – 4
Selection of Circuit Breaker

1. INTRODUCTION 71
2. CLASSIFICATION 71
3. TYPE OF CIRCUIT BREAKER 71
3.1 Vacuum Circuit Breaker 73
3.2 Advantages and Disadvantages 73
3.3 Evaluation of SF6 and Vacuum Switching Technologies 73
3.4 Protection Classes for Switchgear Installation 75
4. RATED CHARACTERISTICS 76
5. STANDARD RATINGS OF CIRCUIT BREAKERS 77
6. CO-ORDINATION OF RATED VALUES 84
7. TESTS 86

5 

 
 8. FAULT CALCULATION 86
8.1 Staged Short Circuit Tests 87
8.2 Circuit Breaker Rating for Short Circuit Duty 87
8.3 Simplified Methods for Calculation Short Circuit Current 87
8.4 E/X Simplified method as per IEEE std. C37010-1999 88
8.5 Simplified Method 89

6 

 
 Section –1
Guide for Design of Outdoor Step up Sub-Station
and Selection of Equipment
1. INTRODUCTION

Outdoor step up substation at hydroelectric stations are provided to step up power at generated
voltage generally for interconnection with the grid to evacuate power. Generation voltage in SHP
varies from 415 volts to 11 kV and step up voltage of small hydro upto 25 MW capacity may not
exceed 145 kV. Guidelines for design and selection of comprises of main equipment, ancillary
equipment, switchyard structures and sub station layout.

2. DESIGN REQUIREMENTS

References and Codes

Latest edition of the following shall apply.

IS: 9920 Part I to IV – Alternating current switches for rated voltages above 1000 volts and less
than 52 kV
IS: 9921Part 1 to 5 – Alternating currents disconnectors (isolators) and earthing switches rating,
design, construction, tests etc.
IS: 1893 – Criteria for Earthquake resistance design of structures
IS: 2705 Part 1 to 4 – Current transformer
IS: 3156 Part 1 to 4 – voltage transformer
IS: 3070 part 1 to 3 – Lightning arrestors
IS: 2544 – Porcelain insulators for system above 1000 V
IS: 5350 – Part III – post insulator units for systems greater than 1000 V
IS: 5621 – Hollow Insulators for use in electrical equipment
IS: 5556 – Serrated lock washers – specification
IS: 3716 – Application guide for insulation co-ordination
IS: 2165 – Phase to earth insulation co-ordination
Rural electrification Corporation (REC) specification and standards
Power Engineers Hand Book - Tamil Nadu Engineer’s Association
Central Board of Irrigation and Power - Manual on Sub-Station Layout
UPSEB - Construction Manual for Rural Electrification and secondary system planning

2.1 General
The equipment shall be designed and manufactured to provide most optimum functional value
and neat appearance. All major assemblies or equipment shall be designed to facilitate easy and
quick surveillance, maintenance and optimum operation. All control sequences shall be simple
and rational.
All live, moving and rotating parts shall be adequately secured in order to avoid danger to the
operating staff. All electrical components shall be electrically earthed.
Suitable lifting eyes and forcing off bolts shall be provided where required or where they will
be useful for erection and dismantling.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 1 
 2.2 Seismic Consideration

Forces caused by earthquake which may occur for the seismic intensity of the zone concerned
should be taken into account. Stresses resulting after including these loads should not exceed
permissible stresses. For Himalayan region projects it may be specified as under:-

Switchyard equipment and structure be designed to safely withstand earthquake acceleration

force 0.3g both in the vertical and horizontal direction.

For other regions refer IS: 1893.

2.3 Basic Insulation Level and Insulation Co-ordination

Insulation coordination is the correlation of the insulation of electrical equipment and system with
the characteristics of protective devices such that the insulation is protected from excessive over
voltages. Thus in a substation the insulation of transformer, circuit breakers, bus supports, etc.
should have insulation strength in excess of the voltage levels that can be provided by protective
equipment such as lightning arrestors and gaps. According to International Electro Technical
Commission Technical Committee No. 28 on Insulation Coordination the same is defined as
follows by IEC:

“Insulation coordination comprises the selection of the electric strength of

equipment and its application in relation to the voltages which can appear on
the system for which the equipment is intended and taking into account the
characteristics of available protective devices, so as to reduce to an
economically and operationally acceptable level the probability that the
resulting voltage stresses will cause damage to equipment insulation or affect
the continuity of service”.

2.3.1 Over-voltages : The selection of basic insulation level for various components of
switchyard equipment and its coordination is based on the extent of different types of over
voltages and dielectric stresses on insulation of the equipment. Overvoltages are classified as
follows (IS: 3716).

(i) Power frequency voltages under normal operating conditions

(ii) Temporary Overvoltages
(iii) Switching overvoltages
(iv) Atmospheric or Lightning overvoltages

The terms atmospheric overvoltages and switching overvoltages are defined by themselves. The
term temporary overvoltages means overvoltages essentially of power frequency or a frequency
close to it. Switching overvoltages are of consequence only at levels above 220 kV and not
applicable to system under consideration. The protection against overvoltages is essentially made
by Surge diverters (lighting arrestors). Lightning impulse wave is defined as time in microsecond
for the wave to reach crest (1.2 micro second) followed by the time in microsecond for the wave
to reach half magnitude (50 micro second). This has been standardized in the test forms to
establish insulation level on a common basis.

2.3.2 Selection of basic Impulse Insulation Level (BIL) : Equipment insulation must
withstand temporary overvoltages and protected against lightning by suitable lightning arrestor.
The basic impulse insulation level should be selected which can be protected with a suitable

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 2 
 lightning protective device. The best protection is provided by modern type (gapless) lightning
arrestors. The spread margin between the BIL and the protective device, allowing for
manufacturing tolerance, is an economic consideration that must balance the chances of
insulation failure against the cost of greater insulation strength. When using lightning arrestors
the economic factor may be one of greater risk to the arrestor than to the equipment insulation.
The arrestor can be applied so that it will protect the insulation but may under certain extreme
conditions, usually unlikely, be subjected to sustained rms temporary over voltages against which
it cannot recover. Practice has been to apply arrestors so that they have an rms voltage rating
above the maximum possible rms line-to-neutral power frequency voltage under any normal or
expected fault condition with sufficient margin. The BIL of the equipment insulation must
therefore be higher than the maximum expected surge voltage across the selected arrestors
selected to withstand highest credible temporary overvoltage.

2.3.3 Station Design for Lightning and Standardisation of Insulation Levels: Station
design for lightning involves in general, provisions of an adequate insulation level for all
equipment and protective measures to prevent, as for as possible lightning overvoltages
approaching that level from appearing on station lines or on equipment. These levels are given in
table 2.1 & 2.2 as per the Indian Standard IS: 2165. In this standard, table 2.1 covers the standard
insulation levels highest system voltages of 52 kV and below and Table 2.2 for highest system
voltages of more than 52 kV and less than 300 kV.

Table 2.1: Standard Insulation Levels for (equipment in range A 1 kV < Um < 52 kV)
clause (4) for preferred value

Highest Rated Lightning Impulse Rated Short Duration Power

Voltage for Withstand Voltage (Peak) Frequency Withstand Voltage (rms)
Equipment Um
List 1 List2
kV kV kV kV
3.6 20 40 10
7.2 40 60 20
12 60 75 28
24 85 125 50
35 145 170 70

Note: Insulation levels as per list 2 are recommended.

For SHP application where temporary overvoltages are high due to speed rise on load throw off
equipment insulation as per list 2 of table 2.1 should be used.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 3 
 Standard Phase-to-Phase Insulation Levels for 52 kV ≤ Um < 145 kV (IS: 2165)
Table 2.2

Highest Voltage Base for P.U. Rated Lightning Rated Short Duration
for Equipment Values Impulse Withstand Power-Frequency
Withstand Voltage
Um Um 2 / 3
(rms) (peak) (peak) (rms)
kV kV kV kV
72.5 59 325 140
123 100 450 185
550 230
145 118 (450)* (230)*
550 230
650 275
245 200 650* 360*
750* 360*
850 360
950 395
1050 460

Generator transformer/step up transformer in SHP are liable to be subjected to high temporary

overvoltages due to load rejection, as well as line capacitance which may remain connected on
interconnecting tie line in case of receiving end breaker opening. Basic insulation level on power
frequency overvoltages of 1.5 per unit for transformers is worked out in table 2.3 for a typical 145
kV transformer.

In case of generator transformer in SHP 90 – 95 % lightning arrestors are recommended.

An increase of impulse level of 15% above the withstand level to earth is recommended for
disconnecting switches between the terminals of each pole in the open condition. A
corresponding increase of distance may be applied for distances between phases for bus bars and
connections, or between connections which may be located on opposite sides of an open
disconnecting switch.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 4 
 Table 2.3
1. Basic Data Example 1.

Highest voltage for equipment Um k V rms 145

Corresponding line to (ground) neutral

⎛Um ⎞ k V rms 83.72
voltage ⎜⎜ ⎟⎟
⎝ 3⎠
Corresponding Temporary over voltage
(derived from system studies)
This voltage is high in step up sub stations k V rms 104.65
due to load rejection i.e. 1.5 per unit

Minimum safety factor

1.25
For lightning overvoltages
Representative Characteristics of Surge
2.
Diverter (obtain from manufacturer)
Rated Voltage (nearest available above 125
kV rms 140
x 104.65)
Maximum lightning impulse spark over
kV 415
voltage
Maximum front-of-wave impulse spark over
kV 470
voltage
Maximum residual impulse spark over
kV 405
voltage

3 Protection Levels

To lightning impulse kV 415

4 Insulation level (phase to earth)

Lightning Impulse

Minimum lightning impulse voltage kV 415

Rated lightning impulse voltage as per IS: kV 550

Ratio of the rated lightning impulse voltage

kV 1.32
to the lightning impulse protective level

2.3.4 Existing Insulation Practice of Substation Equipments

The substation equipments namely the power transformers circuit breakers and disconnecting
switches are considered for detailing the existing practice.
Existing Practice

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 5 
 The commonly adopted insulation levels at present for the above mentioned equipments are given
in table 2.4 with reference to Karnataka and Tamil Nadu (66 kV, 110 kV and 220 kV) and Punjab
(132 kV Bhakra System).

A commonly adopted practice is to locate lightning arrester as near to the transformer as possible.
In large substations additional arresters could be required at suitable locations to protect circuit
breakers, isolators and other equipments. Since each of these equipments cannot be provided with
arrester individually, it is the normal practice to adopt higher insulation to provide the equipment
with as good protection as is economically justified. Insulation level for circuit breaker and other
equipments connected to the busbar together with the bubars themselves are designed for
insulation class about 10% higher than the insulation level for the transformers (one class higher).
Insulation level across the open poles of the isolating switches is kept about 10 to 15 % higher
than that provided between the poles and the earth, so that in the event of a surge at an open
isolating switch, the flashover should pass to earth and not across open poles.

Table 2.4: Insulation Levels of the terminal Equipments Recommended

S. Description Nominal voltage in kV

No. 220 132 110 66 33 11
1. Highest system voltage 245 145 123 72.5 35 12
kV (rms)
2. Power transformer 900 550 450 325 170 75
insulation levels kV
(Crest)
3. Circuit breaker kV 1050 650 550 350 170 75
(Crest)
4. Disconnecting switches 1050 650 550 380 170 75
between pole and earth
kV (Crest)

2.3.5 Protection with Spark Gaps

The spark gap is among the cheapest protective devices used for diverting the surges from line to
earth. After the break down of the spark gap the circuit breaker always operates to interrupt the
fault of power frequency current in the circuit. Thus the operation of the gap generally results in
the circuit outage and interruption of supply of the power system. It is therefore used as a back up
to surge arrestor (lightning arrestor).

Spark gaps specified for fitting to the bushings of power transformers, potential and current
transformers, rated 66 kV and above.

The spark gaps are to conform to the following specification, to prevent any damage to the
bushing due to the flashover gazing the petticoats of the bushing:

a) The rods are to be circular not less than 12 mm diameter

b) The rods should overhang their supports at-least one half of the gap spacing.
c) The rods should be mounted so as to give a height of 1.3 times the gap spacing
plus 100 mm (4 inches) above the ground plane as shown in fig. 2.3.5.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 6 
 Fig. 2.3.5
The gap setting furnished below are adopted for all stations whether lightning arresters are
provided or not.

Spacing for standard rod-gaps is given in table 2.5 (TNEB Practice).

Table 2.5

Critical Flashover Spacing of Standard Rod Gap

voltage 1/50 micro
second
Highest system Um Positive Polarity Negative Polarity
voltage kV rms Um kV Peak × 2
3
72.5 59.1 7.7 6.5
123 100.4 12.4 10
145 118.3 15.4 13
245 200 28.0 23

Note: - The spacing given above are for the standard atmospheric conditions viz:

Barometric pressure = 760 mm Hg.

Temperature = 200C
Humidity = 11 grams of water vapour per cubic meter.

For non-standard atmospheric conditions the spacing to give the critical flash over voltage should
be modified by dividing the above spacing by ‘d’ where:
P
d = 0.386 ×
(273 + t )
P = barometric pressure in mm Hg.
and t = temperature in 0C.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 7 
 When the humidity differs the standard spacing should be increased by 1% for each gramme per
cubic meter below the standard value and decreased by 1 % each gramme per cubic meter above
the standard.

2.4 Electrical Clearances for Installing Equipment in the Field

Space requirements and layout of electrical equipment in switchyard depends upon various types
of air clearances required to be provided for laying the equipment of different rated voltages.
Following basic clearances govern the sub-station design.

(i) Earth clearance i.e. phase to ground clearance.

(ii) Phase clearance i.e. phase to phase clearance.
(iii) Safety clearance i.e. (a) Ground clearance.
(b) Section clearance.

2.4.1 Co-relation between insulation Level and minimum Phase to earth Clearances

Minimum clearances in air between live conductive parts and earthed structures to secure a
specified impulse withstand voltage for dry conditions as per IS 3716-1978 are given in table 2.6.

These minimum clearances are valid for altitudes not exceeding 1000 m and do not include any
addition for construction tolerances, effect of short circuits, safety of personnel etc. these
clearances are suitable for general application, providing as first approximation.

Table 2.6: Correlations between Insulation Levels and Minimum Phase-to- Earth Air
Clearances as per IS: 3716 - 1978

Rated Lightning Impulse Withstand Minimum Phase-to-Earth Air Clearances (mm)

Voltage (kV)
45 60
60 90
75 120
95 160
125 220
170 320
325 630
380 750
450 900
550 1100
650 1300
750 1500
850 1600
950 1900
1050 2400

2.4.2 Working Safety Clearances

Safety clearance consists of ground clearance and section clearance. The ground clearance is the
minimum clearance from any point on or about the permanent equipment where a man may be
required to stand (measured from the position of feet) to the nearest part not at earth potential of

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 8 
 an insulator supporting a line conductor and the same has been taken as 2.59 meters (i.e. 8.5 feet),
which is the dimensions for a tall man with arms outstretched below the conductor.

The section clearance is the minimum clearance from any point on or about the permanent
equipment where a man may be required to stand (measured from the position of feet) to the
nearest unscreened live conductor in the air. The section clearance system upto 132 kV 650 kV
BIL may be determined by adding 2.5 meters to minimum phase to ground clearance of 1.3 which
works to 3.8 meters for 132 kV system.

Height of Bus Bars Above Ground Within Sub-Station Promises

The minimum conductor clearance from ground is obtained by adding ground clearance, earth
clearance and height of bus bar supporting clamps on the post insulator. In consideration to it,
minimum height of bus bar for 132 kV may be about 365 mm which may be raised to about 450
mm to correspond to the terminal height of the 132 kV circuit breakers.

Conductor Clearance from Roadways Within Sub-Station Promises

Minimum clearance between overhead conductors and roadways within sub-station premises is
computed to be as “Ground clearance plus 625 mm. This dimension provides for a truck with a
man standing on its top 130 + 625 meter = 755 meters app.

2.4.3 Minimum and Safety clearances recommended in Central Board of Irrigation and
Power manual

Clearances from the point of view of system reliability and safety of operating personnel
recommended for sub station upto 245 kv are given in table 2.7. These include the minimum
clearances from live parts to earth, between two live parts of different phases and sectional
clearances between live parts of different phases and sectional clearances between live parts and
work section required for maintenance of an equipment. Besides, it is also necessary that
sufficient clearance to ground is also available within the substation so as to ensure safety of the
personnel moving about within the switchyard.

Table 2.7

Highest Lightning Minimum clearances Safety clearances

System impulse voltage (mm)
Voltage (kV) (kVp)
Between phase Between
& earth (mm) phase (mm)
36 170 320 320 2800
72.5 325 630 630 3100
123 450 900 900 3400
550 1100 1100 3700
145 550 1100 1100 3700
650 1300 1300 3800
245 950 1900 1900 4300
1050 2100 2100 4600

Notes:

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 9 
 i) Safety clearances are based on the insulation height of 2.44 m which is the height of
lowest point on the insulator where it meets the earthed metal.
ii) The distances indicated above are not applicable to equipment which has been subjected
to impulse test since mandatory clearances might hamper the design of the equipment,
increase its cost.
iii) The values in table refer to an attitude not exceeding 1000 m and take into account the
most unfavorable conditions which may result from the atmospheric pressure variation,
temperature and moisture. A correction factor of 1.25 % per 100 m is to be applied for
increasing the air clearance for altitude more than 1000 m and upto 3000 m.
iv) No safety clearance is required between the bus-bar isolator or the bus-bar insulator.
However, safety clearance is necessary between the section isolator or the bus-bar itself
and the circuit breaker.
v) For the purpose of computing the vertical clearance of an overhead strung conductor the
maximum sag of any conductor shall be calculated on the basis of the maximum sag in
still and the maximum temperature as specified.
vi) As an alternative to maintain safety clearances in some substation earthed barriers are
used to ensure safety of the maintenance personnel. The use of earthed barriers is quite
common at lower voltages of 36 kV 72.5 kV. In case of paucity of space and if 2.44 m
clearance is not available then localized earthed fencing with clearance can be considered
by the designer.

Following are the normally adopted spacing for the strung bus :

Highest System Voltage rating Spacing between phases in mm

kV
245 kV 4500
145 kV 3600
72.5 kV 2200
36 kV 1300
12 kV 1300 or 920
The spacings for the equipment in a sub-station depend upon the manufacturers practice.

The minimum clearance of live parts to ground in an outdoor sub-station are as follows (Tamil
Nadu Practice) :

Highest System Voltage Clearances in mm

245 kV 5500
145 kV 4600
72.5 kV 4600
36 kV 3700
12 kV 3700

The bottom most portion of any insulator or bushing in service should be at an absolute
minimum height of 2500 mm above ground level.

2.4.4 Section Clearances

A station which can not be shunt down entirely for maintained purpose must be split into sections
so arranged that any one section can be isolated from its neighbour with adequate clearances as

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 10 
 given below. Where it is impossible to obtain the required safety clearances, earthed screens may
be provided.

The following table gives the sectional clearances for persons to enable inspection cleaning,
repairs; painting and general maintenance works to be carried out in a sub-station.

Highest System Voltage Section Clearances

145 kV 3500 mm
72 kV 3000 mm
36 kV 2800 mm
12 kV 2600 mm

The following minimum clearances should be adopted for enclosed indoor busbars and
connections in air which are not filled with any insulating medium like compound etc.

Highest System voltage between Minimum clearances in Air

phases or poles
Between phases or Phase/pole to earth
poles
36 kV 356 mm 222 mm
12 kV 127 mm 76 mm

In indoor kiosks in power stations and main receiving stations, the busbar and connections should
also be taped but the fact of taping should however, be taken into consideration in deciding the
clearances. In addition indoor kiosks etc. should be subjected to a flashover test at works to prove
that clearances are adequate so as to prevent flashovers during surge conditions.

2.4.5 Standard Bay Widths (in meters) as TNEB Practices

66 kV -7
33kV - 4.6
22 kV - 3.8
11 kV - 3.5

2.5 Insulators – Creepage Distance

Provision of adequate insulation in a substation is of primary importance from the point of view
of reliability of supply and safety of personnel. However, the station design should be so evolved
that the quantity of isolators required is minimum commensurate with the expected security of
supply. An important consideration in determining the insulation in a sub-station, particularly if it
is located near sea or a thermal power generating station or an industrial plant is the level of
pollution. As a first step to combat this problem, special insulators with higher creepage distance
should be used.

The creepage distances for the different pollution levels are provided according to table 2.8.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 11 
 Table 2.8: Creepage distance for different pollution levels

Pollution Level Creepage distance (mm/kV of Recommended

highest system voltage) for adopted

Light 16 25 x highest
Medium 20 system voltage
Heavy 25 i.e. 1813 mm for
Very heavy 31 72.5 kV

For determining the creepage distance requirement, the highest line-to-line voltage of the system
forms the basis.

2.6 Insulator Type

Types of insulators used:

A) Bus Support Insulators

(i) Cap and Pin type

(ii) Solidcore type
(iii) Polycone type

B) Strain Insulators

(i) Disc insulators

(ii) Long rod porcelain insulators
(iii) Polymer insulators

2.7 Switchyard Structures

The cost of structures also is a major consideration while deciding the selection of a substation.
For instance, in the case of the strain/flexible bus-bar arrangement, cost of structures is much
higher than in the case of rigid bus type. Similarly the form of structures also plays an important
part and the choice is usually between using a few heavy structures or a large number of smaller
structures. While finalizing the design, size and single line diagram of structures, safety clearance
requirements should be ensured.

Steel is the most commonly used in India for substation structures. Normally the steel structures
are hot-dip galvanized so as to protect them against corrosion. However, galvanizing sometimes
has not proved effective, particularly in substations located in coastal or industrial areas and in
such cases painting also becomes essential. In other countries special paints have developed
which are applied within the shop and these paints have quite effective.

2.7.1 Design Data for Design of Switchyard Structures

(Based mostly on Tamil Nadu Electricity Board Practice)

Design Loads

i) Wind Pressure on Structures (Refer table 7)

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 12 
 Maximum for the area on 1.5 times the projected area of one face for latticed structures
and on single projected area in the case of other structures.

In coastal regions the wind pressure may be assumed as 170 kg/sq.m.

ii) Wind Pressure on Conductor

…… kg/sq.m. (according to area see table 2.9) on two-thirds projected area.

iii) Maximum tension of transmission line conductors strung from terminal tower to station
structures or of strung buses for lines 33 kV and above … 226.8 kg. (Tamil Nadu
Electricity Board Practice - TNEB Practice).

iv) Maximum spans adjacent to stations:

a) Lines rated 66 kV and above …. 152.40 m

b) Lines rated 33 kV and below … 60.96 m

v) Uplift on adjacent spans:

Maximum slope (mean of the 3 – phase) at the point of attachment 1 : 8 above horizontal.

Table 2.9: Wind Pressure & Temperature Data

The table below gives the values of wind pressure and maximum and minimum temperatures specified in
different states, as per REC for design of structure.

State Wind Pressure Zones Max. Temp. Min. Temp. ICE Loading

Kg/m2 0
C 0
C
Andhra - 75 100 - 60 10 Nil
Pradesh
Assam - - 97.8 - 50 4.44 Nil
Bihar - - 97 - 60 4 Nil
Gujarat - 75 100 - 50 10 Nil
Haryana - - - 150 50 (-) 2.5 Nil
Kerala - 75 - - 55 10 -
Madhya - 75 - - 60 4.4 Nil
Pradesh
Maharashtra 50 75 100 150 65 5 Nil
Karnataka 50 70 - - 54.4 10 Nil
Orissa - 75 100 150 60 5 Nil
Punjab - 100 - - 64.5 (-) 2.5 Nil
Rajasthan - - 100 - 50 (-) 2.5 Nil
Tamil Nadu - 73.25 87.8 122 65.5 (-) 5 Nil
Uttar Pradesh - 75 - 150 60 4.44 Nil
West Bengal - 75 100 150 60 0 Nil

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 13 
 2.7.2 Working Stresses

a) for steel:
Bending .. .. 1265 kg/sq.cm.
Shear .. .. 1265 kg/sq.cm.

b) for concrete – 1 : 2 : 4
Bending .. .. 52.7 kg/sq.cm.
Shear .. .. 5.27 kg/sq.cm.
Bend .. .. 7.03 kg/sq.cm.

2.7.3 Factor of Safety

Indian Electricity Adopted by (TNEB) Recommended

Rules
a. Fopr steel 2.0 2.5 based on maximum
loading conditions (on elastic
limit for tension members and
crippling load for As per TNEB
compression members). Practice
b. For R. C. 2.5 3.5 on ultimate breaking load
c. For hand 3.0
Moulded R. C.

Factory of safety against overturning:

a) Steel 2.5
b) R. C. 2.0

2.7.4 Slenderness Ratio (L/R)

Ratio of unsupported length (l) to radius of gyration (r) should not exceed;

a) 140 for leg members

b) 200 for other members having calculated stresses only and 250 for members having
nominal stress only.

2.7.5 Minimum Thickness for Steel Members

2.7.6 Material

Steel employed for structures – open hearth steel with a high yield point and an ultimate strength
of not than 3867 kg/sq.cm.

The following maximum stresses in lbs. per square inch are assumed for outdoor structures,
fabricated out of steel sections manufactured in India;
i. Tension 18,000
ii. Compression 18,000 – 76 l/r where l/r is less than 150 and 13,000 – 48
l/r where l/r is more than 150
iii. Shear on bolts 13,500
iv. Bearing on 27,000
bolts
AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 14 
 2.8 GIS Substations

Advancement in the use of SF6 as an insulating and interrupting medium have resulted in the
development of gas insulated substations. Environment and/or space limitations may require the
consideration of GIS (gas insulated substation) equipment. This equipment utilizes SF6 as an
insulating and interrupting medium and permits very compact installations. GIS substation are
preferable to air insulated system ((AIS) because of following reasons:

i) Compact design reduces space requirements

ii) Higher reliability
iii) Life cycle costs and safety are better because GIS is maintenance free
iv) Location advantage especially in areas (town) where space costs are high
v) Environmental advantage as rain, dust, snow, ice, salt etc. do not affect the
hermetically sealed metal clad GIS

Three-phase or single-phase bus configurations are normally available up to 145 kV class, and
single phase bus to 500 kV and higher, and all equipment (disconnect/isolating switches,
grounding switches, circuit breakers, metering current, and potential transformers, etc.) are
enclosed within an atmosphere of SF6 insulating gas. The superior insulating properties of SF6
allow very compact installations.

GIS installations are also used in contaminated environments and as a means of deterring animal
intrusions. Although initial costs are higher than conventional substations, a smaller substation
footprint can offset the increased initial costs by reducing the land area necessary for the
substation.

2.8.1 GIS Compact Switchgear

Compact sub-station with gas insulated switchgear may be considered in following cases.

i) Installations in areas with high risk of pollution and corrosion from industrial plants or by
marine and desert climates.
ii) Applications involving use of metal clad switchgear with components of conventional
design to minimize area requirement.
iii) Underground substations
iv) Outdoor installation where space is not easily available
v) Installations in difficult site conditions (e.g. seismically active areas, high altitude areas
etc.).

2.8.2 Metal Clad GIS Switchgear

SF6 – insulated metal enclosed high voltage switchgear upto 145 kV are now available and may
be used where space may be provided. The data of siemens GIS sub station as per Siemens Power
Engineers Guide is given in table 2.10 Feeder control and protection are inbuilt.
Table 2.10

Rated voltage (kV) Upto 145

Rated power frequency Upto 275
withstand voltage (kV)
Rated lightning impulse Upto 650
withstand voltage (kV)

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 15 
 Rated normal current bus Upto 3150
bar (A)
Rated normal current feeder Upto 2500
(A)
Rated breaking current (kA) Upto 40
Rated short-time withstand Upto 40
current (kA)
Rated peak withstand Upto 108
current (kA)
Inspection (years) > 25
Bay width (mm) 800

2.8.3 Compact Air Insulated Substation (CAIS)

A compact station is mounted on common base frame with integrated current transformer and
with SF6 insulated dead tank interrupter assembly. Compact air insulated sub-station (CAIS)
factory assembled with dead tank SF6 design is being offered for such-station at 66 kV and 132
kV. Technical particulars of Areva sub station are given in table 2.11 space saving upto 60% is
claimed for H type (single sectionalized bus) substation with two incoming generator
transformers and two outgoing feeders configuration.

Extracts of Siemens Power Engineering guide regarding metal clad switchgear substation upto
145 kV is enclosed as Annexure 1.1.

Extracts from Areva regarding compact substation are at annexure 1.2.

Table 2.11

Technical Characteristics
Rated voltage kV 72.5 123 145
Rated frequency Hz 50/60
Rated power-frequency withstand kV 140 230 275
voltage
Rated lightning impulse withstand kV 325 550 650
voltage
Rated normal current A 2500
Rated short-circuit breaking current kA 40
Rated short-circuit making current kA 100
Rated duration of short circuit s 3
Circuit Breaker Specific Technical Characteristics
Opening Time ms 38 38 38
Break time ms 50 60 60
Closing time ms 85 106 106
2.9 Power Line Carrier Equipment

The carrier equipment required for communication, relaying and telemetering is connected to line
through high frequency cable, coupling capacitor and wave trap. The wave trap is installed at the
line capacitor. The coupling capacitors are installed on the line side of the wave trap and are
normally base mounted. The wave traps for voltage levels upto 145 kV can be mounted on the
gantry structure on which the line is terminated at the substation or mounted on top of the
AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 16 
 capacitor voltage transformer. However, the wave traps for voltage levels of 245 kV and above
generally require separate supporting insulator stacks mounted on structures of appropriate
heights.

2.10 Substation Auxiliary Facilities

Auxiliary facilities for step up sub station in SHP are designed in conjunction with power house
auxiliaries and are discussed in a separate guideline.

2.11 Bus Bar Schemes

Simple single bus bar schemes or single sectionalized bus bars schemes are generally provided in
small hydro scheme.

2.12 Inspection and Maintenance

Adequate facilities must be provided in the substation for inspection and maintenance of various
equipment and at the same time to ensure safety of personnel and maintain proper and other
clearances.

During maintenance, it is essential that the equipment is isolated and earthed. One of the essential
requirements of earthing is that earthing must be actually visible from the point of working in the
substation. Where this is not possible, provision of temporary earthing is made near the
equipment. Besides the permanent illumination, provision should also be made for portable lights
for which purpose power outlets should be provided in marshalling boxes or equipment cubicles.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 17 
 Annexure-1.1
Metal Clad SF6 Insulated Switchgear up to 145 kV

Three-phase enclosures are used for type 8D9N switchgear in order to achieve extremely low component
dimensions. The low bay weight ensures minimal floorloading and eliminates the need for complex
foundations. Its compact dimensions and low weight enable it to be installed almost anywhere. This
means that capital costs can be reduced by using smaller buildings, or by making use of existing ones, for
instance when medium voltage switchgear is replaced by 145 kV GIS.

The bay is based on a circuit breaker mounted on a supporting frame. A special multifunctional cross-
coupling module combines the functions of the disconnector and earthing device. It can be used as:

• An active busbar with integrated disconnector and work-in-progress earthing switch

• Outgoing feeder module with integrated disconnector and work-in-progress earthing switch.
• Busbar sectionaliser with busbar earthing. For cable termination, a cable termination module can
be equipped with either conventional sealing ends or the latest plug-in connectors. Flexible single
pole modules are used to connect overhead lines and transformers by using a splitting module
which links the 3-phase encapsulated switchgear to the single pole connections.

The feeder control and protection can be located in a bay-integrated local control cubicle, mounted in the
front of each bay. It goes without saying that we supply our gas-insulated switchgear with all types of
currently available bay control systems - ranging from contactor circuit controls to digital processor bus-
capable bay control systems, for example the modern SICAM HV system based on serial bus
communication. This system offers:

• Online diagnosis and trend analysis enabling early warning, fault recognition and condition
monitoring
• Individual parameterization, ensuring the best possible incorporation of customized control
facilities.
• Use of modern current and voltage sensors. This results in a longer service life and lower
operating costs, in turn attaining a considerable reduction in life cycle costs.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 18 
 Annexure-1.2
Areva Compact Air Insulated Substation

All components are mounted together on a common base frame. The compact is optimized by combining
single components.

The circuit breaker with an integrated current transformer is the main component of the module. In
addition, the bushings of the breaker also function as insulators for the fixed contacts of the bus and
feeder disconnectrors.

The horizontal interrupter chamber is the determining factor for the low overall height of the entire
module, allowing all energized components to be located on one level.

The three column disconnectors installed in the module allow for a small clearance between phases and a
reduced bay width.

The integrated voltage transformer may substitute the support insulator of the feeder disconnector.

Add-on bus and feeder earthing switches can provide the entire module with additional functions.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 19 
 Section –2
Selection of Switchyard Equipment
1. BUS BARS

The out door bus-bars are either of the rigid type or the strain type.

In the rigid type, pipes are used for bus-bars and also for making connections among the various
equipments wherever required. The bus-bars and the connections are supported on pedestal
insulators. This leads to a low level type of switchyard wherein equipment as well as the bus-bars
are spread out. Since the bus-bars are rigid. The clearances remain constant. However as the bus-
bars and connections are not very high from the ground, the maintenance is easy. Due to large
diameter of the pipes, the corona loss is also substantially less. It is also claimed that this system
is more reliable than the strain bus. This type is however not suitable for earthquake prone area
due to rigidity.

The strain type bus bars are an overhead system of wires strung between two supporting
structures and supported by strain type insulators. The stringing tension may be limited to 500-
900 kg. depending upon the size of the conductor used. These type of busbras are suitable for
earthquake prone areas.

1.1 Bus bar Material – The materials in common use for bus bars and connections of the
strain type are ACSR and all aluminum conductor. The following sizes are commonly used.
Code Name Remarks
12 kV = 6 x 4.72 + 7 x 1.76 Dog upto 10 MVA in case line conductor is
36 kV = 6 x 4.72 + 7 x 1.76 Dog upto 10 MVA of higher sizes same be
72.5 kV = 30 x 2.79 + 7 x 2.79 ACSR Panther adopted as bus bar
145 kV = 30 x 4.27 + 7 x 4.27 ACSR Zebra material
245 kV = 54 x 3.53 + 7 x 3.53 ACSR Moose

In the case of rigid bus arrangement, aluminum pipes of Grade 63401 WP confirming to IS: 5082
are commonly used. The sizes of pipes commonly used for various voltages are given below:

External Dia. Internal Dia System Remarks

Voltages
42 mm 36 mm Upto 36 kV Tamil Nadu Uses 50 mm IPS
Aluminium Tube upto 72.5 kV
60 mm 52 mm Upto 72.5 kV Tamil Nadu Uses 75 mm IPS
80 mm Upto 145 kV Aluminium Tube for 110 & 230 kV

Since aluminum oxides rapidly great care is necessary in making connections. In the case of long
spans expansion joints should be provided to avoid strain on the supporting insulators due to
thermal expansion or contraction of pipe.

The bus bar sizes should meet the electrical and mechanical requirements of the specific
application for which they are chosen.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 20 
2. CIRCUIT BREAKERS

For selection of circuit breakers refer section 4.

Mounting and supporting structure

The circuit breakers should be self supporting type. However, if necessary for the purpose of
minimum ground clearance the circuit breakers should be mounted on raised steel structures
which should be included in the scope of supply of circuit breaker. Information and data for
design of foundations from the supplier of the circuit breaker be obtained.

3. ISOLATORS

Isolating switches are used to isolate equipment for maintenance. Isolating switches on line side
are provided earthing blade for connection to earth in off position for safety. Transfer of load
from one bus to another by isolators is not recommended. The isolating switches are designed for
no load operation. Inadvertent operation of the isolating switch on load will damage the switch.
Although a variety of disconnect switches are available, the factor which has the maximum
influence on the station layout is whether the disconnect switch is of the vertical break type or
horizontal break type. Horizontal break type normally occupies more space than the vertical

Isolators for 12 kV and 36 kV normal system voltage conform to IS: 9920 (Part I to IV) and for
voltage 66 kV and above as per IS: 9921.

Earthing switches is a mechanical switching device for earthing parts of a circuit, capable of
withstanding fir a specified time short-circuit currents, but not required to carry normal rated
currents of the circuit.

Disconnecting switches may be motorized or operated manually it is recommended that

kV and above should be motorized. Earthing switches may be manually operated.

In case of double circuit lines the earthing switches shall be capable of switching inductive
(electromagnetically) and capacitive currents (electrostatically induced) as per the values
specified in IEC 62271 – 102 when parallel circuit is energized. The disconnector must also be
capable of interrupting and making parallel circuits when transferring load between main and
reserve bus bars according to IEC requirements.

3.1 Temperature Rise

Maximum temperature attained by any part of the isolating switch/ isolating cum-earth switches
when in service at site under continuous full load conditions and exposed continuously to the
direct rays of the sun and the air has to be evaluated carefully and depends upon site conditions
e.g. for 2 x 10 M Mukerian SHP 72.5 kV switchyard (Punjab Plains), it was specified as follows
and is recommended for similar breakers.

i) Reference ambient temperature in shade = 500C

ii) Reference temperature under direct rays = 600C
of the sun for limiting temperature rise
as per IS: 9921

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 21 
 3.2 Rating

Each isolating switch should have the following particulars (table 2.3.2) under the site conditions
for the system under design.

Table 2.3.2

1. Highest system voltage 72.5 kV 36 kV 12 kV

2. Rated frequency (cycle/second) 50 c/s 50 c/s 50 c/s
3. Rated lightning impulse withstand voltage (without arcing
horn)
325 kV 170 kV 75 kV
i) To earth and between poles (kV Peak) (+ ve & - ve wave 195 kV 85 kV
ii) Across the isolating distance (kV peak) to earth &
between poles)
4. Rated one-minute power frequency wet withstand voltage
i) To earth and between poles (kV rms) 140 kV 70 kV 28 kV
ii) Across the isolating distance (kV rms) (against ground & 80 kV 32 kV
Voltage against ground and between poles between poles)
5. Continuous rated current (Amps) 1600 A 630 A 400 A
6. Short time current ratings
i) For one second not less than kA (rms) 20 kA 16 kA 16 kA
ii) For 3 second To be stated To be To be
stated stated
7. Rated peak withstand current kA (peak) in closed position To be stated 40 kA 40 kA
8. Transformer off-load breaking capacity A (rms) To be stated 6.3 kA 6.3 kA
9. Line charging capacity A (rms) To be stated 6.3 A 2.5 A
10. Rated DC voltage for auxiliary circuits A (rms) To be stated
11. Rated supply frequency and voltage of AC operating 3 phase 415 volts and single phase 220 V
devices AC

Isolators 36 kV and 12 kV: should conform to IS: 9920

Isolated 72.5 kV & above should conform to IS: 9921

The location of disconnect switches in substations affects substation layouts. Maintenance of the
disconnect contacts is also a consideration in the layout. In some substations, the disconnects are
mounted at high positions either vertically or horizontally. Although such substations occupy
smaller areas, the maintenance of disconnect switch contacts in such substations is more difficult
as the contacts are not easily accessible.

3.3 Isolator Insulation

Insulation to ground, insulation between open contacts and the insulation between phases of the
completely assembled isolating switch should be capable of withstanding the dielectric test
voltages specified as per IS: 2026. Insulation between open contacts of a pole should at least 15%
more than the insulation between the live parts of a pole to ground so that if any flashover occurs
when switch is open, it should be to the ground.

The post insulators should consist of no. of stack units conforming to IS: 2544. The insulators
selected should be suitable for use in the type of normally polluted atmosphere of the area as per

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 22 
 relevant IS and should be specifically suited to meet the particular requirements of ultimate
torosional strength and cantilever loads which they will be called upon to resist during service at
the rated voltages. The guaranteed data and particulars of the insulators adopted for the
equipment should be obtained from the supplier.

The porcelain should be homogeneous and free from all cavities and flaws.

Design of the insulators should ensure ample insulation, mechanical strength and rigidity for
satisfactory operation under site conditions. The design should also ensure that the losses caused
by capacitive currents or conduction through dielectric are minimum and that the leakage due to
moist and dirty insulator surface is least.

3.4 Arcing Horn & Arcing Contacts

A set adjustable arcing horns should be mounted on each insulator stack of the isolating switch.

Besides above adjustable arcing horns which are required for the purposes of insulation co-
ordination, the isolators may be provided make before and break after arcing contacts if
considered necessary by the manufacturers.

A graph showing impulse and power frequency spark over voltages for various gap settings of the
arcing horns be obtained from supplier.

3.5 Load Break Switches

Load break switches for sectionalizing or for selection of bus if required may be used as per
following specifications.

i) 12 kV REC Specification 43; IS: 9920 Part I to IV

ii) 36 kV REC Specification 54; IS: 9920 Part I to IV
iii) 72.5 kV & above IS: 9921

3.6 Terminal Connectors

Each isolator connected with outgoing lines should be provided with appropriate number of
bimetallic, solderless clamp type of connectors suitable for the transmission line conductor. Each
terminal clamp should be suitable for both vertical & horizontal connection of station bus bars
and jumpers. Each isolator should also be provided with appropriate number of grounding
terminals and clamps for receiving grounding connections. The maximum length of the jumper
that may be safely connected or any special instructions considered necessary to avoid undue
loads on the post insulators should be avoided.

3.7 Interlocks

“For the purpose of making the operation of the isolator dependent upon the position of the
associated circuit breaker or other equipment as may be required at site, a suitable electrical
interlock should be provided on each isolator. The interlocks should be of robust design of some
reputed make and contained in a weather proof and dust tight housing.

Besides the electrical interlocks, the earthing switches should be provided with mechanically
operated interlock so as to ensure that: -

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 23 
 (a) It should be possible to close the earthing switch only when the isolating switch is in the
fully open position.
(b) It should be possible to close the isolating switch only when the earthing switch is in the
fully open position.
(c) The earth switch should not open automatically while attempting to close the isolator.
The operation of the earth switches should also be interlocked with the CVTs/CTs
supplies from the transmission line i.e. it should be possible to close the earth switch only
when the line is dead from the feeding end, and there is no supply from the secondaries
of the line CVTs/CTs.

(d) The operation of earth/isolating switch should not take place when the corresponding
isolator/earth switch is in operating stroke.

In addition to the above, the line and the bus isolators should fulfil the following
requirements :-

(i) The circuit breaker of corresponding bay is open.

(ii) The bus isolator of the bus coupler bay should close only when the bus coupler circuit
breaker is open.
(iii) The line isolator should close only when the corresponding circuit breaker and the
earthing switch of the corresponding line are open.
(iv) Electro magnetic type interlocking should also be provided to avoid wrong local
operation of the isolator (manual or motor) when the corresponding circuit breaker is in
closed position. Operation of isolator may be categorized manual or motorized with
remote facility according to facilities provided in the system.

Isolators and earth switches should be so designed that the above noted requirements can be
conveniently met.

3.8 Supporting Structures

All isolators and earthing switches should be mounted rigidly in an upright position on their own
galvanised steel supporting structure and not on the bus-bar structures.

3.9 Tests

Each isolator and earth switch should strictly comply with the requirements of all the type tests
and should be subjected to all routine tests stipulated in the latest edition of relevant Indian
standard.

Copies of the type tests already performed on similar type of isolators must be obtained and
scrutinized for adequacy.

4. CURRENT TRANSFORMERS

a) 12 kV and Above

Current transformers may be either of the bushing type or wound type. The bushing types are
normally accommodated within the transformer bushings and the wound types are invariably
separately mounted. The location of the current transformer with respect to associated circuit

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 24 
 breaker has an important bearing upon the protection scheme as well as layout of, substation.
Current transformer class and ratio is determined by electrical protection, metering consideration.

Outdoor Type: The outdoor CTs shall be either oil filled type or of resin cast type which shall be
enclosed in a sealed housing to avoid direct exposure to sun and other atmospheric effects.
Indoor Type: The CTs shall be of resin-cast type suitable for indoor installation.

Current ratings, design, Temperature rise and testing etc. should be in accordance with IS: 2705
(Part I to IV). Unless otherwise specified in these specification.

12 kV current transformers should conform to REC specification 59/1993

4.1 Type and Rating

The current transformer should be of outdoor type, single phase, oil immersed, self cooled and
suitable for operation in 3 phase solidly grounded system (11 kV CTs will be as per Para 1.6
above).

Each current transformers should have the following (table 2.4.1) particulars under the site
conditions for the system under design (typical values upto 72.5 kV system are given).
Table 2.4.1
i) Nominal system voltage 66 kV 33 kV 11 kV
ii) Highest system voltage 72.5 kV 36 kV 12 kV
iii) Frequency 50 Hz 50 Hz 50 Hz
iv) Insulation level (kV Peak)
(based on system insulation coordination)
Impulse withstand test voltage with 1.2/50 325 kV 170 kV 75 kV
micro-second, + ve and – ve wave to earth
and between poles
v) One minute power frequency (wet) withstand 140 kV 70 kV (rms) 28 kV
voltage against ground and between poles. (rms) (rms)

vi) Short time current rating 31.5 kA 31.5 kA 12.5 kA

(based on system studies)
vii) Rated dynamic current peak 78.75 kA 2.5 time of short time current
(based on system studies) rating vi

viii) Total minimum creepage of CTs bushings As per Para 2.5 of section 1
(based on environment)

4.2 Details of Current Transformer

Details of current transformer i.e. current, number, ratio, no. of cores and protection/metering
class based on metering and relaying scheme be specified.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 25 
 4.2.1 Temperature Rise

a) 36 kV and above

The maximum temperature attained by any part of the equipment in service at site under
continuous overload capacity conditions and exposed continuously to the direct rays of sun
should not exceed the permissible limit fixed by the applicable standard, when corrected for the
difference between the ambient temperature at site and the ambient temperature specified by the
standard.

b) Temperature rise of 11 kV Class CTs

The maximum temperature rise of windings shall not exceed the following (table 2.4.2):

Table 2.4.2
Indoor Type Outdoor Type
Maximum ambient temp. 450C 600C
Permissible temp. rise for
Class E insulation 700C 500C
Class B insulation 800C 600C
Class F insulation 1050C 850C

Note: The supplier shall furnish evidence to the satisfaction of the purchaser about the class of
insulation used.

4.3 General Requirements

a) 36 kV & Above

Current transformers should be of robust design, tested quality and reliable in operation. Only
pure high grade paper, wound evenly under controlled conditions and impregnated with mineral
oil under high vacuum should be used for the main insulation. The assembly of each CT should
be dried, filled with appropriate quality of insulating oil under high vacuum and hermetically
sealed with or without inert gas to eliminate undesirable effect of moisture and oxygen on the
internal insulation. No breathers and/or drying chemicals should be used in the design and
construction of CTs.

The shape of the external metal parts should ensure that rain water runs off and it does not
accumulate. All external surfaces should be resistant to atmospheric corrosion either by the
selection of suitable materials or by proper treatment such as hot dip galvanisation, zinc coating
and suitable enamel painted over rust inhibitive coat of zinc chrome primer etc. Likewise, the
internal metal surfaces coming in contact with oil should be given proper treatment unless the
material used itself is oil resistant. Bolts, nuts and washers to be used as fastners should be
heavily hot dip galvanised throughout. The galvanising should conform to IS: 2629-1966. All
CTs should have an oil level gauge marked with the maximum and minimum levels. Although no
oil samples may be required to be taken for analysis nor any filter connections made for
reconditioning of oil at site but a filling plug at the top and a drain at the bottom of the lower tank
should be provided on each CT for use during initial assembly or any subsequent repair.

The current transformers should be with dead/live tank design. The current transformers should
be of single phase oil immersed, self cooled and suitable for services indicated, complete in all

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 26 
 respects conforming to the latest edition of relevant standard specification. The cores should be of
high grade, non-ageing silicon laminated steel of low hysteresis loss and high permeability to
ensure high accuracy at both normal and fault currents. The CTs should be hermetically sealed
with or without inert gas to eliminate breathing and prevent air and moisture from entering into
the tank. To take care of volumetric variation of oil due to temperature changes-stainless steel
bellows/Nitrogen should be provided. In case Nitrogen is used the supplier should ensure that gas
is filled at suitable pressure to take care of the expansion & compression of nitrogen gas. The
equipment should be provided with oil level gauge and pressure relieving device capable of
releasing abnormal internal pressures. The secondary terminals should be brought out in a
compartment on one side of the equipment for easy access. The secondary taps should be
adequately reinforced to withstand normal handling without damage. Equipment should be
provided with power factor terminals for testing loss angle (Tan delta). The equipment should
also be provided with drain valve, sampling plug to check deterioration of oil characteristics and
replacement of oil at site. Means adopted for sealing the CTs hermetically and to absorb the
variation in volume of oil due to temperature variation by way of provision of stainless steel
volume adjustable bellows or other means should be clearly brought out in the tender. Rubber or
PVC/synthetic bellows for the purpose should not be accepted. The secondary terminal of CTs
should be provided with short circuiting arrangement.

b) 11 kV Class

Windings: Change in the CT ratio shal be obtained by providing tapings in the secondary
winding. The primary bar and secondary windings shall be of copper.

Core: The core of the CT shall invariably be of torroidal type. The magnetic circuit shall be of
high grade, non-ageing electrical silicon laminated steel of low hysterias loss and high
permeability to ensure high accuracy at both normal and over currents.

4.4 Terminal Connectors 33 kV and Above

All current transformers should be provided with appropriate number of solderless clamp type
primary connectors suitable for ACSR conductor and should be suitable for horizontal as well as
vertical take off with single conductor as per actual requirement.

4.5 Type of Mounting

a) 12 kV & Above

The current transformers should be suitable for mounting on steel structures. The necessary
flanged, bolts etc. for the base of CTs should be galvanized.

b) 11 kV Outdoor Type

The CT shall be supported on a suitable post insulator to be mounted on a pedestal/steel structure.

Mounting flanges, bolts, etc. shall be hot dip galvanized and shall be supplied along with the CT.
Suitable mounting holes shall be provided at the base for clamping to the structures.

The CTs shall be provided with bolted type terminals to receive ACRS conductors upto 15 mm
dia (without requiring use of lugs) both in vertical and horizontal directions. The terminals shall
be such as to avoid bimetallic actions.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 27 
 4.6 Tests

Each current transformer should comply with type and routine test including short time current
test as stipulated in relevant Indian Standard specification.

4.7 External Insulation (12 kV & Above)

The external insulation should comprise of a hollow porcelain, which will also serve as a housing
for the main insulation or other internal parts of the CTs. Insulators should be of high grade and
homogeneous procelain made by the wet process. The poreclain should have hard glazing and
should comply with the requirements of IS 5621 in all respects. The skirt forms should be
carefully selected to achieve the necessary flashover distance and total / protected creepage
distances as required.

4.8 Fittings and Accessories (12 kV & Above)

1. Primary terminals
2. High frequency current surge divertors
3. Terminal connectors for connections from line to the CT primary
4. Oil level gauge
5. Pressure relief device
6. Expansion chamber or other suitable type of device for absorbing variations in the
volume of oil due to change of temperature.
7. Weather proof secondary terminal box fitted with door and complete with terminals and
shorting links.
8. Lifting lugs
9. Fixing lugs with bolts, nuts and washers for holding down the CTs on the supporting steel
structures.
10. Rating and diagram plates
11. First filling of oil
12. Oil filling plug and drain valve
13. Earthing terminals

5.0 POTENTIAL TRANSFORMER AND COUPLING VOLTAGE TRANSFORMER

a) 33 kV & Above

The voltage transformer may be either of the electro-magnetic type or the capacitor type. The
electro-magnetic type VTs are costlier than the capacitor type and are commonly used where
higher accuracy is required as in the case of revenue metering. For other applications capacitor
type is preferred particularly at high voltages due to lower cost and it serves the purpose of a
coupling capacitor also for the carrier equipment. For ground fault relaying an additional core or a
winding is required in the Voltage transformers which can be connected in open delta. The
voltage transformers are connected on the feeder side of the circuit breaker. However, another set
of voltage transformer is normally required on the bus-bars for purpose of synchronization.
Potential transformer class and ratio is determined by electrical protection, metering
consideration.

b) 12 kV

The voltage transformer shall of outdoor, 3 phase either oil filled or resin cast type, which

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 28 
 The voltage transformers shall be of outdoor, 3 phase either oil filled or resin cast type, which
shall be enclosed in a weather-proof housing to avoid direct exposure to sun and other
atmospheric influences. The incoming and outgoing terminals shall be brought out through
suitable porcelain bushings. The voltage transformer shall be suitable for operation in a solidly
grounded system.

5.1 Type and Rating of Potential Transformer

Potential transformer, design, Temperature rise and testing etc. should be in accordance with IEC:
186, IS: 3156 (Part I & II).

The PTs should be single phase oil immersed self cooled type suitable for outdoor installation of
kV class required. The core should be of high grade non ageing electrical silicon laminated steel
of high permeability. The PTs sealed hermetically scaled to eliminate breathing and prevent air
and moisture entering the tank. Oil level and pressure releasing device etc. should be provided.

Each potential transformers should have the following (table 2.5.1) particulars under the site
conditions for the system under design (typical values for 72.5 kV system are given).

1. Rated voltage 72.5 kV 36 kV 12 kV

2. Rated frequency 50 Hz 50 Hz 50 Hz
3. Accuracy class of winding 1.0 1.0 1.0
4. Voltage ratio 66 kV/√3/110V/√3 33 kV/√3/110V/√3 11 kV/√3/110V/√3
5. Grade of oil As per IS: 335
6. Maximum phase angle error with 40 min. 40 min. 40 min.
25% and 110% of rated burden at
0.8 p.f. lagging at any voltage
between 80% and 120%
7. Temperature rise at 1-1 times As per IS: 3156 As per IS: 3156 As per IS: 3156
rated voltage with rated burden
(OC)
8. Rated voltage factor & time Continuous 1.2 Continuous 1.2 Continuous 1.2
30 sec. – 1.5 30 sec. – 1.5 30 sec. – 1.5
9. 1 minute power frequency 140 kV r.m.s. 75 kV r.m.s. 28 kV r.m.s.
(wet/dry) withstand test voltage
10. 1.2/50 micro seconds impulse 325 kV (Peak) 170 kV (Peak) 75 kV (Peak)
wave withstand test voltage
11. One minute power frequency 2 kV 2 kV 2 kV
withstand test voltage on
secondary
12. 3 second short time current relay As per IS: 3156 As per IS: 3156 12.5 kA
13. Dynamic Rating As per IS: 3156 As per IS: 3156 2.5 times
14. Minimum creepage distance of
bushings (based on environment) As per Para 2.5 of section 1

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 29 
5.2 Temperature Rise

a) 36 kV & Above

The maximum temperature of the windings, cores etc. should not exceed 45°C over ambient,
while max. temperature of oil at top should not exceed 35°C over ambient. The PTs should be
suitable for mounting on steel structures. All nuts, bolts, flanges and base should be hot dip
galvanized. The terminal connectors should be such as to give intimate contact between
conductor & terminal and offer protection against and effects of electrolytic and atmospheric
corrosion and should also have sufficient mechanical strength. The connectors should conform IS
5556: 1970. The junction boxes should be suitable for terminating all the connections of the PTs
secondaries with other equipments of the power station 400V grade terminal connectors of 15
Amp (continuous) current rating should be provided.

b) 12 kV

When tested in accordance with IS: 3156, the temperature rise of the windings shall not exceed
the following *table 2.5.2) limits:

Class E insulation 500C

Class B insulation 6000C
Class F insulation 850C

Note: Maximum ambient temperature shall be taken as 650C

5.3 11 kV Voltage Transformer

The tank shall be given three coats of rust preventing paint. The other iron parts shall be hot dip
galvanized. The tank shall be provided with lifting lugs either welded on the sides or top cover
plate of the tank.

The dimensions and electrical characteristics of the 11 kV bushings shall be in accordance with
IS: 2099-1986 or its latest version.

The tank shall be provided with two separate earthing terminals.

The unit shall have rating and diagram plate and will have suitable base channels to
facilitate mounting of the equipment on the structure.

Terminals: The voltage transformers shall be provided with bolted type terminals on the 11 kV
side to receive ACSR conductors upto 8 mm dia (without requiring use of lugs) both in vertical
and horizontal directions. The terminals shall be such as to avoid bimetallic action.

Indoor Type

The voltage transformer shall be of resin-cast type suitable for indoor installation and shall be
normally mounted on one of the 12 kV incoming circuit breakers.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 30 
 5.4 Coupling Voltage Transformer (36 kV & Above)

These transformers should be suitable for use on transmission line to pass through the carrier
frequencies for communication and low voltage for protection and metering. The single phase
CVTs should be of suitable ratio (say 66 kV/√3/110V/√3 for 66 kV line) suitable for outdoor
installation on steel structures. The equipment should be supplied with terminal connectors
suitable for vertical take off from line conductor and hot dip galvanized base fasteners. Other
details should be in accordance with the specifications for potential transformers. The secondary
terminals should be provided duly marked for above requirements.

The wave traps should hanged underneath feeder bay structure. The carrier frequencies and wave
trap capacity should be decided in accordance with the other ends of the transmission lines
terminating at sub station.

6. TRANSFORMERS

Selection of power transformer is discussed in section 3. Layout of transformer is discussed as it

is the largest piece of equipment in a substation and it is, therefore, important from the point of
view of handling and station layout. In small hydro stations transformer are installed in the
switchyard and the bay width is determined by transformer dimensions. Handling of transformer
is normally done by the powerhouse crane and for large transformer rails are laid from
powerhouse to the site of installation in switchyard. For this purpose bi-directional rollers are
provided on the transformers. Arrangement for removal of transformer in case of
repair/maintenance without disturbing other equipment is required and also affects layout. In
order to reduce the chances of spread of fire, transformers are provided with a soaking pit of
adequate capacity to contain the total quantity of oil. Sometimes where feasible drainage
arrangements are provided to drain the oil away from the transformers in case of fire. Besides,
separation wall are provided in between the transformers and also between the transformer and
roads within the substation.

7. LIGHTNING ARRESTORS

Lightning arrestors are the basis of insulation co-ordination (Para 2.3 of section 1) in the system
and are installed at outdoor transformer terminals for direct protection against lightning impulse
overvoltage spark over (1.2/50 micro second wave) and are capable of withstanding dissipation of
energy associated with lightning impulse only. This implies that temporary overvoltages (at or
near power frequency) which are of the order of mili-second must be withstood to avoid damage.
Taking into consideration high temporary over voltages expected on load throw off 90- 95 %
lightning arrestors should be provided.

Metal oxide (gapless) lightning arrestor confirming to following standards are now being
specified.

IEC: 99-4 - Specification part – 4 for surge arrestor without gap for AC system
IS: 3070 - Specification for lightning arrestors

Typical parameters for a 66 kV system are given (table 2.7.0) below.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 31 
 Table 2.7.0

1. Nominal system voltage (kV rms) 66 kV 33 kV 11 kV

2. Highest system voltage (kV rms) 72.5 kV 36 kV 12 kV
3. 1.2/50 microsecond impulse voltage
withstand level
a) Transformer (kVp) 325 170 75
b) Other equipment and lines (kVp) 325 170
4. Minimum prospective symmetrical fault 31.5 kA To be stated
current for 1 second at Arrestor location
(kA rms) (based on system studies)

5. Anticipated levels of temporary over

voltage and its duration(based on system
studies)
a > Voltage (p. u.) 1.5/1.2 1.5/1.2 1.5/1.2
b > Duration (seconds)

6. System frequency(Hz) 50 ±2.5 c/s 50 ±2.5 c/s 50 ±2.5 c/s

7. Neutral Grounding Effectively Effectively Effectively
earthed earthed earthed
8. Number of Phases Three Three Three

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 32 
General Technical Requirements

1 The Surge Arrestors should conform to the technical requirements given in table 2.7.1.
2 The energy handling capability of the Arrestor offered, supported by calculations should
be obtained with offer.
3 The Lightning Arrestor should be fitted with pressure relief devices and arc diverting
ports and should be tested as per the requirements of IEC specification for minimum
prospective symmetrical fault current.
4 The grading ring on each complete Arrestor for proper stress distribution should be
provided if required for attaining all the relevant technical parameters.

Table 2.7.1
Technical Requirements For Metal Oxide (Gapless) Lightning Arrestors

1. System voltage 66 kV 33 kV 11 kV
2. Rated Arrestor Voltage kV rms 60 30 9
3. Max. continuous operating 49
voltage (kV rms)
4. Installation Outdoor Outdoor Outdoor
5. Class Station Class Station Class Station Class
6. Type of construction for 10 kA Single Column, Single Column, Single Column,
rated arrestor Single-phase Single-phase Single-phase

7. Nominal discharge current 10 kA 10 kA 5 kA

corresponding to 8/20 micro sec
wave shape (kA rms)
8. Type of mounting Pedestal Pedestal Pedestal
9. Connection Phase To Earth Phase To Earth Phase To Earth
10. Max.Switching Surge kV(P) 140 70 NA
Protective level voltage at 1000
amp.
11. Maximum steep current impulse 186 93 38
residual voltage at nominal
discharge current kV (Peak)
12. Maximum residual voltage at 170 85 32
nominal discharge current kV
13. Minimum prospective 31.5
symmetrical fault current for
pressure relief test(kA rms)
14. a. Terminal Connector suitable Single suitable See note 1
for ACSR conductor size ACSR
b. Take off Vertical/Horizontal Vertical/Horizontal Vertical/Horizontal

15. Whether insulating base and Yes Yes Yes

discharge counter with milli-
ammeter are required
16. Minimum creepage distance As per Para 2.5 of section 1
of Arrestor housing(mm)

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 33 
Note 1

Terminal Arrangement: The tope metal cap and the base of the lightning arrestors shall be
galvanized. The line terminal shall have a built-in-clamping device which can be adjusted for
both horizontal and vertical take off to suit ACSR (conductor size to be specified by the
purchaser). The base of the lightning arrestors shall be provided with two separate terminals
distinctly marked for connection to earth.

Sealing: The arrestors shall be hermetically sealed to avoid ingress of moisture. Suitable rubber
gaskets with effective sealing system should be used. Manufacturers should device a suitable
routine production testing to verify the efficiency of sealing.

Disconnective Device: The arrestors for 11 kV system may be provided with a suitable
disconnecting device. This shall be connected in series with the ground lead and should not affect
the sealing system of the arrestors. The disconnecting device shall conform to the requirements
specified in IS: 3070 (Part – 2) – 1985.

Pressure Relief Device: The arrestors for 33 kV and 66 kV system should have a suitable
pressure relief system in order to avoid damage to its porcelain housing.

7.2 Lightning Protection

A substation has to be shielded against direct lightning strokes by provision of overhead earth
wires or spikes. This equipment is essential irrespective of the isoceraunic level of the area due to
.serious consequences and damage to costly equipment in case substation is hit by a direct stroke.
The choice between these two methods depends upon several factors economy being the most im-
portant consideration. Both the methods have been used sometimes even in the same station.
Generally, the spikes method involves taller structures than the alternative of using earth wires.
Another method' comprises the use of separate lightning masts which are provided at location
determined on the basis of sub station area and height of bus-bars. - Besides providing lightning
protection, these masts serve as supports for luminaires required for switchyard illumination.
Spikes and the earth-wire .have to be suitably placed so as to provide coverage to the entire
substation equipment. Generally an angle of shield of about 45° for the area between ground
wires and, 30° for other areas is considered adequate for the design of lightning protection
system.

7.3 Insulators

Provision of adequate insulation in a substation is of primary importance from the point of view
of reliability of supply and safety of personnel. However, the station design should be so evolved
that the quantity of insulators required is the minimum commensurate with the security of supply.
An important consideration in determining the insulation in a substation, particularly if it is
located near sea or a thermal power generating station or an industrial plant is the level of
pollution. As a first step to combat this problem, special insulators with higher leakage distance
should be used. In case this does not suffice, washing the insulators by using live line equipment
has to be resorted to and this aspect has to be kept in mind while deciding the layout of the
substation. Another method which has proved to be successful in other countries involves the
application of suitable type of greases or compounds on the surface of the insulators. This,
however, also requires cleaning of insulation, the frequency depending upon the degree and the
type of pollution.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 34 
8. EQUIPMENT FOR COMMUNICATION, RELAYING AND TELE METERING AND
OFF-SITE CONTROL

Following types of equipments may be used for the purpose.

i) Carrier Equipment
ii) Microwave
iii) VHF wireless
iv) Dedicated fibre optic cable

VHF equipment is normally recommended for 33 kV systems. Fibre optic cable is recommended
when offsite control is provided.

The carrier equipment required for communication, relaying and Tele metering is connected to
line through coupling capacitor and wave trap. The wave trap installed at the line entrance. The
coupling capacitors are installed on the line side of the wave trap and are normally base mounted.

Economic study for Microwave transmission for the purpose is required.

9. AUXILIARIES

Besides the main equipment a number of auxiliary facilities and system as enumerated below
have to be provided. These are discussed alongwith auxiliaries for the powerhouse. In step-up
substations most of the facilities are provided in the powerhouse.

a) Earthing and Grounding – Steel grounding system is provided for earthmat and
interconnection
b) Oil Handling System – portable oil purification system is provided
c) Illumination and lighting system – illumination system is discussed with auxiliaries
system
d) Compressed air system – is required for cleaning etc. and provided in the powerhouse
e) Fire protection system – All substations should be equipped with fire lighting systems
conforming to the requirements given in latest IS: 1646 and Fire protection manual Part –
I issued by Tariff Advisory Committee of Insurance Companies.
f) AC Auxiliary power system – is provided in the power house
g) DC system is provided in the powerhouse
h) Cables – discussed in powerhouse electrical auxiliaries

10. REPAIR/INSPECTION FACILITIES

Large substations sometimes require the facilities of repair bay alongwith a crane of adequate
capacity for handling the heaviest equipment, which is usually the transformer. In hydropower
station powerhouse crane is generally used for this purpose. Repair/service bay of powerhouse is
used for repair of transformer.

Provision of a rail track should be made for movement of transformer from switchyard to the
repair bay. Points for jacking, winching should be provided at the transformer foundations and
900 turn on the rail track for changing the direction of the wheels.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 35 
11. PALE FENCING

Pale fencing around switchyard consists of 75 mm wide and 2500 mm high pales fixed on two
members 45 x 45 x 6 mm angle horizontal runners. Vertical supports may be of 50 x 50 x 6 mm
angle. Two meter gates of approximately 4000 mm width (2000 mm wide each leaf) is normally
required for entry/exist of transformers etc.

12. SWITCHYARD LAYOUT

Low level layout of the switchyard of step up station should be provided. Layout of switchyard
may be generally designed in accordance with Central Board of irrigation and power manual on
Sub-Station layout for 36 kV and above. Rural electrification standard be adopted for 12 kV
substations. Typical layouts of substations are attached as follows:

12.1 12 kV outdoor switchyard with Lattice type structure recommended for hilly areas – 2 x
500 kVA Agnoor SHP
12.2 12 kV outdoor switchyard with pole structure – REC standard layout
12.3 36 kV outdoor switchyard – single sectionalized bus (H-Type) 2 x 3.5 MW Sikasar
Project – 2 sheets
12.4 36 kV outdoor switchyard – single bus (CBI & P Manual) – 2 sheets
12.5 72.5 kV outdoor switchyard – single sectionalized bus – proposed 2 x 10 MW Mukerian
project stage –II – 2 sheets.
12.6 145 kV outdoor switchyard single bus (CBI & P) manual for single sectionalized bus – 2
sheets.
12.7 245 kV outdoor switchyard single bus (CBI & P) manual for single sectionalized bus – 2
sheets.

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 36 
 Fig. 12.1: Layout of 12 kV Agnoor SHP SubStation

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 37 
 11kV LINE
11kV LA LAS

NOTES
1. THE LAYOUT AS SHOWN ENVISAGES THE USE OF 11k V
VACUUM CIRCUIT BREAKERS (REC SPEC. 22/1983).
WHICH SHALL NOT REQUIRE ISOLATING SWITCHES AS
THEIR INTEGRAL PART AS PARTICULARLY NO
M AINTENANCE IS NEEDED ON THESE BREAKERS AND IT
WILL ALSO ECONOM ISE IN THE COST.

2. CONDUCTORS USED FOR 11k V JUM PERS AND BUSBARS

SHALL NOT BE LESS THAN 50 SQ.M M . (C.E.) ACSR.

3. THE SUPPORTS SHALL NOT BE CYDED BUT M AY BE

SUITABLY CONCRETED

33/11kV P.Tf VCB FDR VCB

12500 4000 4500

11kV LA

11 kV
VCB

11kV

11kV

11kV/0.433kV
STATION TRANSFORMER

Fig. 12.2: 12 kV Outdoor Switchyard with Pole Structure – REC Standard layout

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 38 
AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 39 
Fig. 12.4 Layout of 72.5 kV Switchyard (Plan) (Sheet 1 of 2)-CBI & P Manual

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 40 
 Fig. 12.4 Layout of 72.5 kV Switchyard (Plan) (Sheet 2 of 2)-CBI & P Manual

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 41 
 46400
6800 7600 3000
LA

2000 2000 CVT

X

3000
WT

8500
LI

3000
1000 3500 2000

L
CT

2500
CB

2500
PT

BI

750 2500 2000 2500 750 2550 66 k V

2000

1800 2000 2000 2550 2000 2000 1800

BI
9500

Z
1200

Y
1500

CT
1800

R
L CB
2000

Y
2000
2250
39750

B
LA
1800
2250

12 M VA 11/66 KV
TRANSFORM ER

2000 2000 1800 SINGLE LINE DIAGRAM

Z
2000

7000

X
3500

1500 1500
LEGEND
1 SF 6 CIRCUIT BREAKER
2 ISOLATOR
3 CURRENT TRANSFORM ER
4 WAVE TRAP
5 COUPLING VOLTAGE TRANSFORM ER
6 LIGHTNING ARRESTOR
2250

7 POST INSULATOR
8 POTENTIAL TRANSFORM ER
9 PALE FENCING
10 LIGHTING M AST
11 LIGHTING AND SHIELDING M AST
4250

B Y R B Y R
5000

WATER

2000

8800
TANK

8800 8800 8800

COM PRESSOR ROOM Y

5000

C.L. OF TRACK

PLAN

Fig. 12.5 Layout of 72.5 kV Switchyard (Plan) (Sheet 1 of 2)-Mukerain Stage-II (2 x 10MW)

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 42 
 11

2500
1800 2000 2000 1800
7 6

10000
7500
6000
6000

500
2000
1500 1500 3800 2250 2500 2000 3000 2250 4250 3000
1800 1800 20550
SECTION Y - Y 5000
SECTION Z-Z
2500

10

8
7500

7500
9

500
6000
4000

2000
1800 2000 2000 1800 2300 1500 1500 3050 750 2500 2000 2500 750 2550 2000 2000 1800 1800 2000 2000
7600 9100 7000 9100 7600 2000
40400
SECTION L - L

LEGEND
1 CIRCUIT BREAKER
2500

2 ISOLATOR
3 CURRENT TRANSFORMER
4 WAVE TRAP
8 5 COUPLING VOLTAGE TRANSFORMER
1800 2000 2000 1800 6 LIGHTING ARRESTOR
4 1 7 POST INSULATOR
6 5 3
2 8 POTENTIAL TRANSFORMER
9 PALE FENCING
10 LIGHTING MAST
11 LGHTING AND SHIELDING MAST
10000

6000
7500

1500 1500
1800 1800

SECTION Z-Z
3000 2500 2500 2000 2750 2250 2000 1800

20550

SECTION X -X

Fig. 12.5 Layout of 72.5 kV Switchyard (sections) (Sheet 2 of 2) – Mukerian Stage II (2 x 10

MW)

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 43 
Fig. 12.6:145 kV Outdoor Switchyard Single Bus (CBI & P) Manual for Single Sectionalized bus (Sheet 1
of 2)

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 44 
 Fig.12.6: 145 kV Outdoor Switchyard Single Bus (CBI & P) Manual for Single Sectionalized bus (Sheet 2 of 2)

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 47 
Fig. 12.7: 245 kV Outdoor Switchyard Single Bus (CBI & P) Manual for Single Sectionalized bus (Sheet 1
of 2)

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 48 
Fig. 12.7: 245 kV Outdoor Switchyard Single Bus (CBI & P) Manual for Single Sectionalized bus (Sheet 2 of 2

AHEC/MNRE/SHP Standards/E&M Works- Guidelines for Selection of Switchyard SHP Station  Page 50 
 Section –3
Selection of Power Transformer
1. GENERAL

Power transformers function is to convert electric power from one voltage level to another. In
hydroelectric plants, step up transformer perform the task of delivering power produced by the
generators to the transmission system. Most of these transformers are unit connected i.e. directly
connected to generators with or without a generator breaker. These power transformers are
generator transformers. Power transformers are liquid immersed. Power transformers are located
outside preferably in the switchyard /or transformer deck in powerhouse. These guidelines are for
generators/power transformers used in SHP for outdoor switching i.e. 11 kV to 220 kV.

1.1 Relevant national and international standards in this connection are as follows :

IS: 2026 (Part 1 to 4) - Specifications for Power Transformer

IS: 2099 - Bushings for alternating voltage above 1000V
IS: 3639 - Fittings and accessories for power transformer
IEC: 60076 (Part 1 to 5) - Specifications for Power Transformer
CBI & P - Manual on transformer (oil immersed)
(Publication No. 295-2007)
IS : 1180

2. GENERATOR TRANSFORMERS

Power transformer which step up the power produced by hydroelectric generating units (0.415 to
11 kV) to a level which matches the sub transmission/transmission system voltage (typically 12
kV to 245 kV class) for range of power houses under considerations are 2 winding oil immersed
transformers.

Three Phase Versus Single Phase Transformer

Three phase generator transformers should be used unless transport limitations or other
special reasons require use of single-phase transformer because of the following reasons.

a) Higher efficiency than three single-phase units of equivalent capacity.

b) Smaller space requirements and reduction in weight and dimensions.
c) Lower installed cost.
d) Lower probability of failure when properly protected by surge arrestors, thermal devices
and oil cooling and preservation system.

3. TRANSFORMER RATING

The full load kVA rating of the generator transformer should be at least equal to the maximum
kVA rating of the generator or generators with which they are associated. Where transformers
with auxiliary cooling facilities have dual kVA ratings. The maximum transformer rating should
match the maximum generator rating.

AHEC/MNRE/SHP Standards/E&M Works­ Guidelines for Selection of Switchyard SHP Station  Page 52
4. STANDARD RATING

Standard rating for power transformer of voltage class commonly used are given in table 1 (A, B,
C & D) may be used if possible.

Table 1 (A) 11 kV Class Transformers

Three phase power Voltage ratio kV (Nominal) Cooling

rating kVA

200 11/0.433 ONAN

315 11/0.433 ONAN
630 11/0.433 ONAN
1000 11/0.433 ONAN
1600 11/0.433 ONAN

Table 1 (B) 33 kV Class Transformers

Three phase power Voltage ratio kV Cooling

rating MVA

1.0 33/11 ONAN

1.6 33/11 ONAN
3.15 33/11 ONAN
4.0 33/11 ONAN
5.0 33/11 ONAN
6.3 33/11 ONAN
8.0 33/11 ONAN
10.0 33/11 ONAN

Table 1 (C) 66 kV Class Transformers

Three phase power Voltage ratio kV Cooling

rating MVA

6.3 66/11 ONAN

8.0 66/11 ONAN
10.0 66/11 ONAN
12.5 66/11 ONAN/ONAF
20.0 66/11 ONAN/ONAF

Table 1 (D) 132 kV Class Two Winding Transformers

Threes phase power rating Voltage ratio kV Cooling

MVA
16 132/11 ONAN/ONAF
25 132/11 ONAN/ONAF
31.5 132/11 ONAN/ONAF

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5. COOLING

Transformer cooling system for generator transformers specified table 2.4 (A,B & C) in
accordance with IS: 2026 (part II) are identified according to the cooling method employed.
Letter symbols used in the table are as follows :

(i) Cooling Medium Symbol

a. Mineral oil or equivalent flammable O

synthetic insulating liquid
b. Air A

(ii) Kind of Circulation

a. Natural N
b. Forced (oil not directed) F

Transformer is identified by four symbols for each cooling method for which a rating is assigned
by the manufacturer.

1st Letter 2nd Letter 3rd Letter 4th Letter

Kind of cooling Kind of circulation Kind of cooling Kind of circulation
medium indicating medium indicating
the cooling that is in the cooling medium
contact with the that is in contact
windings with the external
cooling systems

Following cooling systems are used in hydroelectric stations upto 25 MVA capacity

Symbol
ONAN Oil Immersed Natural Air Cooled
ONAF Oil Immersed Forced Air Cooled
OFAF Oil Immersed with forced oil circulation Forced Air Cooled

Transformers when located in powerhouse should be sited so that unrestricted ambient air
circulation is allowed. The maximum transformer rating should match maximum generator rating
with forced cooling in dual rating transformers, which are commonly employed. The rating of
these dual rated transformers is usually as follows:

ONAN/OFAF

ONAN - 60%
OFAF - 100%

The rating under ONAF condition although not guaranteed should be about 80%.

Standby cooling capacity should be provided for different type of forced cooling as follows as per
Central Board of Irrigation and Power Manual on Transformer.

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 ONAN/OFAF -2 – 50% group
2 – 100% pump of which one will be standby, 2 –
Standby fans one in each 50% group
Or
3 – 50% group with independent pump and fans out
of which one group to act as standby.

6. TEMPERATURE RISE, OVERLOAD CAPACITY AND CONTINUOUS RATING

Conservative value of temperature rise, overload capacity and continuous rating of transformer
located in the switchyard should be specified. For the purpose of standardization of maximum
temperature rise of oil and windings, the following ambient temperatures are recommended by
CBI & P.

Cooling medium : Air

Maximum ambient temperature : 500C
Maximum daily average ambient temperature : 400C
Maximum yearly weighted average temperature : 320C

With the above ambient temperature condition the temperature rises for power transformers as
per CBI & P are as given below :

Oil 0C Winding 0C
50 55

However more conservative temperature rise are specified for generator, transformers. Reference
ambient temperatures and climatic conditions and temperature rise specified for generators
transformer at Mukerian stage II in Punjab given in Annexure 3.1.

7. TRANSFORMER STUDIES

It is recommended that following studies be carried out for transformers 72.5 kV and above from
economic considerations.

a) Type of cooling
b) Insulation level
c) Departure from normal design impedance

8. ELECTRICAL CHARACTERISTICS

8.1 Type of Transformer and Operating Conditions

All transformers, should be oil immersed and may be either core or shell type and should be
suitable for outdoor installation. Normally oil immersed transformer should be provided with
conservator vessels. Where sealed transformers are specified, there will be no conservator but
adequate space will be provided for expansion of oil without developing undue pressure.

Transformers designed for mixed cooling should be capable of operating under the natural cooled
condition upto the specified load. The forced cooling equipment shouldl come into operation by
pre-set contacts in WTI and the transformer will operate as forced cooled unit.

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 Transformer should be capable of remaining in operation at full load for 10 minutes after failure
of blowers without the calculated winding hot-spot temperature exceeding 1500 C. Transformer
fitted with two coolers each capable of dissipating 50% of the losses at continuous maximum
rating (CMR) should be capable of remaining in operation for 20 minutes in the event of failure
of the blower associated with one cooler without the calculated winding hot-spot temperature
exceeding 1500C.

8.2 Continuous Maximum Rating and Overloads

Transformers provided with mixed cooling should comply, as regards its rating temperature rise
and overloads, with the appropriate requirements of IS: 2026 when operating with natural cooling
and with mixed cooling.

All transformers, except where stated should be capable of operation continuously, in accordance
with IS: loading guide at their CMR and at any ratio. In case bi-directional flow of power is
required, that should be specifically stated by the purchaser.

Temperature rise test should be performed at the tapping as desired by the purchaser. If nothing
has been stated by the purchaser, the test should be carried out at the tapping with the highest load
losses.

The transformer may be operated without danger an any particular tapping at the rated kVA
provided that the voltage does not vary by more than + 10% of the voltage corresponding to the
tapping.

The transformer should be suitable for continuous operation with a frequency variation of +3 %
from normal 50 Hz. Combined voltage and frequency variation should not exceed the rated V/f
ratio by 10%.

8.3 Voltage Ratio

The high voltage rating should be suitable for the voltage of the transmission system to which it
will be connected. The low voltage rating should be suitable for the generator voltage (if unit
connected) or generator bus. Generator transformers are generally provided with Off-circuit taps
on HV side for HV variation from +2.5 to – 7.5 % in steps of 2.5 %. On load taps if provided
should have tapping range of +5% to – 10 % in steps of 1.25%.

For interconnecting 2 transmission voltage system say 66 kV and 132 kV size, auto-transformers
with standard ratings as per IS should be provided. For interconnecting auto-transformers, use of
either regulating transformer or on-load tap changer may be made. Interconnecting transformer
are generally star-star connected with tertiary delta winding for flow of 3rd harmonic current.

8.4 Duty Under fault Condition

Generator transformer should be designed for exceptional circumstances arising due to sudden
disconnection of the load and should be capable of operating at approximately 25 % above
normal rated voltage for a period not exceeding one minute and 40 % above normal rated voltage
for a period of 5 seconds. All transformers above 5 MVA should be provided with over fluxing
protection device.

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 8.5 Electrical Connections

Transformers shall be connected in accordance with IS vector symbol specified in ordering

schedule of the requirements. Vector symbol specified for generator transformers is normally
YND11.

Auto connected and star/star connected transformers shall have delta connected stabilizing
windings if specified in the order. Two leads from one open corner of the delta connection shall
be brought out to separate bushings. Links shall be provided for joining together the two
terminals so as to complete the delta connection and earthing it external to the tank.

8.6 Flux density

The maximum flux density in any part of the core and yokes, of each transformer at normal
voltage and frequency should be such that the flux density in following over voltage conditions
does not exceeds 1.9 tesla/19000 lines per cm2.

i) The above flux density has been specified to meet with the over
fluxing of the core due to temporary over voltage of the order of
31% for 1 min., 44% for 5 sec. That may appear in abnormal
conditions such as those following sudden loss of large loads/
tripping of Generator breaker.
ii) Yoke bolt area and flitch plate areas shall not be counted in the
net core area, if these are provided for fastening of core.
iii) The design of limb and yoke shall be so coordinated that there is
no cross fluxing at the joints.

The flux density at normal voltage frequency and ratio should not exceed 1.57 tesla.

8.7 Current Density

The transformer shall be so designed that the current density of HV windings at the lowest tap
should not exceed 250 A/cm2. And that of LV winding should not exceed 200 A/cm2.

8.8 Short Circuit Strength

Transformers shall be designed and constructed to withstand without damage the thermal and
dynamic effects on external short circuits for 5 seconds under condition specified in IS: 2026
(Part-I)- 1977.

The transformers shall be provided with separate tapping coil to limit the short circuit forces.

The position of the tapping coil shall be so arranged that at extreme negative tap, the percentage
regulation is less than at normal tap.

The bidders shall submit test certificates of the short circuit test, if already done on the offered
design and rating. However, the thermal and dynamic ability to withstand short-circuit forces
shall be demonstrated by calculations.

Manufacturers shall supply calculation for Thermal & Dynamic withstand capacity of the
transformer as per their design alongwith the tenders.

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 8.9 Frequency and System Voltage

The transformers shall be suitable for continuous operation with a frequency variation of 3% from
normal 50 cycles per second without exceeding the specified temperature rise.

8.10 Parallel Operation

The transformer shall be capable of parallel operation with each other and with existing grid.

8.11 Vibration and Noise

Every care shall be taken to ensure that the design and manufacture of all transformers and
auxiliary plant shall be such as to have minimum noise and vibration levels following good
modern manufacturing practices.

The manufacturers will ensure that the noise level shall not exceed the figures as per NEMA Pub.
No. TR-1.

8.12 Basic Insulation Levels (BIL)

Transformers are the starting point for insulation co-ordination and are as such directly protected
by lightning arrestor. Refer Para 2.3 of section -1.

9. IMPEDANCE

Impedance of the transformers has a material effect on system stability, short circuit currents, and
transmission line regulation, and it is usually desirable to keep the impedance at the lower limit of
normal impedance design values. Detailed study should be made if reduced short circuit level or
line regulation consideration are materials and specific feasible impedance values are required.

Typical values of impedance voltage for transformers with two separate windings (at rated
current, given as a % of the rated voltage of the winding to which the voltage is applied) as per IS
2026 part I – 1977 and for generator transformers as per CBI & P Manuals on Transformers are
given in table 2.

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 Table - 2

Rated Power (kVA) Impedance Impedance Voltage (%) as per CBI & P
Voltage (%) as manual
per IS 2026 Three phase power Impedance
rating voltage (%)
11 kV Trans. (kVA) 5
Upto 1600 kVA
Up to 630 4.0 33 kV Trans. (MVA)
631 to 1250 5.0 1.00 5
1251 to 3150 6.25 1.60 6.25
3151 to 6300 7.15 3.15 6.25
6301 to 12500 8.35 4.00 7.15
12501 to 25000 10.0 5.00 7.15
Above 25001 12.5 6.30 7.15
8.00 8.35
10.00 8.35
66 kV Trans. (MVA)
6.3 8.35
8.0 8.35
10.0 8.35
12.5 8.35
20.0 10.00

16 10
25 10
31.5 12.5

Transformers with lower or higher values of impedance are normally furnished with difference in
cost. The value of transformer impedance should be determined giving consideration to impacts
on selection of interrupting capacities of station breakers and on the ability of the generators to
aid in regulating transmission line voltage. Transformer impedances should be selected based on
system and plant fault study. Impedances shown are subject to a tolerance of plus or minus 10%
as per IS:

10. TRANSFORMER EFFICIENCY

Transformer losses represent a considerable economic loss over the life of the power plant.
Standard losses as per CBI & P manual on the basis of optimized design of manufacturer is given
in table 3 for 11 kV to 66 kV class transformers. Based on these losses Capitalization for
transformer losses should be carried out in accordance with CBI & P manual on transformer
Section L enclosed at Annexure 3.3.

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 Table 3: STANDARD LOSSES AT 750C

Sl. Three-phase power rating No-load loss (kW) Load loss (kW)
No.
(a) 11 kV Transformers (kVA)
200 570 (W) 3300 (W)
315 800 (W) 4600 (W)
630 1200 (W) 7500 (W)
1000 1800 (W) 11000 (W)
1600 2400 (W) 15500 (W)

(a) 33 kV Transformers (MVA)

1.00 1.8 8
1.60 2.1 14
3.15 3.2 22
4.00 4.0 24
5.00 4.6 27
6.30 5.4 33
8.00 6.1 44
10.00 7.2 53
(b) 66 kV Transformers (MVA)
6.3 6.0 40
8.0 7.1 48
10.0 8.4 57
12.5 9.7 70
20.0 13.0 102

11. TERMINAL BUSHINGS

Connections for the generator transformers are mostly by power cables for small hydro stations
upto 10 MVA rating from generator terminals to power transformer in switchyard. Bus ducts
which could be isolated phase for large units or segregated phase bus ducts for smaller units may
be used. Accordingly terminal for the generator transformers should be as follows:

LV Side: LV bushings should be mounted on turrets suitable for connection to bus bar in
bus ducts. For SHP cable boxes may be provided, if cables are used.

HV Side: Solid Porcelain/Oil Communicating and other type bushings upto 36 kV voltage class
in accordance with IS: 3347. The dimensional parameters of the bushings upto and including 36
kV voltage class should be in accordance with IS: 3347. The rated current, voltage, Basic
Insulation Levels should be in accordance with IS: 2099.

66 kV to 220 kV bushings are oil impregnated paper (OIP) type condenser bushings in
accordance with IS 2099 and IEC 137. Dimensions interchange capability current, insulation
level and creepage distance for various classes of the bushings should be in accordance with
CBI & P Manual on transformers Section P.

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 The electrical characteristics of bushing insulator shall be in accordance with IS: 2099 as
amended from time to time. All type and routine tests shall be carried out in accordance with IS:
2099. The test voltage for various tests as stipulated in IS: 2099 – 1986 are as follows:

Nominal Rated voltage of the One minute wet and dry Lightning impulse
system voltage bushing power frequency withstand test 12/50
voltage withstand test micro sec. kV peak
kV kV kV kV
11 12 28 75
33 36 70 170

12. TANKS

The main tank body excluding tap-changing compartments, radiators and coolers shall be capable
of withstanding vacuum given in the following table:

Highest system MVA rating Vacuum gauge pressure (mm of Hg)

voltage kV kN/m2
Up to 72 kV Up to 16 above 1.6 34.7 250
& up to 20 68.0 500

Above 72 kV For all MVA ratings 100.64 760

13. PRESSURE RELIEF DEVICE

The pressure relief device shall be provided of sufficient sizes for rapid release of any pressure
that may be generated within the tank, and which might result in damage to the equipment. The
device shall operate at a static pressure of less than the hydraulic test pressure for transformer
tank. Means shall be provided to prevent the ingress of rain water.

Unless otherwise approved the relief device shall be mounted on the main tank, and, if on the
cover, shall be fitted with skirt projecting 25 mm inside the tank and of such a design to prevent
gas accumulation.

14. ANTI EARTHQUAKE CLAMPING DEVICE

To prevent transformer movement during earthquake, a claming device shall be provided for
fixing the transformer to the foundations. The contractor shall supply necessary bolts for
embedding in the concrete. The arrangement shall be such that the transformer can be fixed to or
unfastened from these bolts as desired. The fixing of transformer to the foundation shall be
designed to withstand seismic events to the extents that a static coefficient of 0.3g applied in the
direction of least resistance to that of loading will not cause the transformer or clamping device as
well as bolts to be over stressed.

15. FITTINGS AND ACCESSORIES

(a) Rating and diagram plate

(b) 2 Nos. earthing terminals
(c) Cover lifting lugs.

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 (d) Skids and pulling eyes on both directions.
(e) Oil-filling valve with flange
(f) Jacking pads.
(g) Pocket on tank cover for thermometer.
(h) Air release devices.
(i) Conservator with oil filling hole, cap and drain plug-size 19 mm nominal pipe (3/4 in.
BSP/M 20).
1. Plain oil level gauge for all transformers upto and including 1.6 MVA.
2. Magnetic type oil gauge for transformers above 1.6 MVA, with low oil level
alarm contact.
(j) Silica gel breather with oil seal.
(k) Pressure relief device.
(l) Valves:
1. Drain valve with plug or blanking flanges. The same can be used for filtering
purpose.
2. A sampling device or sampling facility on drain valve.
3. 1 No. filter valve on upper side of transformer tank.
(m) Buchholz relay with alarm and trip contacts with one shut-off valve on conservator side.
1. Size of Buchholz relay up to 10 MVA-50 mm
2. 10 MVA and above-80 mm
(n) Oil temperature indicator with one electrical contact shall be provided with anti-vibration
mounting.
(o) Winding temperature indicator with two electrical contacts for alarm and trip purposes.
Switching of fans shall be done by winding temperature indicator for all transformers
having ONAF rating. The winding temperature indicator shall be provided with anti-
vibration mounting.
(p) Tank mounted weather-proof marshalling box for housing control equipment and
terminal connectors. Wiring up to marshalling box with PVC SWA PVC copper cables
660/1100 volts grade.
(q) Rollers-4 Nos.

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 Sl. Rating Type Gauge
No. Shorter axis Longer axis
1. Up to 5 MVA Flat, uni-directional As per manufacturer’s practice,
however, not to exceed 1000 mm
2. 6.3 MVA Flanged, bi-directional 1435 mm 1435 mm
3. 10 MVA and above Flanged, bi-directional 1676 mm 1676 mm

(r) Inspection cover.

(s) Cooling accessories
ONAN/ONAF cooling
1. Radiators with shut-off valves and air release plugs.
2. Fans.
3. Filter valves.
4. Drain and sampling device.
5. Air release device.
16. DIELECTRIC TESTS
(a) 220/132 kV winding

i) Lighting impulse on all the line terminals (routine test)

ii) Induced over-voltage with partial discharge indication (routine test)

(b) 33 kV winding

i) Separate source AC on the all line terminal (routine test)

ii) Lightning impulse on all the line terminals (routine test)

17. ACCESSORIES

Normal accessories are arcing horns, oil flow alarm, fans and pumps, dissolved gas monitoring
system, Temperature detectors, Lifting devices.

Provision of Following Oil preservation system are preferred for generator step-up transformer.

(i) Inert gas pressure system. Positive nitrogen gas pressure is maintained in the space
between the top of the oil and the tank cover from a cylinder through a pressure-reducing
valve.
(ii) Air-cell, constant-pressure, reservoir tank system. A system of one or more oil reservoirs,
each containing an air cell arranged to prevent direct contact between the oil and the air.

18. OIL CONTAINMENT AND FIRE PROTECTION SYSTEM

If any oil filled transformers are used in the power plant, provisions should be made to contain
any oil leakage or spillage resulting from a ruptured tank or a broken drain valve. Physical
separation in the use of fire wall/barriers is also provided in power plants. Specifications for fire

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 protection of power transformers may be provided in accordance with CBI & P Manual on
Transformer in Section ‘O’ or specification refer chapter on mechanical auxiliaries.

19. FACTORY AND FIELD TESTING

Transformer specifications must contain complete and exhaustive section for quality control,
Inspection, factory and field test. Provision for witness testing of factory test and method for type
test should be specified in detail. Various routine, type and special tests are detailed in IS 2026
part I. For explanations, details on the methods and procedure for corrections when ideal test
conditions cannot be achieved reference may be made to test manual for transformers issued by
CBI & P.

20. ERECTION, MAINTENANCE TESTING AND COMMISSIONING

Refer CBI & P manual on transformers section K entitle Erection, Maintenance and
Commissioning manual.

21. TYPICAL TRANSFORMER RATING AND CHARACTERISTICS

Transformer rating and characteristics for a 11/66 kV transformer for Mukerain Stage-II HEP ( 2
x 10 MW) is enclosed as Annexure 3.4.

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 Annexure-3.1

Ambient temperature & temperature rise for Mukerian Stage II

Generator transformer 11/66 kV class rated 10/12.5 MVA and 6.6/33 kV
class transformer for Sikasar Project Generator Transformer
3.3/33 kV class rated 2 x 3.5 MW
A. Reference Ambient Temperatures

The reference ambient temperatures for which the transformers are to be designed are as under:-

i) Maximum ambient temperature 50 degree C

ii) Maximum daily average ambient temp : 40 degree C
iii) Maximum yearly weighted average ambient temp : 40 degree C
iv) Minimum ambient air temperature : ;(Cooling medium Minus 5 degree C
shall be Air)
B. CLIMATIC CONDITIONS :
i) Maximum relative humidity 100%
ii) Yearly average number of thunder storms _______ varies
from 30 to 50 .
iii) Average no. of rainy days per annum 60 days
iv) Fog : The atmosphere is subject to fog for two month in
winter.
v) Number of months during which tropical monsoon 3 months
conditions prevail
vi) Dust storms occur at frequent intervals
vii) Average annual rainfall 60 cms
viii) Maximum wind pressure 150 kg/sq.m.

B. ALTITUDE

Altitude above M.S. level not exceeding 1000 mtrs.

C. TEMPERATURE RISE , OVER LOAD CAPACITY & CONTINUOUS RATING

a) With the above service conditions, given in clause-6.4 each transformer shall be capable
of operating continuously on any tap at normal rating without exceeding following
temperature rises, over maximum ambient temperature of 50 deg. C.

i) 30 deg. C in oil by thermometer

ii) 45 deg. C in winding by resistance
iii) The temp. of hot spot in the winding not to exceed 90 deg. C when calculated
over max. annual weighted average temp. of 40 deg. C & 105 deg. C at worst
ambient of 50 deg. C.

b) The limits of temperature rise mentioned above and over load capacity as per IEC-354
(1993) will have to be satisfied by the manufacturer by carrying out the heat run test at
the lowest negative tap. This test shall be carried out by feeding the following losses: -
(Total max. losses at 75 deg. C at highest current tap) x 1.1

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 c) The safe overload capacity of the transformer and the duration of overload for each type
of cooling (ONAN/ONAF/ ) under maximum temperature conditions (Clause 6.5 above )
without any damage to the winding or harmful effects on the insulation shall be clearly
stated in the tender, which must be as per IEC-354 (1993) – Guide for loading of oil
immersed transformers, suitable for climatic conditions given in clause-6.4 above.

d) The transformer may be operated without exceeding temperature rises, winding gradients
and hot spot at any particular tapping at the rated MVA provided that the voltage does not
vary by more than ±10% of the voltage corresponding to that tappings. Transformer shall
be able to withstand for 30 minutes after achieving steady state at full load rating without
injurious heating to winding/insulation etc. under auxiliary failure condition.

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 Annexure-3.2

Rationalization of capitalization Formula for Transformer Losses

The rated capitalization of transformer losses depends upon the rate of interest, rate of electrical energy
per kWh, life of transformer and average annual loss f actor. The annual loss factor takes into account the
loading of the transformer during the year. In computing the rate of capitalization of iron losses, copper
losses and auxiliary losses. Following assumptions are recommended.

(i) Rate of interest (r):

(ii) Rate of electrical energy (EC): It is the cost of energy per kWh at the bus to which the
transformer to be connected.
(iii) Life of the transformer (n): It is taken 25 years.
(iv) Life transformer is in service for a period of 350 days in a year (allowing 15 days for
maintenance, breakdown, etc.).
(v) The cooling pumps remain in service for 40% of the time, the transformer is in service.
(vi) Annual loss factor: The annual loss factor may be worked out on the basis of the formula
given below.

LS = 0.3LF + 0.7 (LF)2

Where:
LS is the annual loss factor
LF is the annual load factor

Assuming annual load factor as 60%, annual loss f actor works out to 0.432.

Capitalization Formula Suggested

Capitalised Cost of Transformer = Initial cost + Capitalised cost of annual iron losses +
Capitalised cost of annual copper losses + Capitalised
cost of annual auxiliary losses.

Capitalised cost of iron losses per kW = 8400×EC×

(1 + r )n − 1
r (1 + r )
n

Capitalised cost of copper losses per kW = 8400×EC×

(1 + r )n − 1 ×LS
r (1 + r )
n

Capitalised cost of iron losses per kW = 0.4×8400×EC×

(1+ r) −1
n

r (1 + r )
n

Substituting the values, the capitalized cost of transformer.

Actual value can be worked out by the purchaser by considering appropriate value of r, EL, LF,
and LC.

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 Example Calculation -1

Generator Transformer

Difference of loss = 2.381 kW

Load factor = 80% = 0.8

Rate of interest (r) = 10% = 0.1

Rate of electrical energy (EC) = 2.5 Rs

Life of transformer (n) = 35 year

LS = 0.3(LF)+0.7(LF)2

LS = 0.3x0.8+0.7x(0.8)2
= 0.688

Capitalised Cost of Additional Copper loss per kW

= 8400×EC×
(1 + r )n − 1 × LS
r (1 + r )
n

= 8400×2.5×
(1 + 0.1) − 1
35
× 0.688
0.1(1 + 0.1)
35

= Rs. 139338.81
Capitalised cost of additional transformer losses

= 139338.81 x 2.381
= Rs. 331766

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 Annexure-3.3

Loss Capitalization formula (Loading factor)

Method for calculating the loading factors for evaluation of loss capitalization to be specified by the
purchaser as per CBI & P is as follows:

The values indicated are typical values and the utility may adopt values different from those indicated in
case the rates of interest, cost of energy and the number of hours of operation are different from those
indicated in the example below. A life expectancy of less than 25 years is not recommended.

Loading factor for no load loss

[{ n
}
A = H × E C × (1 + r ) − 1 / r (1 + r )
n
] = [{(1 + r ) − 1}/ r (1 + r ) ]
n n

Rate of
interest
Expect
ed life
Number of
hours of
Cost of
energy to
1+r (1 + r )n (1 + r )n − 1
⎢
{ }
⎡ (1 + r )n − 1 ⎤
⎥
A = loading
factor per
⎣⎢ / r (1 + r ) ⎦⎥
n
in per operation in a the utility kW of iron
unit year at 11 kV loss
level

r n h Ec
0.08 25 8400 Ec 1.08 6.84847 5.84848 10.97477619 Rs.
5 8966xEc

Loading factor for copper loss LLF = 0.2* LF + 0.8 *LF*LF

= 0.3

B = A x LIF
= Rs. 89668 x Ec x 0.3 = Rs. 26900 x Ec

Where,

A= Loading factor in Rs. Per kW of no load loss

B= Loading factor in rs. Per kW for load loss
H= No. of hours, the transformer will remain charged in a year i.e. no. of operation (taken as
8400 hrs.)
Ec = Cost of energy to the utility at 11 kV level
r = Rate of ineterst per unit (taken as 8 %)
n= expected life of the transformer (taken as 25 years)
LLF = Loss load factor (where LLF = 0.2 x Load factor + 0.8 x L.F.2)
LF = Load factor (taken as 0.5)
Ec = Cost of energy (in rupees per unit at 11 kV feeder level)

Note: In case of non-availability of Ec (energy cost per unit) at 11 kV feeder level, utility should
consider the Bulk Rate Tariff plus 5% as the cost of energy at 11 kV feeder level. Load factor
considered for B factor is 0.5, higher load factor may be considered for urban areas.

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 Annexure-3.4

TRANSFORMER RATING AND CHARACTERSTICS

The rating and electrical characteristics of the transformers shall be as under:

S.No. Particulars 10/12.5 MVA (Outdoor type)

1. Continuous kVA ratings 10/12.5 MVA ONAN/ONAF
2. Type Oil immersd
3. Frequency 50 C/s
4. Type of cooling ONAF
5. No. of phases Three
6. Rating voltage on H.V. side 72.5 kV r.m.s.
7. Rated voltage on L.V. side 11 kV r.m.s.
8. Vector symbol YND11
9. Connections
a) H.V. Winding Star with neutral earthed
b) L.V. winding Delta
10. Off load taps on H.V. side (for H.V. + 2.5 to –7.5 % (in steps of 2.5%)
Variation)
11. H.V. and L.V. bushings suitability L.V. suitable for cable box.
H.V. condenser bushings with plain sheds

INSULATION LEVELS

1. Insulating material to be used, shall be of class”A” as specified in the latest edition of IS :

12371
2. The dielectric strength of winding insulation and of the bushings shall conform to values
given in IS: 2026/1981 part-III amended upto date except for the changes made in this
specification.
3. The following impulse test and power frequency test voltage must be offered.

Rated Highest 1.2/50 µ Sec. One minute power frequency

System system positive impulse withstand voltage
Voltage voltage with stand voltage -------------------------------------
(kV) (kV) of line end Line Neutral
(kV peak) end(kV) end(KV)
-----------------------------------------------------------------------------------------------------------
11 12 95 28 -
33 36 170 70 -
66 72.5 325 140 38
132 145 550 230 -
------------------------------------------------------------------------------------------ -----------

The provision of note under clause 5.4 IS: 2026 (Part-III) – 1981 should be kept in view while
offering this parameter. The star connected windings of the transformers shall have graded
insulation. All windings for system voltage lower than 66 KV shall have uniform insulation.

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 Section – 4
Selection of Circuit Breaker
1. INTRODUCTION

Circuit breaker is a mechanical switching device capable of making, carrying and breaking
current under normal circuit condition as well as under specified abnormal circuit condition such
as short circuit etc. Circuit breakers are generally classified according to interrupting medium
used to cool and elongate electrical arc permitting interruption. Selection of outdoor circuit
breakers for switchyards 12 kV and above upto 245 kV (highest system voltage) as regards types,
rating, performance requirements and tests for AC high voltage circuit breakers that are installed
in SHP outdoor switchyard after the step up transformer on outgoing transmission line feeders.
Special requirement for rating of AC high voltage generator circuit breakers between the
generator and transformer terminals are also discussed.

1.1 References

Relevant National and important international standard in this connection are as follows:-

1. IS: 13118 - Specification for high-voltage alternating current circuit

breakers
2. IEC: 56 - High voltage alternating current circuit breakers
3. IEEE: 37010 - IEEE Application Guide for AC high voltage circuit breakers
4. IEEE 37013 - AC high voltage generator circuit breaker rated on
symmetrical current basis
2. CLASSIFICATION

2.1 Following types of circuit breakers formerly used in high voltage outdoor substations
are no longer in use and are being phased out.

i) Bulk oil circuit breakers (Dead Tank Design) – In these circuit breakers oil
contents is used for arc extinction and also for insulating live parts from the tank
which is dead and generally earthed (ground).

ii) Minimum oil breakers (Live Tank Design) – In these circuit breakers oil is
primarily used for arc extinction and not necessarily for insulating live parts from
earth (ground). The tank of these circuit breakers are insulated from earth ground.
The circuit breakers are phase separated. These circuit breaker were widely used
upto 72 kV level and are being phased out from existing installation.

iii) Air blast circuit breaker – circuit breaking in these circuit breakers occurs in a
blast of air under pressure. These circuit breakers were widely used upto 765 kV
system. These circuits breakers are being phased out.

3. TYPE OF CIRCUIT BREAKER

Following types of circuit breakers are in use now-a-days for max. voltage class used for 25 MW
hydro station.

i) SF-6 – Sulphur Hexa Flouride Breakers 36 kV to 220 kV class

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 ii) Vacuum circuit breakers upto 36 kV class
iii) Air circuit breaker upto 12 kV (Generator circuit breaker)

Sulphar Hexafluoride as an Arc Quenching Agent:- Pure sulphar hexafluoride gas is inert and
thermally stable. It possesses very good arc quenching as well as insulating properties which
make it ideally suitable for use in a circuit breaker. Sulphar hexafluoride remains in a gaseous
state upto a temperature of 90C at 15 kg/cm2 pressure its density is about five times of air and the
free heat convection is 1.6 times as much as that of air. Apart from being a gas, it is non-
inflammable, non-poisonous and odourless. When arcing takes place through the gas, some by-
products are produced due to breakdown of the gas. These by-products are a hazard to the health
of the maintenance personnel therefore should be properly taken care of.

At a pressure of three atmospheres the dielectric strength of sulphar hexafluoride is about 2.4
times that of air and compares very well with that of oil. Even when gas is exposed to electric
arcs for fairly long periods, it has been found that decomposition effects are small and the
dielectric strength is not materially affected. On the other hand the metallic fluorides at the
temperatures of the arc are good insulators and the arc is therefore, not at all harmful to the
breaker.

Gas circuit breaker generally employ SF-6 (sulphar hexafluoride) as an interrupting medium and
sometimes as an insulating medium. In “single puffer” mechanisms, the interrupter is designed to
compress the gas during the opening stroke and use the compressed gas as a transfer mechanism
to cool the arc and to elongate the arc through a grid (arc chutes), allowing extinguisher of the arc
when the current passes through zero. In other designs, the arc heats the SF6 gas and the resulting
pressure is used for elongating and interrupting the arc. Some older low-pressure SF6 breakers
employed a pump to provide the high pressure SF6 gas for arc interruption.

Gas circuit breakers typically operate at pressures between six and seven atmospheres. The
dielectric strength of SF6 gas reduce significantly at lower pressures, normally as a result of
lower ambient temperatures. Monitoring of the density of the SF6 gas is critical and some designs
will block operation of the circuit breaker in the event of low gas density.

Circuit breakers are available as live-tank or dead-tank designs. Dead –tank designs put the
interrupter in a grounded metal enclosure. Interrupter maintenance is at ground level and seismic
withstand is improved versus the live-tank designs. Bushings are used for line and load
connections which permit installation of bushing current transformers for relaying. The dead-tank
breaker does require additional insulating gas to provide the insulation between the interrupter
and the grounded tank enclosure.

Live-tank circuit breakers consist of an interrupter that is mounted on insulators and is at line
potential. This approach allows a modular design as interrupters can be connected in series to
operate at higher voltage levels. Operation of the contacts is usually through an insulated
operating rod or rotation of a porcelain insulator assembly by an operator at ground level. This
design minimizes the quantity of gas used for interrupting the arc as no additional quantity is
required for insulation of a dead-tank enclosure. The design also readily adapts to the addition of
pre-insertion resistors or grading capacitors when they are required. Seismic capability requires
special consideration due to the high center of gravity of the interrupting chamber assembly.

Interrupting times are usually quoted in cycles and are defined as the maximum possible delay
between energizing the trip circuit at rated control voltage and the interruption of the main
contacts in all poles. This applies to all currents from 25 to 100% of the rated short circuit current.

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 Breaker ratings need to be checked for some specific application. Applications requiring
reclosing operation should be reviewed to be sure that the duty cycle of the circuit breaker is not
being exceeded. Some applications for out –of- phase switching or back-to-back switching of
capacitor banks also require review and may require specific duty circuit breakers to insure
proper operation of the circuit breaker during fault interruption.

3.1 Vacuum Circuit Breaker

Vacuum circuit breakers use an interrupter that is a smaller cylinder enclosing the moving
contacts under a high vacuum. When the contacts part, is a formed from contact erosion. The arc
products are immediately forced to and deposited on a metallic shield surrounding the contacts.
Without anything to sustain the arc, it is quickly extinguished.

Vacuum circuit breaker are widely employed for metal-clad switchgear up to 36 kV class. The
small size of the breaker allows significant savings in space and material compared to earlier
designs employing air magnetic technology. When used in out door circuit breaker designs, the
vacuum cylinder is housed in a metal cabinet or oil filled tank for dead tank construction.

3.2 Advantages and Disadvantages

Advantages: Advantages of SF6 breakers over the conventional breakers is given below:

i) due to outstanding arc quenching property of SF6, the arcing time is very small. This
reduces contact erosion.
ii) using SF6 gas at low pressure and low velocity; the current chopping can be minimized.
iii) during arcing of SF6 breaker, no carbon dioxide is formed and hence no reduction of
dielectric strength.
iv) SF6 breaker is silent in operation and moisture ingression into the gas cycle is almost nil.
v) SF6 breaker performance is not affected due to variation in atmospheric conditions.
vi) SF6 breaker is compact in size and electrical clearances are drastically reduced.

Disadvantages: The only disadvantage of using SF6 to some extent is suffocation. In case of
leakage in the breaker tank, this gas, being heavier than air settles in the surroundings and may
lead to suffocation of the operating personnel. However, it is non-poisonous.

3.3 Evaluation of SF6 and Vacuum Switching Technologies

SI. No. Criteria SF 6 circuit breaker Vacuum circuit breaker

1 2 3 4

I. SWITCHING DUTIES

1. Summated breaking To 50 times rated short circuit To 100 times rated short
current capacity breaking current To 10,000 circuit breaking current To
times continuous rated current. 20,000 times continuous
rated current.

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 2. Critical switching Very well suited Over voltage Well suited. Under certain
i. Motor, Reactors generally under 2.5 p.u. circumstances steps may be
small inductive Normally no action necessary to necessary to limit over
current. limit over voltages. voltages because of
possibility of virtual current
chopping. Use of surge
arresters recommended
ii. Capacitors Well suited. Restrike free. In Suited. Generally Restrike
special cases reactors may be free. In special cases reactors
necessary to limit in rush current may be necessary to limit in
- Low over voltage. rush current-Reignition and
restrikes possible in certain
cases due to statistical scatter
of breakdown voltage in
vaccum.
iii. Over head and Very well suited-Restrike free. Very well suited Restrike
cable feeders. free.

iv. Switching of arc Only suitable in applicable with Suitable also for applications
furnaces. comparatively low number of with very high number of
operations per day. operations (over 100 co-per
day.
3. Suitability of single Very well suited Very well suited.
and multi shot auto
reclose cycles.

SI. No. Criteria SF 6 circuit breaker 3 Vacuum circuit breaker

1 2 4

II. MAINTAINABILITY

1. Number of 500 to 20,000 C-O 10,000 to 20,000 C-O

operations between Operations operation
servicing, referred to
operating
mechanism.

2. Service life of 5000 to 20,000 Cooperations 20,000 to 30,000 Cooperations

interrupters (Between over hauls) or (manufacturers guidelines)

3. Service interval Lubrication of operating Lubrication of operating

mechanism after 5 to 10 mechanism after 10 years (if
years (if limiting number of limiting number of operations
operations not reached) not reached.

4. Expenditure on Overhaul involves complete Tester used to check

overhaul of dismantling of interrupter. vacuum level. If necessary
interrupters. Labour costs high, material replace interrupter. Low
costs low. labour costs. High material

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 SI. No. Criteria SF 6 circuit breaker 3 Vacuum circuit breaker
1 2 4

costs.

5. Supervision of Supervision of SF6 gas Checking the insulation and

Circuit breaker pressure possible (Pressure quench media not easily
condition. guage with contacts for possible-But generally
remote signalling.) supervision of vacuum level
not necessary (sealed for life)

6. Refilling of arc Possible Not possible

quenching media

III. RELIABILITY

1. Failure rate Lowest (7-13 per 1000 CB- Lowest

Yrs) (7-13 per 1000 CB-Yrs)

2. Mechanical life Good Excellent

3. Fire Hazard Zero Zero

4. Interrupting capacity Switching of rated current Not possible

in case of leakage. still possible.

IV. COST
1. Cost of production Sightly higher than VCB -

2. Maintenance cost Lowest negligible cost for Lowest negligible cost for
minimum 10 years. minimum 10 years.

3.4 Protection Classes for Switchgear Installation

The protection classes are identified by a compound symbol made up of the two code letters' EP,
which always remain the same two digits denoting the degree of protection and, if] required, the
supplementary code letter B. The supplementary code letter must be stated if in the case of
switchgear and distribution equipment the protection class is attained only through taking certain
measures when the apparatus is installed. The term 'Production class* denotes the complete
compound symbol (code letters, code digits and the supplementary code letter if applicable)

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 Protection Class
IP 4 3 B

Code

First Digit Degree of protection against contact

And ingress of foreign bodies
Second Digit Degree of protection against ingress
Of water

Supplementary Sealing material between code letter

floor, ceiling or wall

If in addition to the code letters IP only one code digit for the degree of protection is used, the
missing digits a to be replaced by a dash.

eg. IP - 4 (Protection
class : Splash proof)

Degree of protection against Degree of protection against water

Contact and foreign bodies :

First Description Second Description

Digit Digit
0 No Protection 0 No Protection
1 Protection against large 1 Protection against vertically galling
foreign bodies water droplet
2 Protection against medium 2 Protection against obliquely falling
sized foreign bodies water droplet
3 Protection against small 3 Protection against sprayed water
foreign bodies (spray proof)
4 Protection against granular 4 Protection against splashing (splash
foreign bodies proof)
5 Protection against dust 5 Protection against water jet (Hot
deposit proof)
6 Protection against ingress of 6 Protection against inundation
dust
7 Protection against immersion in water
8 Protection against indefine immersion
in water

4. RATED CHARACTERISTICS

The main characteristics of a power circuit breaker including its operating devices and
auxiliary equipment used to determine the rating are as follows :-

• Rated voltage
• Rated insulation level
• Rated frequency
• Rated normal current

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 • Rated short-time withstand current
• Rated short-circuit breaking current
• Rated short-circuit making current
• Rated operating sequence (duty cycle)
• Rated transient recovery voltage (TRV) for terminal fault
• Total breaking time (maximum)
• Rated characteristics for short-time faults, for three pole circuit breakers designed for
direct connection to overhead transmission lines and rated at 52 kV and above and at
more than 12.5 kA rated short breaking current

In addition, the following characteristics are necessity for specific application.

• Rated line charging breaking current

• Rated inductive breaking current
• Rated capacitor breaking current
• Rated out of phase breaking current

5. STANDARD RATINGS OF CIRCUIT BREAKERS

5.1 Rated Voltage: Voltage rating of the power circuit breaker is in terms of three phase line
to line voltage of the system. The rated voltage of the circuit breaker should be of standard rating
chosen so as to be at least equal to the highest voltage of the system at the point where the circuit
breaker is to be installed. The operating voltage and the power frequency recovery voltage should
not exceed the rated maximum values because this maximum is upper limit for continuous
operation.

It is however considered that operation at altitude above 1000 meters should be given special
considerations and certification from manufacturer be obtained because of possible influence of
altitude on interrupting capacity.

In case of generator circuit breakers the rated maximum should be equal to the maximum
operating voltage of the generator, which is usually equal to 1.05 times rated voltage.
The rated voltage is expressed in kV (rms) and refer to phase to phase voltage.

Nominal system voltage Rated voltage of circuit breaker

kV rms kV rms
11 12
22 24
33 36
132 145
220 245

5.2 Rated Insulation Level: - Insulation level of power circuit breakers should be selected
from standard insulation level listed in IS: 13118. Refer table 2.1 (section-1) for voltage upto 36
kV and table 2.2 (section-1) for voltages upto 245 kV. For insulation co-ordination refer (Para
2.3.4. of section1).

The surge protection of the system should be coordinated with the impulse strength of the
breaker, both across the open contacts and to ground. Attention should also be given to increase

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 in surge voltage because of reflections which occur at breakers when their contacts are open,
especially where cables are involved.

Surge arrestors are generally installed on the bus or on transformers and not on each circuit
breaker, the surge voltage at the breaker can exceed that at the arrestors. The amount of the
excess depends upon the steepness of the wave front and the distance from the circuit breaker to
the surge arrestors. When the circuit breaker is in the open position, either intentionally left open
or during operation, an incoming surge voltage may be doubled by reflection at the open contacts.
Selection of too low an insulation level for circuit breakers, if not individually protected by
arrestors, may result in line-to-ground, or open gap insulation failure of the circuit breaker. Use of
individual line entrance surge arrestors may be required if the lightning trip-out rate of the line
exceeds 1 per year (refer IEEE std. 37.010-1999). Refer section 1 for more details.

5.3 Rated Frequency: standard power circuit breakers are rated at 50 cycles. Service at other
frequencies requires special consideration.

5.4 Rated Normal Current: rated normal current of a circuit breaker is the rms value of the
current which the circuit breaker shall be able to carry continuously at rated frequency. With the
rise in temperature of its different parts not exceeding specified values. Values of rated normal
currents should be selected from standard value of normal currents as per IS: 13118 which are
400A; 630A; 800A; 1250A; 1600A; 2000A; 2500A; 3500A; 4000A; 5000A; 6300A (if required
higher values can be selected). These ratings are based on operation of the circuit breaker or
switchgear assembly where the ambient temperature (measured outside the enclosure) does not
exceed 400C and the altitude does not exceed 1000 m. Standard equipment may be operated at
higher altitude by reducing the continuous current rating in accordance with the following tables
(based on American Practice).

Altitude in meters (approx.) Insulation level Rated continuous

current

1000 m 1.00 1.00

1500 m 0.95 Refer to manufacturer
3000 m 0.80 Refer to manufacturer

The rated continuous current is based on the maximum permissible total temperature limitations
of the various parts of the circuit breaker when it is carrying rated current at an ambient
temperature of 400C.

When the ambient temperature is greater than 400C, the current must be reduced to less than rated
continuous current to keep temperatures within allowable limits.

5.5 Rated short-time withstand current

Rated short-time withstand current is equal to the rated short circuit breaking current. The rated
peak withstand current is equal to rated short circuit making current. Rated duration of short
circuit should be as per IS 13118.

5.6 Rated Short Circuit Breaking Current

The rated short circuit breaking current is the highest short circuit current which the circuit
breaker will be capable of breaking in a circuit having power frequency recovery voltage

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 corresponding to rated voltage and transient recovery voltage (refer Para 3.5.7) equal to the rated
value of the circuit breaker as specified in IS. For three pole circuit breakers the AC component
relates to three phase short circuit including short line fault.

Rated short circuit breaking current is characterized by two values Fig. 1 (Annexure-1).

i) rms value of AC component and is termed rated short circuit current

ii) Percentage DC component

rms value of AC component of the rated short-circuit breaking current should be selected from
standard values given in IS 13118. Percentage DC component is dependant upon the time from
initiation of short circuit current and standard values are given in IS 13118.

The standard values practice of breaking current or being 6.3 kA, 8 kA, 10 kA,12.5 kA kA,16 kA,
20 kA, 25 kA, 31.5 kA, 40 kA, 50 kA, 63 kA, 80 kA, 100 kA. The earlier practice was to express
the rated breaking capacity in MVA.

MVA : 3 kV × kA
MVA : breaking capacity of circuit breaker
kV : rated voltage
kA ; rated breaking current

5.7 Rated Short Circuit Making Current

The circuit breakers some times, close on to a existing fault. In such cases, the current increases
to the maximum values as the peak of first current loop. The circuit breaker must be able to close
without hesitation as contacts touch. The circuit breaker must be able to withstand the high
mechanical forces during such closure.

As per IS: 13118 rated short circuit making current should be at least 2.5 times the rms value of
the A. C. component of its rated short circuit breaking current.

5.8 Transient Recovery Voltage and Restriking Voltage and First Pole to clear Factor

The instantaneous value of the recovery voltage at the Instant of arc extinction is called the active
recovery voltage figure 3.3 (Annexure-3).

5.9 Rated Transient Recovery Voltage (TRV) for terminal faults:- The rated transient
recovery voltage (TRV) for terminal faults relating to the rated short-circuit breaking current
is the reference voltage. This constitutes the limit of the prospective transient recovery voltage of
circuits, which the circuit breaker will be capable of breaking in the event of a short circuit at
its terminals.

Wave form of transient recovery voltage varies according to the arrangement of actual circuit.

Standard value of rated TRV for 3 pole circuit breaker as per in IS: 13118 for the circuit breakers
used in the outdoor substations under consideration are given below table 3.2.

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 Table 3.2

Rated First pole to Time TRV Rate of rise Remarks

voltage clear factor Peak
value
(kV) (µs) (kV) (kV/µs)

3.3 1.5 40 6.2 0.15

7.2 1.5 52 12.3 0.24
12 1.5 60 20.6 0.34
36 1.5 108 62 0.57
72.5 1.5 166 124 0.75
145 1.3 77 215 2.0
145 1.5 89 249 2.0
245 1.3 130 364 2.0

5.10 First Pole to Clear Factors

The ratio of transient voltage that appears across the contacts at the instant of arc extinction to
service frequency recovery voltage is called the restriking voltage first pole to clear factor.

In three-phase circuits the restriking voltage refers to the voltage across the first pole to clear
because this voltage is generally higher than that appears across each of the other two.

5.11 Recovery voltage

The active recovery voltage depends upon the following factors.

i) the power factor

ii) the armature reaction
iii) the circuit conditions

Effect of power factor on recovery voltage:- With low p.f., for example when the ratio of
reactance to resistance of the circuit is high, the active recovery voltage will be high; whereas
with high p.f. i.e. when the resistance is high as compared to the reactance, the active recovery
voltage would be correspondingly lower. This is illustrated in fig. 3.4. In fig. (a) the p.f. is zero
and at the instant of arc extinction A the active recovery voltage is at peak value equaling to AB
while in Fig (b) the p.f. is 0.5 and the active recovery voltage at the instant of arc extinction is CD
which is less than AB.

In general the active recovery voltage equals the maximum value of the system voltage multiplied
by sin θ where θ is the power factor angle.

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 (a) (b)

Fig. 3.4 Effect of p.f. on recovery voltage

Effect of armature reaction on recovery voltage: The recovery voltage is less than the normal
system voltage because of demagnetizing effect of armature reaction. The fault currents flowing
in the generator winding are of lagging power factor. They have a demagnetizing armature
reaction. Hence they reduce the terminal voltage.

Effect of circuit conditions on recovery voltage: Another factor that influences the recovery
voltage is the circuit conditions e.g. three phase faults that are insulated from earth, either at
neutral or at fault, produce recovery voltages in the first phase to clear which are normally more
severe than those produced by single phase or three phase faults on systems with earthed neutrals.
This is explained below.

Consider an unearthed three phase fault, on a three-phase system with the neutral earthed, being
cleared by a circuit-breaker. When the breaker opens, it draws out an arc in each phase. Assume
that the arc in R phase is the first to be cleared (fig. 3.4 a). At the instant of this extinction the Y
and B phases are still acting and have the same instantaneous phase voltage – 0.5v, where v is the
phase to neutral value of the system. Now the resistance of the arcs in the Y and B phases at this
instant are negligible, which means that the fault itself is momentarily at the potential – 0.5V.
Since the fault is common to all three phases the momentary value of the recovery voltage
component in phase R must be V + 0.5V i.e., 1.5V (fig. 3.4 b). This means that the recovery
voltage component in the first phase to clear on a 3-phase unearthed fault is 1.5 times that on an
earth fault assuming an earthed neutral.

5.12 Rated Characteristics for Short-Line faults

Rated characteristics for short line faults are required for three generator pole circuit breakers
designed for direct connection to overhead transmission lines and having a rated voltage of 52 kV
and above and a rated short-circuit breaking current exceeding 12.5 kA. These characteristics
relate to the breaking of a single phase earth fault in a system with earthed neutral.

The short line fault circuit is taken as composed of a supply circuit on the source side of the
circuit breaker and a short line on its load side (fig. 3.5) with the following rated characteristics.

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 L

Xs IL XL

CB Z

G V

G = source of power Xs = reactance on source side

V = voltage, phase-to-neutral value: V/√3 XL = reactance on line side
IL = short-line fault current Z = surge impedance of the line
CB = circuit breaker L = length of line to fault

Fig. 3.5 Short-line fault circuit

5.13 Rated Supply Circuit characteristics

Voltage equal to the phase-to-earth voltage V/√3 corresponding to the rated voltage V of the
circuit breaker.

Short circuit current, in case of terminal fault, equal to the rated short circuit breaking current of
the circuit breaker.

Prospective transient recovery voltage, in case of terminal fault, given by the standard values in
IS: 13118.

5.14 Rated line Characteristics

Standard values of rated surge impedance rated peak factor and time should be taken from IS:
13118.

5.15 Rated out –of-phase breaking current

Rated out –of-phase breaking current is required to be specified for generator breaker and as per
IS 13118. This provision will provide with following.

a. The power frequency recovery voltage should be 2.0/√3 times the rated voltage for
earthed neutral systems and 2.5/√3 times the rated voltage for other systems.
b. The rated out-of-phase breaking current should be 25% of the rated short-circuit breaking
current.
c. Transient recovery voltage as pre IS: 13118.

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 5.16 Rated Line Charging Breaking Current

Rated Line Charging Breaking Current is required to be specified for feeder circuit breakers.
Standard value of line charging capacity of circuit breakers for the commonly used voltages are
as follows:
Table 3.3

Rated voltage (kV) Rated line-charging breaking current (A)

12 2.5
36 40
72.5 40
145 50
245 125

This implies for overhead line length equal to 1.2 times the rated voltage of the circuit breaker in
kilovolts. In case line length is longer than it may be necessary to specify a higher value of line
charging capacity.

5.17 Rated time quantities and operating sequence

Rated values to be assigned to the following time quantities (fig. 3.6) will depend upon
rated supply voltage reclosing operations etc.

• Opening time;
• Break time;
• Closing time;
• Open-close time;
• Reclosing time;
• Close-open time;

Rated operating sequence is defined as follows:-

o – t – co - t´ - co

Where

o - opening operation
co - closing operation followed immediately by an opening operation
(without internal time delay)
t,t´ - time interval between successive operation/ t& t˝ are in minutes or
seconds

Power circuit breakers are rated for interrupting ability on the basis of a standard operating duty.

AHEC/MNRE/SHP Standards/E&M Works­ Guidelines for Selection of Switchyard SHP Station  Page 83
 Fig. 3.6 Reclosing – Close Open Reclose Time

The rated interrupting time of a circuit breaker is the maximum permissible interval between the
energization of the trip circuit at rated control voltage and rated mechanism pressure and the
interruption of the current in the main circuit in all poles. It is used to classify breakers of
different speed.

For line-to-ground faults, the interrupting time is estimated to exceed the rated interrupting time
by 0.1 cycle. For asymmetrical faults, it is estimated that the interrupting time may exceed rated
time by an additional 0.2 cycle. Hence, for grounded asymmetrical faults, the last phase to clear is
estimated to be 0.3 cycle slower than the rated interrupting time. Additionally, rated interrupting
time may be exceeded during extreme cold weather or when the breaker has been closed for an
extended period of time. Also, the breaker may be slower at the lower limits of control voltage
and/or mechanism stored energy. These interrupting times are in the range of several milliseconds
have system stability implications.

The rated interrupting time may be exceeded for close-open operations. The increase in
interrupting time on close-open operation may be important from the standpoint of possible
system instability. For low values of current, these considerations are less important.

6. CO-ORDINATION OF RATED VALUES

Co-ordination of rated voltages, short circuit breaking current and rated normal current for
guidance as per IS 13118 for rated voltage 33 kV and above as commonly used are as follows.
(Table 3.4).

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 Table 3.4
Rated Rated short- Rated normal current (A)
voltage circuit breaking
(kV) current (kA)
3.6 10 400
16 630 1250
25 1250 1600 2500
40 1250 1600 2500 4000
7.2 8 400
12.5 400 630 1250
16 630 1250 1600
25 630 1250 1600 2500
60 1250 1600 2500 4000
12 8 400
12.5 400 630 1250
16 630 1250 1600
25 630 1250 1600 2500
40 1250 1600 2500
50 1250 1600 2500
17.5 8 400 630 1250
12.5 630 1250
16 630 1250
25 1250
40 1250 1600 2500
24 8 630
12.5 630 1250
16 630 1250 1600
25 1250 1600 2500
40 1600 2500 4000
36 8 630
12.5 630 1250
16 630 1250 1600
25 1250 1600 2500
40 1600 2500 4000
52 8 800
12.5 1250
20 1250 1600 2000
72.5 12.5 800 1250
16 800 1250
20 1250 1600 2000
31.5 1250 1600 2000
145 12.5 800 1250
20 1250 1600 2000
25 1250 1600 2000
31.5 1250 1600 2000 3150
40 1600 2000 3150
50 2000 3150
245 20 1250 1600 2000
31.5 1250 1600 2000
40 1600 2000 3150
50 2000 3150

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7. TESTS

7.1 Type Test

Following type tests as applicable in accordance with IS 13118 and IEC 56 are recommended
to determine adequacy of the circuit breaker.

i) Dielectric tests (1.2/50 micro second lightning impulse withstand) and 1 minute power
frequency voltage with stand (dry & wet) test
ii) Radio interface voltage (r.i.v.) tests
iii) Temperature rise tests
iv) Measurement of the resistance of the main circuit
v) Short-time withstand current and peak withstand current tests
vi) Mechanical and environmental tests
vii) Miscellaneous provisions for making and breaking tests
viii) Short circuit making and breaking tests
ix) Basic short circuit test duties
x) Critical current tests
xi) Single phase short making and breaking tests
xii) Capacitive current switching tests
xiii) Magnetizing and small inductive current switching tests

7.2 Routine tests

i) Power frequency voltage withstand dry tests on the main circuit

ii) Voltage withstand tests on control and auxiliary circuits
iii) Measurement of the resistance of the main circuit
iv) Mechanical operating tests
v) Design and visual checks

8. FAULT CALCULATION

In order to determine interrupting duty of circuit breakers it is necessity to determine fault current
at each circuit breaker location. Determination of maximum short circuit current is the most
important requirement of circuit breaker application. Rigorous determination of short circuit
current as a function of time involves complex calculations. Growth in interconnecting power
system as systems expand will increase short circuit duty. Accordingly some approximation and
degree of judgment should be used.

Different published methods of determining short circuit currents are available. Reference may be
made to the following for details and selection.

IEEE application guide for AC high voltage circuit breakers rated on a symmetrical current basis
IEEE std. C37010-1999.

First step in carrying out short circuit studies is to determine system impedances with reference to
the point of fault and current distribution for different kind of faults. For present day large
interconnected system this becomes time consuming laborious study.

AC or DC network analyzer for calculation of fault current was previously frequently used for
short circuit studies. In the analyzer all the essential elements of the power system were

AHEC/MNRE/SHP Standards/E&M Works­ Guidelines for Selection of Switchyard SHP Station  Page 86
 represented in a miniature replica and fault currents determined from calculation readings. In this
method constant voltage behind sub transient/synchronous reactance were used as required.
Accordingly real time studies to determine DC component of fault current in addition to AC
component to determine the critical current value existing at the time of primary arcing contact
parting can not be calculated. Further network analyzers is a fixed place study. Now-a-day
computer studies are carried out for such application.

8.1 Staged Short Circuit Tests

Staged fault short circuit tests adequately controlled on actual systems have been carried out
mostly on new equipments and systems to determine circuit breaker capability. These are
accurate, costly and not always possible as selection of circuit breaker precedes power system
installation.

8.2 Circuit Breaker Rating for Short Circuit Duty

Steps involved in fixing circuit breaker short circuit rating are as follows:

1. Determine normal current duty of the circuit breaker and select higher available rated
current from standard values as per IEC/IS 13118 clause 4.4.

2. Short Circuit studies be carried for following types of faults which are considered worst
according to IEEE std. C37010-1999.

a. Three phase ungrounded faults

b. Phase to ground fault

More severe of the short circuit faults be taken for selecting the short circuit rating.

3. Determine short circuit currents for the required accuracy by a suitable method. For line
to ground faults, the required symmetrical interrupting capability is 15% higher.

4. Circuit breaker having the rms value of the ac component of the short circuit higher then
short circuit duty as calculated from table X A of IS 13118 (table 2.4 for commonly used
voltages) be selected.

5. A circuit breaker having adequate symmetrical interrupting capability will normally have
adequate capability to meet normal asymmetrical requirement. Maximum symmetrical
interrupting capacity of new circuit breaker is as follows:

⎛ Rated max imum voltage ⎞

Rated short current x ⎜⎜ ⎟⎟
⎝ operating voltage ⎠

For higher X/R ratio or other special conditions refer the detail methods given in IEEE
std.C37010-1999.

8.3 Simplified Methods for calculation short circuit current

Simplified methods calculating fault current to fix short circuit rating of circuit breakers have
been recommended by standardizing agencies over years as given below.

AHEC/MNRE/SHP Standards/E&M Works­ Guidelines for Selection of Switchyard SHP Station  Page 87
 Simplified conservative method of calculation were recommended by protective devices
committee of AIEEE for general use of the industry. It was recommended that rigorous methods
be used when specifically required. The method is based upon determination of an initial value of
rms symmetrical current (ac component) to which following multiflying factor are applied for
application purposes (table 3.5).
Table 3.5

General Generator current breakers/short circuit more than

500,000 kVA
A. 8 cycle breaker 1.0 1.1
5 cycle breaker 1.1 1.2
3 cycle breakers 1.2 1.3
2 cycle breakers 1.4 1.5
B. Mechanical stresses
and mandatory duty 1.6

Accordingly the steps involved for determining short circuit rating of circuit breakers are as
follows as per the AIEE simplified method:

1. Determine highest value of rms symmetrical current for any type of fault equal E/X1
phase fault or 3E/2X1+X0 for ground fault whichever is greater.
2. Multiply this current by appropriate factors from table 3.5.
3. The resulting interrupting and momentary current should be used to select the available
normal rated circuit breaker.

8.4 E/X Simplified method as per IEEE std. C37010-1999

The AIEEE simplified method was further referred in IEEE std. 37010-1999. This simplified
method is now recommended. For short circuit duty of circuit breakers unless complex more
accurate studies are warranted.

In these studies generating station and transmission lines interconnected with the system are
represented in detail and the system is represented by equivalent system.

For small hydro say 5 MW unit size connected to regional grids, the grid size can be assumed to
be infinite size and calculation carried out accordingly.

Calculation based on simplified method of calculating short circuit current for the application of
recommended by IEEE std. 37-01-1999 are given as an example and compared with calculation
made according AIEE committee report.

Steps involved in applying method are as follows :

1. Calculate E/X1 for 3 phase faults where X1 = positive sequence

Positive sequence X1 is assumed equal to negative sequence X2 and obtained from design
date or test.

2. Calculate ground fault current 3E/2 X1 + X0

AHEC/MNRE/SHP Standards/E&M Works­ Guidelines for Selection of Switchyard SHP Station  Page 88
 X0 = zero sequence reactance obtained from design date or test
E = phase to neutral voltage
3. If phase fault current does not exceed 80% of 100% symmetrical circuit breaker
interrupting capacity or 70% ground fault current then the circuit breaker selection is
adequate.

More exact procedure of calculation with adjustment for AC and DC decrements should be used
if the criteria is not fulfilled. In this method multiplying factors to initial value of
symmetrical short circuit current are given in the factor of curves for 2 cycle to 8 cycle.

8.5 Simplified Method

Breakers to include effect of ac and dc components for the following types of faults.

i) Three phase fault

ii) Line-to-ground fault
iii) Three phase to ground fault

8.6 Characteristics specified for 72.5 kV Mukerian Stage II (2 x 10 MW) in Punjab and 36
kV Sikasar HE Project (Chattisgarh 2 x 3.5 MW) are given in table 3.6.

Table 3.6

S. Description Mukerain Stage –II HEP Sikasar HEP

No. (2 x 10 MW) (2 x 3.5 MW)
Type and circuit breaker SF6 SF6
i. Number of poles 3 3
ii. Class Outdoor Outdoor
iii. Rated frequency 50 c/s 50 c/s
iv. Rated voltage of breaker 72.5 kV 36 kV
v. Rated insulation level :
a). 1.2/ 50 micro sec. Lightning impulse
withstand voltage for complete C.B.
i. to earth (with C.B. closed) 325 kVp 170 kVp
ii. across terminals of open circuit
breaker 325 kVp
a. one minute dry and wet power
frequency withstand voltage
i. to earth (breaker closed) 140 kV rms
ii. across terminals of open circuit 140 kV rms
breaker
vi. Rated normal current at site conditions 1600 A 630 A
vii. Rated line charging breaking current Not less than 10A. 100 A
corresponding switching
over voltage values on line
side & supply side to be
intimated by the tenderer

viii. Rated short circuit breaking current

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 a) rms value of AC component ( rated 31. 5 KA at 72. 5 KV
short circuit current ) 12.5 kA at 36 kV
b) percentage D.C. component As per IEC-56 (Latest (750 MVA) as per IS:
edition) 13118
ix. First pole to clear factor 1.5
x. Rated transient recovery voltage for As per IEC –56 (latest
terminal faults edition)
a) corresponding to rated short circuit
breaking current (Symmetrical & -do-
Asymmetrical)
b) Corresponding to currents below the
rated & short circuit current
xi. Breaking capacity under short line fault -do-
conditions with rated supply side and line
side characteristics
xii. Rated short circuit making current 78. 75 KA peak 2.5 times the rms
at 72. 5 kV value of Ac
component
xiii. Rated operating sequence Break dead Time-Make-
Break (Minimum dead
time should not be more
than 15 cycles at 50 c/s
inclusive of the time for
auto reading relay. Unit of
adjustment of dead time
shall be 15 to 35 cycles.
xiv. Total break time for any current upto rated Not more than 60 ms
breaking current
xv. Min. short time current rating and its 31.5 kA for 3 sec.
duration
xvi Minimum total creepage distance phase to 1700 mm
earth
xvii Difference in the instant of closing/opening
. of contacts of all the 3 pole
a) Opening Not more than 3.33 ms.
b) Closing Not more than 5 ms.
xvii Small inductive current interrupting Any value upto 10A with
i capacity out switching over voltage
exceeding 2.0 p.u.
xix. Whether breaker suitable for single pole Gang operation of three
operation or gang operation of three poles poles through mechanical
linkages
xx. Number of trip coils Two Nos. per breaker

AHEC/MNRE/SHP Standards/E&M Works­ Guidelines for Selection of Switchyard SHP Station  Page 90
Example :- Circuit Breaker Rating for hydro electric power system shown in fig. 3.5 is proposed to
be determined.

100MVA;11kV WATER WHEEL

GENERATOR WITH DAMPER WINDING
AND HIGH RESISTANCE GROUNDING

G G

GEN. CIRCUIT BREAKER

100MVA;11/132kVTRANSFORMER
X = 12%

132kV BUS
A

60km 132kV DOUBLE CIRCUIT LINES

X1 = 8% X1 = 8%

OPEN

132kV BUS
B

EQUIVALENT SYSTEM

X1 = 0.03

Fig. 3.5
Data

AHEC/MNRE/SHP Standards/E&M Works­ Guidelines for Selection of Switchyard SHP Station  Page 91
 i) Sub transient reactance of generator on own base - 24%
ii) 100 MVA transformer impedance - 12%
iii) 132 KVA transmission lines impedance - 8%
iv) Power house is interconnected with grid at bus B.
v) Equivalent system X1 = 0.03 of X0 = 0.04

1. Consider the fault at M which is fed by the grid system and the hydro- generators
which is considered worst.

2. Three phase fault calculations:- In the system shown in figure 4.5 per unit
reactances are indicated.

Apparent power is 100 MVA base and nominal voltage 132 kV is used as base at all levels.

⎛ 0.24 0.12 ⎞
⎜ + ⎟ x(0.08 + 0.03)
⎝ 2 2 ⎠ 0.18 x0.11
X1 = = = 0.068
⎛ 0.24 0.12 ⎞ 0.18 + 0.11
⎜ + ⎟ + (0.08 + 0.03)
⎝ 2 2 ⎠

OPEN
X1=0.24 X1=0.12 X1=0.08

X1=0.03

X1=0.08

X1=0.24 X1=0.12

Base voltage 132 kV

Base current 437

The value of operating voltage corresponding to the highest operating voltage at faults is 145 kV
or 1.098/unit

1.098
Isc = x 437 = 7056A
0.068

3. Single line to ground fault current

Zero sequence impedance would be that of transformers above as 12 % on 100 MVA. Impedance
X of diagram is shown in figure.

AHEC/MNRE/SHP Standards/E&M Works­ Guidelines for Selection of Switchyard SHP Station  Page 92
 X0 =
(0.04 + 0.24)x0.12 =
0.28 x0.12
= 0.084
(0.04 + 0.24) + 0.12 0.28 + 0.12

0.24 0.12

X0 = 0.04

0.24

Since X0 is greater than X1, single line to ground fault need not be considered.

4. Selection of Breaker rating as per IEEE std. 37010-1999.

Load current = 437 x 2 = 874A

Rated normal continuous current = 1250A

As per table Xc of IS 13118

Rated short breaking current = 20,000A at 145 kV

Three phase short circuit current is 7056A is less than 80% of symmetrical interrupting capability
( 16,000A) and large growth margin exists; the 132 kV breakers at step up sub station are rated
1250A; with rated short circuit breaking current of 20,000A.

Rating as per earlier AIEEE Committee method

Maximum initial symmetrical current = 7050A

Rating for 5 cycle breakers & factor = 1.1

and mandatory duty factor = 1.6

short circuit rating = 7050 x 1.1 x 1.6

= 12419A
and for 3 cycle breakers = 134547.5
According 20,000 kA; 1250 A breakers as O. K.

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 Annexure-1

Current wave

AA = envelop of current wave

BB´

BX = normal zero line

CC´ = displacement of current wave zero line at any instant

DD´ = r.m.s. value of the ac component of current at any instant, measured

from CC´

EE´ = instant of contact separation (initiation of the arc)

IAC = peak value of ac component of current at instant EE´

IAC/√2 = r.m.s. value of ac component of current at instant EE´

IDc = d.c. component of current at instant EE´

I DC x100
= percentage value of the d.c. component
I AC

Fig. 1 short-circuit making and breaking currents, and of percentage d. c. component (IS:
13118).

Annexure-2

AHEC/MNRE/SHP Standards/E&M Works­ Guidelines for Selection of Switchyard SHP Station  Page 94
 G

Vr

Vrc

LINE

Vr is recovery voltage stated in terms of voltage between phases at service frequency

Vrc is recovery voltage component existing across the breaks of each pole.

Fig. 2 Recovery voltage across poles

AHEC/MNRE/SHP Standards/E&M Works­ Guidelines for Selection of Switchyard SHP Station  Page 95
 Annexure-3

Fig. 3.3 Arc extinction

AHEC/MNRE/SHP Standards/E&M Works­ Guidelines for Selection of Switchyard SHP Station  Page 96
 Version 2

STANDARDS/MANUALS/
GUIDELINES FOR
SMALL HYDRO DEVELOPMENT

Electro-Mechanical Works–
Monitoring, Control, Protection and Automation of Small
Hydropower Station

Sponsor: Lead Organization:

Ministry of New and Renewable Energy Alternate Hydro Energy Center

Govt. of India Indian Institute of Technology Roorkee

May 2011
 GUIDE LINES FOR MONITORING, CONTROL, PROTECTION
AND AUTOMATION OF SMALL HYDROPOWER STATIONS

CONTENTS
SECTION-I

1.0 INTRODUCTION .............................................................................................................. 3

1.1 OBJECTIVES ................................................................................................................. 3
1.2 GENERAL ...................................................................................................................... 3
1.3 REFERENCES AND CODES ........................................................................................ 3

SECTION-II

2.0 MONITORING OF SHP .................................................................................................... 5

2.1 SYSTEMS FOR MONITORING ................................................................................... 5
2.1.1 Water Conductor System ........................................................................................ 5
2.1.2 Hydro-mechanical Parameters ................................................................................ 5
2.1.3 Electro-mechanical Operating Parameters .............................................................. 6
2.2 REQUIREMENTS OF MONITORING SYSTEM ........................................................ 7
2.2.1 Instrument Transformers & Sensors ....................................................................... 7
2.2.2 Indicating Meters .................................................................................................... 7
2.2.3 Temperature Scanners ............................................................................................. 7
2.2.4 Indicating Lamps .................................................................................................... 7
2.2.5 Alarm & Annunciations .......................................................................................... 7
2.2.6 PLC Based System.................................................................................................. 8
2.3 LEVELS OF MONITORING ......................................................................................... 8

SECTION-III

3.0 CONTROL OF UNITS OF SMALL HYDROPOWER PLANT ....................................... 9

3.1 GENERAL ...................................................................................................................... 9
3.2 Technology ..................................................................................................................... 9
3.3 CONTROL FUNCTIONS .............................................................................................. 9
3.3.1 Turbine Control ..................................................................................................... 10
3.3.2 Generator Control ................................................................................................. 10
3.3.3 Plant Control ......................................................................................................... 11
3.4 Considerations for Selecting Control System ............................................................... 12
3.5 Categorization of Control System ................................................................................. 15
3.6 System Architecture, Communication and Databases ................................................. 17
3.7 Control Data Networks ................................................................................................. 17
3.8 Man-Machine Interface (MMI).................................................................................... 17
3.9 Hardware ...................................................................................................................... 18
3.10 Grounding ..................................................................................................................... 18
3.11 Static Control ............................................................................................................... 18
3.12 Information and Control Signals ................................................................................... 18
AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 1
and automation of SHP Oct. 2009  
 3.13 Communication Links................................................................................................... 19
3.14 Recommendations for control systems for various categories of MHP & SHPs ......... 21
3.14.1 Micro processor based control for micro hydro power plant (MHP up to 100 KW). 21
3.14.2 PC based Integrated Generation Controller (100KW to 1000KW) ........................... 21
3.14.3 Computer Based Control System for Powerhouses (1MW to 5 MW)....................... 22
3.14.4 Computer Based Control System for Power Plant above 5 MW .......................... 24

SECTION-IV
4.0 Protection of SHP generating units 26
4.1 General 26
4.2 Equipment trouble 27
4.3 Devices used in typical protection system 28
4.4 Criteria of selection of protection system ....................................................................... 333
4.4.1 Requirements of Protection of Turbine................................................................. 33
4.4.2 Requirements of Protection of Generator ............................................................. 33
4.5 Generator Protection System and Relay Selection ........................................................... 34
4.5.1 Categorisation .............................................................................................................. 34
4.5.2Transient overvoltage and surge protection .................................................................. 34
4.5.3 Protection for Micro hydel systems (up to 100 kVA).................................................. 34
4.5.4 Protection for Generating Units above 100 kVA and up to 5 MVA ........................... 35
4.5.5 Protection for generating Units above 5MVA and up to 25 MVA .............................. 41
4.6 GENERATOR CONNECTED IN PARALLEL TO GRID ............................................ 46
4.7 GENERATORS CONNECTED IN PARALLEL ON A COMMON BUS .................... 46
4.8 PROTECTION GROUPS ................................................................................................ 46
4.8.1 CONTROLLED ACTION SHUT DOWN ........................................................... 46
4.8.2 EMERGENCY SHUT DOWN ............................................................................. 47
4.8.3 IMMEDIATE ACTION SHUT DOWN………………………………………....46
4.8.4 ELECTRICAL SHUT DOWN…………………………………………………..46
ANNEXURE-I ............................................................................................................................. 49
COMPUTERISED AUTOMATION AND REMOTE CONTROL OF SMALL HYDRO
POWER PLANT ........................................................................................................................... 49
ANNEXURE-II ........................................................................................................................... 85
LIST OF GENERATOR PANEL INDICATION AND RELAYS .............................................. 85
ANNEXURE-III .......................................................................................................................... 86
LIST OF PROTECTION ELEMENTS IN MICRO PROCESSOR BASED RELAYS .............. 86

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 2

and automation of SHP Oct. 2009  
GUIDE LINES FOR MONITORING, CONTROL, PROTECTION
AND AUTOMATION OF SMALL HYDROPOWER STATIONS
SECTION-I

1.0 INTRODUCTION

1.1 OBJECTIVES
The purpose of this guide is to provide guidance for selection of monitoring,control and
protection system for SHP up to 25 MW by developers, manufacturers, consultants,
regulators and others. The guide includes selection of technology, extent of automation
and monitoring system for different categories (micro up to100 KW, small up to 5 MW
and above 5 MW to 25 MW) that is economical, easy to adopt and sustainable feasible
and essential for safe operation.

1.2 GENERAL
The generating units of a small hydropower plant may have its shaft vertical, horizontal
or inclined with the type of turbine selected to suit the site’s physical conditions. Small
hydro turbines may be selected as per site conditions, head and discharge available. Small
hydro-generator are of the alternating current type and may be either synchronous or
induction type. Usually small hydro units up to 5 MW are expected to require minimum
amount of field assembly and installation work. While machine having capacity from 5
MW to 25 MW may have slow speed, large diameter and with split generator, stator that
may require final winding assembly in the field.

Mini & micro power stations are generally provided system suiting to these being run
unattended or with few attendants while bigger machines up to 5 MW capacity have more
elaborate arrangement of control monitoring and protection. Machine having capacity up
to 25 MW and provision of parallel operation with other systems will have more
comprehensive control, monitoring & protection system.

This guide will serve as a reference document along with available national &
international codes standards, guide & books. For the purpose of convenience this guide
has been subdivided as follows:

• Monitoring
• Control
• Protection

1.3 REFERENCES AND CODES

IEEE Std 1020 - IEEE guide for control of small hydro electric power
plants
IEEE Std 1010 - IEEE guide for control of hydro electric power plants
IEEE Std 60545:1976 - Guide for commissioning operation and maintenance of
AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 3
and automation of SHP Oct. 2009  
 Hydraulic Turbines
IEC 61116:1992 - Electro mechanical guide for small hydroelectric
installations
IEEE std 1046 - IEEE application guide for distributed digital control
and monitoring for power plants
IEEE std. 1249 - IEEE guide for computer–based control for power plant
automation
IEEE std. C 37101 - IEEE guide for generator ground protection
IEEE std. C 5012 - IEEE standard for salient pole 50 Hz and 60 Hz
synchronous generator and generator / motors for
hydraulic turbine application rated 5 MVA and above
IEEE std 4214 - IEEE guide for preparation of excitation system
specification
ANSI/ IEEE std 242:1996 - IEEE recommended practice for protection and
coordination of industrial and commercial power
systems
ANSI/ IEEE std C 372-1987 - IEEE standard electrical power systems device function
numbers
ANSI/ IEEE std C 37.95 : 1974 - (R1980) IEEE guide for protective relaying of utility
ANSI/ IEEE std C 37.102:1987 - IEEE guide for generator protection

The guidelines are based on the following:

a) Technology recommended under UNDP-GEF Project for Himalayan range SHP
project. These recommendations were made by AHEC (Alternate Hydro Energy
Centre) as Indian consultant based on specific recommendations of M/s Mead and
Hunt – US consultant; M/s MHPG Group of European Consultants; World
Literature review and local experience.
a) UNDP/world bank recommendation for cost effective irrigation based Mini
Hydro Schemes in India under Energy Sector Management Assistance
programme (ESMAP) by standardization of designs and equipment.
b) “Economic Computer Controls for Low Head Hydro” by R. Thapar and D.A.
Perrault; WATERPOWER’85, U.S.A.
c) Thapar, Rakesh, et.al, “Microprocessor Controller for a small Hydroelectric
System”, I.E.E. October, 1986.
d) “Microcomputer Based Control and Monitoring Systems”; DIGITEK INC. 11807,
North Creek Pkwy, So. Bothell, WA 98011 U.S.A. – Technical Literature.
e) “Small Hydro-Electric – Technology for Economic Development” by O.D.
Thapar, Presented in Eleventh National Convention of Electrical Engineers and
Seminar on Environmental Friendly Electric Power Generation- Nov. 1995,
Roorkee.
f) Report on study and design and development of Model SHP based self sustained
projects - E & M Equipment standardization and cost reduction Vol. III (a)
prepared by Alternate Hydro energy Centre, IIT Roorkee for Power finance
corporation Ltd. – 2002.
g) Design of al large number of SHP projects for different states and organization.
h) Art & science of protective relaying 1956 by MASON, CR
AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 4
and automation of SHP Oct. 2009  
 SECTION-II

2.0 MONITORING OF SHP

Monitoring of operating parameters of the generating unit and their auxiliaries is very
important for the life and optimum utilization of available discharge for generation. The efficient
running of unit requires regular monitoring. The primary input data and generation output data
are monitored periodically. The details of data required for monitoring performance of a
generating station is as follows.

2.1 SYSTEMS FOR MONITORING

2.1.1 Water Conductor System

• Storage level at dam / barrage / weir

• River discharge
• Headrace channel discharge
• Discharge at outlet of desilting basin
• Fore bay level
• Discharge of spillway
• Penstock pressure
• Tail water level

2.1.2 Hydro-mechanical Parameters

• Turbine and accessories

o Pressure and levels in oil pressure system
o Bearing temperatures (oil & pads)
o Oil level in bearing sumps (if provided)
o Cooling water pressure and temperatures
o Clean water pressure for shaft gland
o Vibration in shaft for large machines( optional)
o Status of inlet and other valves.
• Generator and accessories
o Stator winding temperature
o DE/NDE end bearing temperatures
o Cooling water and air temperatures
• Transformers
o Winding temperature
o Oil temperature
o Oil level
o Cooling water temperature and pressures

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2.1.3 Electro-mechanical Operating Parameters
• Turbine & accessories
o Speed
o Guide vane opening & limits (precent)
o Runner blade opening in Kaplan Turbine (percent)
o Nozzle opening in impulse turbine (percent)
• Generator & auxiliaries
o Governor actuator balance current (Amp)
o Generated power (kW or MW)
o Generated units (kWh)
o Kilovolt ampere (kVA)
o Kilovolt ampere reactive (kVAR)
o Power factor (PF)
o Frequency (Hz)
o Excitation voltage (Volts)
o Excitation current (Amp)
o Recorder for kW, Hz, kWh etc
• Transformers
o Tap position
o HV/LV current
o Primary/ secondary voltage
• Grid system & transmission line
o Grid voltage
o Grid frequency
o Power export / import (kW)
o Current (Amp)
o Kilowatt hour (kWh) export / import
• Station auxiliaries
o Voltage and current on LT AC system
o Kilowatt hour (kWh)
o Diesel generator running hour, kWh & other parameters
o Drainage & dewatering system
ƒ Running hours of pumps
ƒ Water level in sump
o Fire extinguisher – periodical testing
o Battery set- Regular monitoring as per manufacturers recommendations
o Battery chargers & distribution boards – voltage current etc.
o Air compressors – HP /LP pressures and running hours
o OPU system
ƒ Running hours of pumps
ƒ Level in pressure accumulators
ƒ Pressure of oil

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2.2 REQUIREMENTS OF MONITORING SYSTEM

2.2.1 Instrument Transformers & Sensors

i) CTs & VTs

Current and voltage transformers of rated voltage and appropriate ratio, class of accuracy
are selected as per the requirement of the system.

ii) Sensors

The sensors for temperatures, pressures, levels and speed are installed at the proper
location.

2.2.2 Indicating Meters

Analogue type of meters, separate for each parameter with selector switches etc were
being used earlier installed on control panels. Now a days digital meters are being used for such
parameters. Digital multifunction meters are now in use, only one meter provides several
parameters on selection, as well as provides routine display.

2.2.3 Temperature Scanners

Digital temperature scanners indicating the temperatures of stator winding, bearing pads,
oil coolers etc. are provided and installed on the generator control panels. These scanners get the
signals from the sensor installed at specific locations preferably through screened cables.

2.2.4 Indicating Lamps

Indicating lamps of suitable colours as per code and practices should be provided on
control panels for indication status of machine and various auxiliaries, pumps, electrical
equipment like breaker, isolator, AC/DC supply system etc. Lists of such indication and relays
are enclosed as Annexure-I&II.

2.2.5 Alarm & Annunciations

The protection system relays and auxiliary relays also provide signals to alarm and
annunciation system. A set of annunciation windows are provided on control panels for each
fault clearing relay with accept test and reset facility through push buttons. Alarm and trip
annunciation indicate the fault and advise operating personnel of the changed operating
conditions.

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2.2.6 PLC Based System

Recently control of machine and auxiliaries is done through PLC based control system
automatically in addition to manual systems with local and remote facilities. The data is acquired
through sensors and operation of machine is achieved on preset values through PC Monitors etc.

The PLC will acquire data from generating units, transformers, switchgears and
auxiliaries through transducers / sensors/ CTs / VTs.
Wherever signals are weak, noise level is high shielded cables should be used for
carrying data / signals. For sending output signals PLC will use relays for operating breakers etc
and comparators for giving ON/OFF signal.

2.3 LEVELS OF MONITORING

Normally two levels of monitoring is provided in SHP as per recommendation of IEC

1116. The levels are:

• Alarm
• Tripping

In case of manned power plant ‘alarm’ comes first so as to make the operator alert if no
corrective action is possible then tripping command with indication / hooter and annunciation
will be there.

But in case of unattended power plant direct tripping command will be initiated and shut
off the facility to avert possibility of any damage to the plant.

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 SECTION-III

3.0 CONTROL OF UNITS OF SMALL HYDROPOWER PLANT

3.1 GENERAL

For small hydro installation simplicity of control system is advised, however, the
sophistication of control should be based on the complexity and size of the installation, without
compromising unit dependability and safety of personnel. Simplicity of control is desirable to
keep total cost of installed equipment as well as cost of maintenance, repair and tests at
economical level. Moreover a simpler system is more reliable as compared to complex one.

3.2 Technology

Up to 1980s, control of a hydro plant’s generating units was typically performed

from governor panel or unit control switchboard. If the plant had multiple units, a centralized
control board was provided. The unit control board and centralized control board using relay
logic contained iron vane meters, hardwired control switches, and hundreds of auxiliary relays to
perform the unit start/stop and other control operations. All the necessary sensors and controls
required to operate the unit or units were hardwired to the unit control board and/ or centralized
control board, allowing operator to control the entire station from one location. Data acquisition
was manual.

Modern systems still permit control of the entire plant from a single location.
Modern control rooms utilize the far more cost-effective computer based automation which
implies (IEEE: 1249 definition) use of computer component, such as logic controllers, sequence
controllers, modulating controllers and microprocessors in order to bring plant equipment into
operation, optimize operation in a steady state condition and shut down the equipment in the
proper sequence under safe operating conditions.

This includes programmable logic controllers (PLC’s) for control system and PC
monitor and hard disc for data display and data acquisition system and distributed computer
control systems with graphic display screens to implement a vast array of control schemes. The
SCADA (supervisory control and data acquisition) control scheme also provides flexibility in
control, alarming, sequence of events recording, and remote communication that was not
possible with the hardwired control systems. Data acquisition, storage and retrieval is provided
by the computer.
A detailed write up on computerized automation, remote control and SCADA is
enclosed as Annexure –I for reference.

3.3 CONTROL FUNCTIONS

There are many functions to be controlled in a small hydropower system. For example
turbine governor controls the speed of turbine, plant automation covers operations as auto start,
auto synchronization, remote control startup or water level control and data acquisition and
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retrieval covers such operation as relaying plant operating status, instantaneous system efficiency
or monthly plant factor.

3.3.1 Turbine Control

This is the speed / load control of turbine in which governor adjusts the flow of water
through turbine to balance the input power with load.

In case small plants in the category of micro hydel (100 kW unit size), load controllers
are used, where excess load is diverted to dummy load to maintain constant speed.

With an isolated system, the governor controls the frequency of the system.

In interconnected system, the governor may be used to regulate unit load and may
contribute to the system frequency control. Figure 1 shows the different types of control
applicable to turbines.

Fig. 1: Turbine Control

3.3.2 Generator Control

This is the excitation control of synchronous generator. The excitation is an integral part
of synchronous generator which is used to regulate operation of generator. The main functions of
excitation system of a synchronous generator are:

• Voltage control in case of isolated operation and synchronizing

• Reactive power or power factor controls in case of inter connected operation.

The different generator controls are shown in fig. 2.

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 Fig. 2: Generator Controls

3.3.3 Plant Control

Plant control deals with the operation of plant. It includes sequential operation like
startup, excitation control, synchronization, loading unit under specified conditions, normal
shutdown, emergency shutdown etc. The mode of control may be manual or automatic and may
be controlled locally or from remote location. Plant control usually includes monitoring and
display of plant conditions. Different plant controls are given in fig 3.

Fig. 3: Overview of Plant Automatic Control

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3.4 Considerations for Selecting Control System

Governor and control systems for small hydro units especially in developing countries
have to be selected keeping in view the following:

i) Traditional mechanical flow control governor with mechanical hydraulic devices is

complex demanding maintenance and high first cost. Further performance requirements
of stability and sensitivity i.e. dead band, dead time and dashpot time especially for
interconnected units may not be possible with mechanical governors.

ii) The manpower as available for operation is unskilled and further adequate supervision
is not feasible.

iii) Load factors for stand-alone micro hydels are usually low which affects economic
viability.

iv) Cost of speed control and automation with electronic analaog flow control governors,
unit control and plant control is high. These systems require attended operation and are
mostly based on large capacity hydro units. This is making most of the units very costly
and uneconomical to operate. Experience in successful operation of analog electronic
control system in India for SHP is not good.

v) Electronic digital flow control governors can take up plant control functions.

vi) Flow control turbine governors are expensive and not recommended for small hydro
units in micro hydel range. Electronic load control governing system with water cooled
hot water tanks as ballast loads for unit size upto 100 kW be used. This will make a
saving of about 40% on capital cost. If the thyristor control (ELC) is used then the
alternator needs to be oversized upto 2% on kVA to cope with the higher circulating
current included. Accordingly, in case of small units upto 100-150 kW size elimination of
flow control governors by digital shunt load governor (electronic load controllers) will
make these units economically viable and properly designed will eliminate continuous
attendance requirement.

vii) Data storage function can be added to the digital governors.

viii) The dummy loads in the Shunt Load Governors (ELC) can be useful load system or
can be used for supplying domestic energy needs.

ix) Analog electronic governors and plant controllers are also used for small hydro auto
synchronizing and for remote control and monitoring of system.

x) Digital generation controllers were evolved to take care of speed control, unit control
and automation, unit protection and generation scheduling and have been successfully in
operation for over ten years.

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 xi) PLC based system are reliable and suitable for harsh conditions. These have been in
operation in India and abroad.

xii) Dedicated PC based systems for complete generation control can be easily adopted
for data acquisition and storage at low cost and can also be adapted to SCADA system.
Customized software is used in these systems which inhibits wide spread use. Future
systems using PC as controller and for SCADA with open architecture and use of
commercially available software is recommended for economy and wide spread use.

Comparison of various options for control systems are given in table 1

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 Table1. Comparison of various options for control system, including turbine governing supervisory control and data acquisition
S. Turbine Gov. and Unit size Mode Suitability Cost including Gov. control, Recommendation Remarks
No. Controller Type of protection, SCADA data
kW operati Turbine Unit Data storage SCADA Aq., Storage and Retrieval
on Gov. Unit Prot. and Retrieval (see note-1)
control
Capital O&M

1. Mech. Flow control Gov. 50-100 Iso. 9 At high extra cost Very high High without Not
SCADA recommendation
Grid 9
100-500 & Iso. 9
above
Grid 9
2. Load control governor 50-100 Iso. 9 Suitable At extra cost Low Low Not considered
Grid 9
Do not available
Digital load
100-500 Iso. See note 3 control governor
may be developed
Grid × Not feasible
for SCADA

3. Analogue, Electronic 50-100 Iso. Suitable At high extra cost Very high cost Not recommended
Gov. & Plant Controller Grid
Above 100 Iso. High Moderate to high

Grid
4. PLC integrated controller SHP 100 kW Iso. Suitable Low Moderate Recommended
with SCADA by PC to 5 MW
Grid

5. PLC digital governor with Above 5 Iso. Suitable High Moderate Recommended for
plant controller and MW See note 2 units above 5 MW
SCADA with redundant Grid
PC
6. Data Logger with PLC 5 to 100 kW Iso. Data not available Low Moderate Recommended
load controller Grid
7. PC based integrated 100 kW to Iso. Suitable – Indigenous system not available Low Medium Recommended with
system for governing; 2500 kW high speed PC
plant control protection suitable for harsh
and metering area
Grid

Notes: 1. Cost normalized with main and backup SCADA system.

2. Dedicated digital controller for Gov. and plant control with PC based SCADA backup.
3. Recommended in conjunction with partial water flow control

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3.5 Categorization of Control System

The control system can further be defined by identifying following three categories of
control:

Control Subcategory Remarks

category
Location Local Control is local at the controlled equipment or within
sight of the equipment
Centralized Control is remote from the controlled equipment, but
within the plant
Offsite Control location is remote from the project
Mode Manual Each operation needs a separate and discrete initiation;
could be applicable to any of the three locations
Automatic Several operations are precipitated by a single
initiation; could be applicable to any of the three
locations
Operation Attended Operator is available at all times to initiate control
(supervision) action
Unattended Operation staff is not normally available at the project
site

Relationship of local centralized and off site control function as per IEC: (62270-2004)
guide in fig. 4 & 5.

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 STATION OPTICAL
TO REMOTE FIBRE UNIT 1 SART/STOP SEQUENCING
CONTROL COMMUNICATION LOCAL/MANUAL
NETWORK (DUAL) CONTROL SYNCHRONIZING
CENTRALISED TRASHRACK CONTROL
CONTROL PLC BLACK START CONTROL
UNIT AUXILIARIES CONTROL
USER GOVERNOR/EXCITATION CONTROL/STATUS
INTERFACE
UNIT LOAD CONTROL
UNIT ANNUNCIATION
UNIT METERING
UNIT RELAY STATUS
UNIT FLOW DATA
UNIT 2 CONDITION MONITORING
LOCAL/MANUAL
CONTROL
INDIVIDUAL UNIT CONTROL
SWITCHYARD CONTROL
STATION SERVICE CONTROL PLC
& MONITORING USER
PLANT REAL POWER CONTROL INTERFACE
& MONITORING
AUTOMATIC VOLTAGE CONTROL
WATER & POWER OPTIMIZATION
AUTOMATIC GENERTAION CONTROL
SWITCHGEAR AND RELAY STATUS STATION
REPORT GENERATION SERVICE
DATA LOGGING/TRENDING LOCAL
HISTORICAL ARCHIVING CONTROL

USER
INTERFACE

SWITCHYARD
CONTROL

PLC
USER
INTERFACE

POWER HOUSE
Fig. 4

LOCAL CONTROL SYSTEM

PROTECTION
SYSTEM

STATION
COMMUNICATION
LINK

PROCESS
COMPUTER PROCESS (UNIT,
BASED INTERFACE SWITCHGEAR
CONTROL GATES, ETC.)

LOCAL
USER
INTERFACE
BACKUP
CONTROL

Fig. 5

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3.6 System Architecture, Communication and Databases

i. Open architecture system should be followed in accordance with IEEE-1249-

1996. Interface or operating standards for the following should comply with
ISO/IEC 12119/IEEE 802.

Hardware interconnectivity
Time stamping of data,
Communications
Operating system
User Interface
Data base

ii. Each of these elements should be capable of being replaced by or communicate with
system elements provided by other vendors.
iii. The scope of the bidder is not limited to the parts & components explicitly identified
here in and shall have to provide any and all parts/components needed to meet the
functional requirements laid down herein or are necessary for satisfactory operation
of the plant.

3.7 Control Data Networks

Local area networks (LANs) should be configured to IEEE 802.3 (Ethernet) standard.

Commercially available software should be used as far as possible.

3.8 Man-Machine Interface (MMI)

The operator’s station of the station controller (SCADA system) should have an elaborate
and friendly man-machine interface. A 19” or larger monitor should be provided for the
display. Provision should be made for connecting a second colour monitor in parallel.
The screen displays should be suitably designed to provide information in most
appropriate forms such as text, tables, curves, bar charts, dynamic mimic diagrams,
graphic symbols, all in colour. An event printer should be connected to PC of the
SCADA system. Events should be printed out spontaneously as they arrive. Provision
should be made to connect and use another printer simultaneously. Touch control screen,
voice and other advanced modes of MMI are desired and should be preferred. The entire
customization of software for MMI and report generation should be carried out. A
window based operating system should be preferred.

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3.9 Hardware
Input/output system should have following capabilities.

i. Portability and the exchange of I/O cards from one I/O location to another. This
can reduce spare parts requirements.
ii. Availability of I/O cards to be replaced under power. This avoids the need to
shutdown an entire I/O location to change one card.
iii. Sequence-of-Events (SOE) time tagging at the I/O locations; accuracy and
resolution.
iv. Availability of I/O signal types and levels that support the field device signals to
be used.
v. Support of redundant field devices, capability for redundant I/O from field device
to the database and operator interface.
vi. I/O diagnostics available at the card, e.g., card failure indicating LEDs, or through
software in the system.

3.10 Grounding

Each equipment rack in which automation system components are located should be
separately connected to the powerhouse ground mat by a large gauge wire.

Shielded cables should be used for analog signals between the transducers and the
automation system. Each shield should be tied to the signal common potential at the
transducer end of the cable. If there are terminations or junction boxes between the
transducers and automation system, each shield circuit should be maintained as a separate
continuous circuit through such junction or termination boxes.

3.11 Static Control

Equipment should be immune to static problems in the normal operating configuration.

Anti-static carpet and proper grounding for all devices that an operator may contact
should be provided.

3.12 Information and Control Signals

Information and control signal for proper control and monitoring will be acquired from
the following main and auxiliary/associated equipment and shall be provided as
tentatively detailed along with the equipment as out lined in this paragraph. Deviation
will be intimated in the bid 25% spare capacity for inputs and output shall be provided.

The control system shall receive input signals from main equipment such as the turbine
or the generator, and from various other accessory equipments, such as the governor,
exciter, and automatic synchronizer. Status inputs shall be obtained from control
switches, level and function switches indicative of pressure, position etc, throughout the
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 plant. The proper combination of these inputs to the control system logic will provide
outputs to the governor, the exciter, and other equipment to start or shutdown the unit.
Any abnormalities in the inputs must prevent the unit’s startup, or if already on-line,
provide an alarm or initiate its shutdown.

i. Generator
ii. Generator field excitation equipment
iii. Generator terminal equipment (Line and Neutral side)
iv. Unit generator breaker equipment
v. Turbine
vi. Governor
vii. Generator cooling
viii. Service air
ix. Service water
x. DC power supply
xi. AC auxiliary power supply
xii. Water level monitoring
xiii. Fire protection

Following four types of signals are provided between control board and particular
equipment

• Analog inputs for variable signals from CTs, VTs, RTDs, pressure, flow, level, vibration
etc.
• Digital inputs provides digitalized values of variable quantities from the equipment
• Digital outputs – command signals from control boards to equipment
• Analog outputs – transmit variable signals from control to equipment e.g. governor,
voltage regulator etc.

3.13 Communication Links

a. Communication links with remote control

Following methods are available for implementing control from a remote location:
• Hardwired communication circuits (telephone type line, optical cables etc.)
• Leased telephone lines
• Power line carries communication system
• Point to point radio
• Microwave radio
• Satellite

Metallic circuit in hardwired communication circuits and leased telephone lines, requires
special protection for equipments and personals against ground potential rise (GPR) due to

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electric system fault, since the hydro-generator is source of fault current. GPR is also caused by
lightning transmitted through power lines entering the power plant. As such suitable mitigation
has to be provided.

Power line carrier including insulated ground wire system can be used for
communications purposes. This method couples a high frequency signal on the power line or
insulated ground wire and is decoupled at an offsite point.

Space radio can be used, utilizing power frequencies and micro wave radio can be
practical if hydro plant owner has an existing microwave system.

b. Communication with control boards

Data and control signals of following equipments will be required to be transmitted

between control board & equipments.

• Generator neutral and terminal equipment

• Head water and tail water level equipment
• Water passage shut off or bye pass valves gates etc.
• Turbine
• Unit transformer
• Circuits breaker and switches
• Generator
• Intake gates or main inlet valve and draft tube gates
• Turbine governing system
• Generator excitation system

The communication link between control board and equipment should be reliable. Optical
fiber cable, shielded cable and Ethernet are various options

c. Communications with Auxiliaries

Data and control signals of following auxiliaries/ equipments will be required to be

transmitted between control board and equipments.

• Fire protection
• AC Power supply
• DC Power supply
• Service water
• Service air
• Water level monitoring
• Turbine flow monitoring

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3.14 Recommendations for control systems for various categories of MHP & SHP

3.14.1 Control for micro hydro power plant (5KW to 100 KW)
Manual control and manual synchronization with ELC is recommended. However,
data logger with PLC load controller may also be provided. Recommendations of “Micro
hydel Standard issued by AHEC, IIT, Roorkee” are also to be reffered.

3.14.2 PC based Integrated Generation Controller (100KW to 1000KW)

Integrated governor and plant control system are discussed in “Guidelines for selection of
turbine and governing system”.

PC based integrated generation controller capable of following function was developed

by M/s Digitek of USA and M/s Predeep Digitek in India for SHP.

• Governor speed control

• Automatic sequencing for start up and shutdown including synchronizing
• Automatic sequencing for emergency shutdown
• Data recording and reporting
• Alarm anunciation
• Full remote control and monitoring
• Control via terminal keyboard
• Water level control
• Flexible architecture
• Modular card system
• Ability to communicate with other microprocessor based equipment
• Alarm and status logging
• Data logging at user selected intervals
• Event recording
• Line protection- frequency and voltage
• Generator protection - voltage, current, reverse power, differential, loss of field

PC based system for unit control, governor control and other functions provided for Sobla
SHP in Uttarakhand is attached as Fig.-6 is a cheaper alternative but lacks redundancy
which can be provided by spare cards for each type. The scheme envisages
installation of integrated generation controller, generator and line protection and metering
was however provided by conventional meters and electromagnetic relays as shown in
Fig.-6.

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 Fig. 6

3.14.3 Computer Based Control System for Powerhouses (1MW to 5 MW)

Most of the small powerhouses in the range have the control room at the same level as
the machine hall. Accordingly the unit control and supervisory control functions can be
provided in the control room.

i) PLC Based System

One PLC integrated controller per unit may be provided for unit control, governor
control, plant control, supervisory control and data acquisition and remote control
provision AVR and measuring units and auxiliaries.

Separate controllers may be provided for switchyard, common auxiliaries etc.

Remote/Supervisory control and data acquisition all the unit may be provided by one PC.

The recommended control system is shown in Fig. 7. Manual control facility is provided
on PLC panel.

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 See note-1

Fig. 7 -Typical Configuration for Computerized Hydro Station (proposed for SHP)

Note-1 In case machine level and station level is same, manual/automatic control panel
be combined with unit PLC panel

ii) PLC integrated unit controller with PC for supervisory control data acquisition and
remote control facilities for Triveni canal fall SHPs with provision for remote control of
three nearby canal fall power plants have been shown in Fig.-8.

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 Fig.8 – System Configuration Triveni SHP project (Punjab) (Canal based)
(Provided by M/s ALSTHOM)

3.14.4 Computer Based Control System for Power Plant above 5 MW

3.14.4.1 Functional Capabilities

Functional capabilities summarised below may be provided to the extent economically

feasible.

i. Computer based automation system should permit operation of power plant,

switchyard, outlet works, Inlet valves etc. from a single control point.
ii. Manual/Local control should be provided by equipment located near the
generating unit. The local unit computer (PLC) should be part of the equipment.
iii. Automatic unit start/stop control sequencing should be part of computer based
automation. Automation system should include capability to provide diagnostic
information so as to isolate the problem and get the unit on line as fast as possible.
iv. Auto synchronising should be computer based. There is no objection to provide
synchronising function as internal to the automation system. Check synchronising
relay should be provided for security.
v. The computer system shall optimise individual unit turbine operation to enhance
unit operation in respect of following:

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 a) Efficiency maximization - gate position, flow, unit kW output, unit
reactive power output.
b) Minimization unit vibration or rouges running zone - gate position, unit
vibration.
c) Minimization of cavitation: Gate position, flow, Hydraulic head, turbine
manufacturers cavitation curve.
d) Black start control - this may including starting emergency generator.
e) Centralised Control – Individual units, switchyard, station service control,
plant voltage/Var control, water and power optimization; Forebay level
control.

vi. Data acquisition capabilities

vii. Alarm processing and diagnostics
viii. Report generation
ix. Maintenance and management interface
x. Data archival and retrieval
xi. Data access
xii. Operator simulation training
xiii. Provision of frequency relay for operation in stand alone or in an isolated or
islanded mode, should be made.

A typical block diagram of computer based control system for 2 x 10 MVA Mukerian
Stage–II power house with offsite control is shown in FIG.9. A provision for a
programming station with back up for operation is also included as redundant system.

Fig. 9 – Redundant computer based control system for 2 x 10 MW

Mukerian Stage II with remote control for stage (proposed by M/s BHEL)
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 SECTION-IV

4.0 PROTECTION OF SHP GENERATING UNITS

4.1 GENERAL

Small hydro turbine-generators should be protected against mechanical, electrical,

hydraulic and thermal damage that may occur as a result of abnormal conditions in the plant or in
the utility system to which the plant is electrically connected.

The abnormal operating conditions that may arise should be detected automatically and
corrective action taken in a timely fashion to minimize the impact. Relays (utilizing electrical
quantities), temperature sensors, pressure or liquid level sensors, and mechanical contacts
operated by centrifugal force, etc., may be utilized in the detection of abnormal conditions. These
devices in turn operate other electrical and mechanical devices to isolate the equipment from the
system.

Where programmable controllers are provided for unit control, they can also perform
some of the desired protective functions.

Operating problems with the turbine, generator, or associated auxiliary equipment require
an orderly shutdown of the affected unit while the remaining generating units (if more than one
is in the plant) continue to operate. Alarm indicators could be used to advise operating personnel
of the changed operating conditions.

Loss of individual items of auxiliary equipment may or may not be critical to the overall
operation of the small plant, depending upon the extent of redundancy provided in the auxiliary
systems. Many auxiliary equipment problems may necessitate loss of generation until the
abnormal conditions has been determined and corrected by operating or maintenance staff.

The type and extent of the protection provided will depend upon many considerations,
some of which are:
(1) The capacity, number, and type of units in the plant;
(2) The type of power system;
(3) Interconnecting utility requirements;
(4) The owner’s dependence on the plant for power;
(5) Manufacturer’s recommendations;
(6) Equipment capabilities; and
(7) Control location and extent of monitoring.

Overall, though, the design of the protective systems and equipment is intended to detect
abnormal conditions quickly and isolate the affected equipment as rapidly as possible, so as to
minimize the extent of damage and yet retain the maximum amount of equipment in service.

Small hydroelectric power plants generally contain less complex systems than large
stations, and therefore tend to require less protective equipment. On the other hand, the very
small stations should be typically unattended and under automatic control, and frequently have
AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 26
and automation of SHP Oct. 2009  
little control and data monitoring at an off-site location. This greater isolation tends to increase
the protection demands of the smaller plants.

An inherent part of the power plant protection is the design of the automatic controls to
recognize and act on abnormal conditions or control failures during startup. Close coordination
of the unit controls and other protection is essential.

4.2 EQUIPMENT TROUBLE

4.2.1 Plant Mechanical Equipment Troubles
4.2.1.1 Turbines

(a) Excessive vibration

(b) Bearing problems
(c) Over speed
(d) Insufficient water flow
(e) Shear pin failure
(f) Grease system failure

4.2.1.2 Hydraulic Control System

(a) Low accumulator oil level

(b) Low accumulator pressure
(c) Electrical, electronic or hydraulic malfunctions within the governing or gate
positioning system

4.2.1.3 Water Passage Equipment

(a) Failure of head gate or inlet valve

(b) Head gate inoperative
(c) Trash rack blockage
(d) Water level control malfunction

4.2.2 Plant Electrical Equipment Troubles

4.2.2.1 Generator

(a) Abnormal electrical conditions

(b) Stator winding high temperature
(c) Low frequency
(d) Bearing problems
(e) Motoring
(f) Fire
(g) Excessive vibration
(h) Cooling failure
(i) Over speed

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and automation of SHP Oct. 2009  
4.2.2.2 Main Transformer

(a) Insulation failure

(b) High temperature
(c) Abnormal oil level
(d) Fire

4.2.2.3 Generator Switchgear and Bus

(a) Electrical fault

(b) Mechanical failure
(c) Loss of control power

4.2.3 General Plant Troubles

4.2.3.1 Station Service

(a) Transformer failure

(b) Unbalanced current
(c) DC System Trouble
(d) Station Air System Trouble
(e) Service Water System Trouble
(f) Flooding
(g) Fire
(h) Unauthorized Entry
(i) Protection or Control Logic System Malfunction
(j) Water level Monitoring System Malfunction

4.2.4 Utility System Troubles

Utility line faults and other abnormal utility system conditions should be detected and the
plant be disconnected from the utility system. Abnormal utility system conditions include the
following situations:

a. Ground or phase faults

b. Single phasing
c. Abnormal voltage
d. System separation (islanding)

Coordination with the utility is needed in selecting specific protective equipment,

particularly for line fault detection.

4.3 DEVICES USED IN A TYPICAL PROTECTION SYSTEM

There are numerous ways of providing the functional protective requirements of the
plant. While standard devices are generally available that can provide the protective functions

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 28

and automation of SHP Oct. 2009  
required, however each station should have specific design suitable for protection requirements
of the power plant equipment as well as the interconnection.

The following section describes components of a typical protection system that might be
applied to a small hydro plant. Discussions and diagrams are included to illustrate location and
arrangement of relays.

4.3.1 Protective Devices

4.3.1.1 Temperature

A temperature device, possibly incorporating display and contacts for alarm,

annunciation and tripping to monitor bearing, stator and transformer winding temperatures.
Resistance temperature devices operating relays can also be used to detect generator stator
overheating.

4.3.1.2 Pressure and Level

Pressure and level switches installed in the turbine air and oil systems, to alarm, block
startup, or trip, as necessary.

4.3.1.3 Over and under speed

Direct-connected or electrically driven speed switches for alarm, control, and tripping.

4.3.1.4 Vibration

Vibration detectors monitoring turbine or generator shaft sections, with alarm and trip
contacts.

4.3.1.5 Water level

A measuring system incorporating level sensors and monitoring equipment, to alarm, trip,
or control turbine output on limiting values of headwater or tail water level, or head.

4.3.1.6 Fire

Sensors located in areas where fire can occur and connected to a central fire monitor for
alarm. Small generators usually do not have fire sensors or suppression equipment, since they are
not usually enclosed.

4.3.1.7 Miscellaneous mechanical

Sensing devices are integral to the protected systems, such as automatic greasing system,
wicket gate shear pins, transformer cooling and station sump drainage system.

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 29

and automation of SHP Oct. 2009  
4.3.2 Protective Relay and Protection System

4.3.2.1 Features of relays

The protective relays stand watch and in the event of failures short circuits or abnormal
operating conditions help de-energize the unhealthy section of power system and restrain
interference with rest of it and limit damage to equipment and ensure safety of personnel. The
protective relays should possess following features:

• Reliability – To ensure correct action even after long period of inactivity and also to offer
repeated operation under sever condition.
• Selectivity – To ensure that only the unhealthy part of system is disconnected
• Sensitivity – Detection of short circuit or abnormal operating condition.
• Speed – To prevent and minimize damage and risk to instability of rotating plant.
• Stability – The ability to operate only under those conditions that calls for its operation
and to remain either passive or biased against operation under all other conditions.

4.3.2.2 Protective Relay Technology

Protective relay technology has changed significantly in recent years. Induction disk
relays for each individual protective function were normally used. Individual solid state static
relays for protective function were introduced in the decade 1980-1990 and IS 3231-1965 was
accordingly revised in 1987.

The old conventional electromagnetic relays were replaced with static relays which are
much faster and maintenance free. These relays are more reliable and sensitive. These days
microprocessor based multifunction relays are available which have different protections
elements and therefore, a separate relay for each protection is not required.

4.3.2.2.1Microprocessor based Multifunction Relays:

Microprocessor based multi function relays are now being used. Advantages
of these relays are as follows:
i) Self-monitoring of operating status on continuing basis and to alarm when to function.
ii) Multiple protective functions in one relay reduce panel space and wiring end.
iii) Self calibration by software programming
iv) Programmable set point by software programming
v) Interfacing with SCADA will be easy

Microprocessor relaying has gained widespread acceptance among both utilities and
consumers. The relay functions are the same as those in electromechanical and solid-state
electronic relaying, but microprocessor relays have features that provide added benefits.
Microprocessor relays may have some disadvantages, however, so that there are additional
considerations when these are applied for protection in SHP.

4.3.2.2.2Benefits of Microprocessor Relays:

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and automation of SHP Oct. 2009  
 The benefits of microprocessor relays include the ability to combine relay functions into
economical unit. Where an electromechanical over current relay may be only a single phase
device, a microprocessor relay will often include three phases and a neutral. It could also
include reclosing, directional elements, over/under voltage, and over/under frequency. A
microprocessor generator relay could include differential, over current, negative sequence,
frequency, voltage, stator ground, and other protective functions.
Similarly, a microprocessor transformer relay might combine differential an overcurrent
protection. A transmission line relay could combine multiple zone phase and ground distance
elements, over current fault-detectors, pilot scheme logic, and reclosing. An electromechanical
scheme will normally consist of individual relays for each zone of phase and ground protection,
separate fault-detectors, and additional relaying for pilot scheme logic. These same devices can
include non-relaying functions such as metering, event recording and oscillography. All of
these functions are contained in an enclosure that requires less space than the combination of
relays and other devices they duplicate.

A microprocessor relay has self-monitoring diagnostic that provide continuous status of

relay availability and reduces the need for periodic maintenance. If a relay fails, it is
typically replaced rather than repaired. Because these relays have multiple features, functions,
increased setting ranges, and increased flexibility, it permits stocking of fewer spares.

Microprocessor relay also have communication capability that allows for remote
interrogation of meter and event data and fault oscillography. This also permits relay setting
from a remote location. The relays have low power consumption and low CT and VT burdens.
They also increase the flexibility of CT connections. For instance, microprocessor transformer
differential relays can compensate internally for ratio mismatch and the phase shift associated
with delta-wye connections.

All of these features have economic benefits in addition to the lower initial costs and
potentially reduced maintenance costs that microprocessor relays have when compared to
individual relays.

4.3.2.2.4 Disadvantages:
The operating energy for most electromechanical relays is obtained from the measured
currents and/or voltages, but most microprocessor relays require a source of control power.
Another disadvantage is that the multifunction feature can result in a loss of redundancy. For
instance, the failure of a single-phase over current relay is backed up by the remaining phase and
neutral relays. In a microprocessor scheme, the phase and neutral elements are frequently
combined in one package and a single failure can disable the protection. Similarly, a
microprocessor generator/transformer package that has both differential and over current
relaying provided less redundancy than a scheme comprising separate relays. The self-
diagnostics ability of the microprocessor relay, and its ability to communicate failure alarms,
mitigates some of the loss of redundancy. It may also be economical to use multiple
microprocessor relay.
Microprocessor relays require more engineering in the application and setting of the
relay though less work in the panel design and wiring. The increased relay setting flexibility is
accompanied by an increase in setting complexity that requires diligence to avoid setting errors.

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 31

and automation of SHP Oct. 2009  
Also, some relays have experienced numerous software upgrades in a short period of time.
Microprocessor relays have relatively shorter product life cycles because of the rapid advance in
technology. As a result, a specific microprocessor relay model may only be available for a
relatively short period of time. As a failure may require replacement rather than repair, it may not
be possible to use an exact replacement, which may require more engineering and installation
work. Although less frequent testing may be required, but for testing it requires a higher level of
training for the technician and more test equipment than is normally used with electromechanical
relays in order to obtain the full benefit of all the features of the microprocessor relay. The self-
monitoring capability of these relays is only effective if the alarm output can be communicated
to a manned location such as a control center. Also, the remote communication ability assumes
there is a communication channel available to the relay.

Following annexure are enclosed for ready reference

• Annexure-II - List of SHP Generator panel indications & relays

• Annexure-III - List of protection elements in Microprocessor based relays

4.3.2.2.5 Protection relays for SHP

i) The application of relays must be coordinated with the partitioning of the

electrical system by circuit breakers, so that least amount of equipment is
removed from operation following a fault, preserving the integrity of the balance
of the plant’s electrical system.
ii) Generally, the power transmitting agency protection engineer will coordinate with
the utility protection engineer to recommend the functional requirements of the
overlapping zones of protection for the main transformers and high voltage bus
and lines. The utility protection engineer will determine the protection required
for the station service generators and transformers, main unit generators, main
transformers, and powerhouse bus.
iii) Electromechanical protective relays, individual solid state protective relays, multi-
function protective relays, or some combination of these may be used as
appropriate for the requirements.
iv) Individual solid state protective relays and/or multifunction protective relays offer
a single solution for many applications plus continuous self diagnostics to alarm
when unable to function as required. Multi-function protective relays may be cost-
competitive for generator and line protection where many individual relays would
be required.
v) When multi-function relays are selected, limited additional backup relays should
be considered based upon safety, cost of equipment lost or damaged, repairs and
the energy lost during the outage or repairs.
vi) When redundancy is required, a backup protective relay with a different design
and algorithm should be provided for reliability and security.
vii) Generators, main transformers, and the high voltage bus bar are normally
protected with independent differential relays (above 1000 kW unit size).

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 32

and automation of SHP Oct. 2009  
4.4 Criteria of selection of protection system

The designer must balance the expense of applying a particular relay against the
consequences of losing a generator. The total loss of generator may not be catastrophic if it
represents a small percentage of the investment in an installation. However, the impact on
service reliability and upset to loads supplied must be considered. Damage to equipment and loss
of product in continuous processes can be dominating concern rather than generating unit.
Accordingly there is no standard solution based on MW-rating. However, it is rather expected
that a 100 kW, 415 V hydro machines will have less protection as compared to 25 MW base load
hydro electric machine.

With increasing complications in power system, utility regulation, stress on cost

reduction and trends towards automation, generating unit protection has become a high focus
area. State of the art, micro processor based protection schemes offer a range of economical,
efficient and reliable solution to address the basic protection and control requirements depending
upon the size and specific requirement of the plant.

4.4.1 Requirements of Protection of Turbine

Two level protections are recommended as per IEC 1116. Elements to be considered are:

(a) Speed rotation

(b) Oil levels in bearing
(c) Circulation of lubricants
(d) Oil level of the governing system
(e) Oil level of speed increaser (if provided)
(f) Bearing temperatures
(g) Oil temperature of governing system
(h) Oil temperatures of speed increasers
(i) Oil pressure of governing system
(j) Pressure of cooling water

Immediate tripping is required for a, c, i, and j. While for item b, d, e, f, g and h only
alarm and annunciation is required to alert the operator and take corrective action, but in case
corrective action is not taken, tripping will eventually follow. Applying brakes at a particular
speed (30% of full speed) is done to reduce time to achieve stand still position of machine.

It is recommended two independent devices must be provided for over speed shut down
on larger machines. One for alarm mostly at 110% and other for tripping at 140%, specially for
machines which are not designed for continuous run away speed.

4.4.2 Requirements of Protection of Generator

Elements to be considered normally are

a. Stator temperature
AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 33
and automation of SHP Oct. 2009  
 b. Over current (stator and rotor)
c. Earth fault with current limits (stators & rotor)
d. Maximum and minimum voltage
e. Power reversal
f. Over/ under frequency
g. Oil level in bearing sumps
h. Pad & oil temperature of bearings
i. Cooling air temperature

Immediate tripping is required for items b, c, d, e & f while for items a, g, h and i first
alarm and annunciation is required for taking correcting measure and then tripping if correcting
measure is not taken within permissible time.

It is advisable to provide heating arrangement to prevent condensation in generator.

4.5 Generator Protection System and Relay Selection

4.5.1 Categorisation

In view of the economy and plant requirements generator protection for small
hydropower stations is categorized a follows:

• Generator size less than 100 kVA

• Generator size 100 kVA to 5000 kVA
i) Generator size 100 kVA to 1000 kVA
ii) Generator size 1 MVA to 5 MVA
• Generator size above 5 MVA

4.5.2 Transient overvoltage and surge protection

Transient over-voltages and lightning surges are controlled by lightning arrestors. Surge
capacitors are provided to restrict rate of rise of surge voltages and their magnitudes. Every
generator is provided with a set of lightning arrestors / surge diverter of appropriate rating and
generated voltage.

4.5.3 Protection for Micro hydel systems (up to 100 kVA)

Monitoring and Protection as recommend in micro hydel standards be provided.

Micro hydel (100 kVA) may be provided with series over current and short circuit
protection (MCCB), residual current breakers for earth fault protection and surge protection
equipment. A typical 50 kW micro hydel single line diagram showing protection is attached as
Fig. 10. MCCB could be provided with shunt trip coil for providing over voltage; over current
and unbalance load trip as a part of shunt load governor if possible.

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 34

and automation of SHP Oct. 2009  
 62

Grid Feed er-1

27
81 H
81 L
LEGEND
R esidu al C u rren t
Op erated C ircuit B reaker

As As 81L-Freq Relay (Low)

A A
81H-Freq Relay (High)
MC C B W ith
Shu n t Trip C oil MC C B 27-Under Voltage Relay
62-Timing Relay
A- Ammeter
V
F-Frequency Meter
Vs V-Voltmeter
F 32-Reverse Power Relay
LA-Lightning Arrestor
kWh-Kilo Watt Hour Meter
3
kW h
kW h MCCB-Moulded Case
A Circuit Breaker
32 As A
MCB-Miniature Circuit
Breaker
F F F F F F or
MC B
LA
Su rg e Protectio n

Controller
Module

Triacs

H eater Mod u le G

50 kW 415 V

Fig.-10.

4.5.4 Protection for Generating Units above 100 kVA and up to 5 MVA

Monitoring and protection with two levels of protection and recommended as follows in
SHP as per IEC-1116.

4.5.4.1 Turbine

In principle, two levels of protection can be specified: alarm and tripping.

Elements to be considered are:

(a) speed of rotation;

(b) oil level in the bearings;
(c) circulation of lubricant;
AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 35
and automation of SHP Oct. 2009  
 (d) oil level of the governor system;
(e) oil level of the speed increasers;
(f) bearing temperature;
(g) oil temperature of the governor system;
(h) oil temperature of speed increasers;
(i) oil pressure of the governor system;
(j) circulation of cooling water

Immediate tripping is required for items a), c), i) and j). Items b), d), e), f), g) and h) may
have an alarm annunciated first if the station is manned allowing corrective action to be
taken, but in any case, in the absence of corrective action, tripping will eventually follow.
In some cases, braking is used to reduce the time to standstill.

It is recommended that two independent over speed shut-down devices be used on larger
units which might not be designed for continuous runaway.

4.5.4.2 Generator

The following are normally specified.

(a) Stator temperature;

(b) Over current (stator and rotor);
(c) Earth fault with current limits (stator and rotor);
(d) Maximum and minimum voltage;
(e) Power reversal)
(f) Over/under frequency;
(g) Oil level in the bearing sump;
(h) Bearing temperature;
(i) Cooling air temperature.

Immediate tripping is required for items (b), (c), (d), (e) and (f). Items (a), (g), (h) and (i)
may have an alarm annunciated if the station is manned allowing corrective action to be
taken, but in any case, in the absence of corrective action, tripping will eventually follow.

Depending on the individual case, heating equipment to prevent condensation may be

required.

It is advisable to consider differential protection when the size of the generator and/or its
environment justifies it.

The instruments and devices generally recommended for monitoring and protection are
as follows: voltmeter, ammeter, wattmeter, energy meter, power factor meter,
tachometer, hours of operation counter, synchronizer, water-level and/or pressure
indicator, turbine opening indicator, emergency stop device, short-circuit current
protection, over current protection, reverse power relay, frequency monitor, voltage
monitor, bearing monitor.

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 36

and automation of SHP Oct. 2009  
 Monitoring and control and data acquisition system (SCADA system) can be a part of the
P.C. based digital governor and generation control equipment. Provision of data storage
of one month with 16 MB of Ram memory and a 540 to 850 MB Hard Drive as part of
the PC based governing and control system should be provided. This data could be
retrieved on a floppy drive after one month for examination. As the communication links
develop the data can also be transmitted via a Modem to a remote point for examination
and supervisory control.

Typical single line diagram for synchronous and asynchronous generators are attached as
figure 11 and figure 12 respectively.

Typical single line diagram for 2×2.5 MW SHP developed by M/S ANDREZ HYDRO is
shown in FIG. 13 for reference

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 37

and automation of SHP Oct. 2009  
 Fig.-11

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 38

and automation of SHP Oct. 2009  
 Fig. -12
AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 39
and automation of SHP Oct. 2009  
FIG.13-A typical single line diagram for 2×2.5 MW SHP( Source ANDREZ Hydro)
AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 40
and automation of SHP Oct. 2009  
4.5.5 Protection for generating Units above 5MW and up to 25 MW

The following protection may be provided by using integrated numerical generator

protection relay on generator, generator transformers and feeders. Back up electromagnetic
relays with instrument transformers may be provided as mentioned below:

4.5.5.1 Generator

1. Generator Differential Protection (87G)

2. Negative Phase Sequence (46) (Phase Unbalance)
3. Generator Reverse Power Protection (32)
4. Voltage Restrained Over Current Protection (51V)
5. Stator Earth Fault Protection (64 G)
6. Loss Of Excitation Protection (40)
7. Over /Speed (electrical) Protection (12G)
8. Rotor Earths Fault Protection (64R)
9. Over Voltage Protection (59)
10. Fuse failure Protection (97) on PTS
11. Under voltage (27)
12. Check synchronizing

Following additional back up electromagnetic relays from different set of CTs and PTs be
also provided.

1. Voltage restraint over current relay

2. Stator earth fault

Following Mechanical Protections are proposed

1. Embedded Temperature detector (PT-100) in stator core and in bearing for
indication, alarm, recording and shut down of the unit.
2. Governor oil pressure low.
3. Over speed mechanical for normal and emergency shut down.
4. For large generators, fire protections system will use CO2 as the quenching
medium which will operate automatically. Hot spot/ smoke detectors are
provided all around the periphery of generator winding. Bank of CO2 cylinders
with control panel etc. are provided common for all the generators. The individual
pipes let the CO2 enter in the faulty generator and quench the fire. Generator is
isolator from the bus bar and machine stopped. The system is more effective in
closed cycle cooling systems of generators.

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and automation of SHP Oct. 2009  
4.5.5.2 Power Transformer

1. Generator transformer differential protection ( 87 GT)

2. Over current and earth fault protection with high set Inst. Element (50/51,64)
3. Stand by earth fault protection (64GT) on 33 kV side.
4. T/ F Winding Temperature High Alarm/ Trip (49T)
5. T/ F Oil Temperature High Alarm/ Trip (38T)
6. Buchholtz relay

4.5.5.3 Station Transformer Protection

1. Fuse set on 33 kV side.

2. Digital over current and earth fault relay with high set unit on B.T. side. (50/51, 64).

A typical single line diagram of metering and relaying is shown as figure 13 and
figure 14.

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 42

and automation of SHP Oct. 2009  
 TO 33 kV SUBSTATION TO 33 kV SUBSTATION
NOMENCLATURE
40 -------- LOSS OF EXCITATION RELAY
41G -------- EXCITATION BREAKER
L.A. 45G -------- FIELD SURGE PROTECTION
L.A.
51 -------- OVER CURRENT RELAY
51V -------- OVER CURRENT VOLTAGE RESTRAINT RELAY
51D -------- DIRECTIONAL OVER CURRENT RELAY
E/F -------- EARTH FAULT RELAY

//
/ P.T.
// / P.T.
59 -------- OVER VOLTAGE RELAY
63 -------- BUCHHOLZ RELAY
64F -------- ROTOR EARTH FAULT RELAY
64G -------- STATOR EARTH FAULT RELAY
PS CLASS FOR BUS
64T -------- BACKUP POWER SYSTEM E/F RELAY
PS CLASS FOR BUS
DIFFERENTIAL DIFFERENTIAL 87G -------- GENERATOR EARTH FAULT RELAY
87GT -------- GEN. TRANSFORMER E/F RELAY
CT CT 25 -------- CHECK SYNCHRONISING
CORE-1, 5P10 CORE-1, 5P10 46 -------- NEGATIVE SEQUENCE RELAY

CT CT
CORE-2, METERING CORE-2, METERING
ACC.CLASS 1-0 ACC.CLASS 1-0

52-3 52-5

LEGEND
331661132 kV BUS 52-6
ISOLATING SWITCH

HV CIRCUIT BREAKER

LINK

CT CT
TRANSFORMER

41G
EXCITATION BREAKER WITH
52-1
DISCHARGE RESISTOR
52-2

CURRENT TRANSFORMER

CT 5P10 CT POTENTIAL TRANSFORMER

GENERATOR GENERATOR
TRANSFORMER-1 87GT TRANSFORMER-2
64T 51 64T LIGHTNING ARRESTOR

SATTAION AUX. T/F FUSE

51 EARTH
87GT 87GT
11 KV BREAKER

DG SET

11 KV CIRCUIT 11 KV CIRCUIT
BREAKER 11-1 BREAKER 11-2

CT TO P.T.
CT TO P.T.

EXCITATION EXCITATION RECTIFIER

CONTROL RECTIFIER
P.T. BRIDGE P.T. CONTROL BRIDGE
CT CT

P.T. P.T.
41G
41G
GENERATOR-
G1 GENERATOR-2 G2
45G
PS CT PS CT

5P10 CT
5P10 CT

PS CT CT
PS
FIG. 2.3.1 TYPICAL SINGLE LINE DIAGRAM
DISTRIBUTION DISTRIBUTION
TRANSFORMER TRANSFORMER

AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 43

and automation of SHP Oct. 2009  
 Figure 13
33 K.V. BUS NOMENCLATURE

GENERATORS
CT
NOTES 12 CENTRIFUGAL SPEED SWITCH
12G ELECTRICAL OVERSPEEDC RELAY
25 CHECK SYNCHRONISING RELAY
1.THE SCHEME MAY BE MODIFIED TO SUIT ACTUAL 26AU/AI AIR COOLER (OUTLET/INLET)
BREAKER EQUIPMENT ORDERED AIR TEMPERATURE
52-1
2.COMMON TRIPPING RELAYS FOR SIMILAR 26G TEMPERATURE DETECTORS FOR
FUNCTIONS WILL BE PROVIDED WITH LOCK FIRE PROTECTION SYSTEM
OUT FACILITIES, SIGNAL TYPE CURRENT 26GS STATOR WINDING TEMPERATURE
RELAYS FOR DISCRIMINATION OF FAULTS ARE
PROPOSED TO BE PROVIDED IN THE 32 REVERSE POWER RELAY
87T INDIVIDUAL CIRCUITS OF COMMON TRIPPING 33AB AIR BRAKE POSITION INDICATION
RELAYS . 33CW/80CW COOLING WATER VALVE POSITION/FL
64T
3.TRIPPING BLOCK DIAGRAM DOES NOT INCLUDE 38 BEARING TEMPERATURE DEVICE
63T FIRST STAGE ALARMS 38-2
5P10
4.DETAILS OF R.T.D. (RESISTANCE
TEMPERATURE 38GT GUIDE BEARING TEMPERATURE
CT
DETECTORS) ARE AS UNDER : 38QB BEARING OIL TEMPERATURE
(A) GENERATOR STATOR WINDINGS - 12 NO. 38THT THRUST BEARING TEMPERATURE
38T (B) GENERATOR THRUST BEARING - 2 NO.
87 GT (C) TURBINE GUIDE BEARING - 2 NO. 40 FIELD FAILURE RELAY
GEN.TRANSFORMER
50/51 5. UNIT-2 IS SAME AS UNIT-1 45F FIELD SURGE PROTECTION
CT 46 NEGATIVE PHASE SEQUENCE RELAY
PS 47 PHASE SEQUENCE CHECK RELAY
LINK (FOR SYNCHRONIZING)
48 INCOMPLETE SEQUENCE RELAY
C.T. 5P10 50/51 T TARNSFORMER OVERCURRENT RELAY
51V INSTANTANEOUS OVERCURRENT
250 kVA
WITH VOLTAGE RESTRAINTRELAY
11/.415 kV
TO 86 EB 11 KV 60 VOLTAGE BALANCE RELAY
11-1 GENERATOR 63 GOVERNOR LOW OIL PRESSURE SWITC
BREAKER 51/64
63FG FIRE EXTIGUISHING SYSTEM OPERATIO
87 GT 51 EX C.T. 63QTH THRUST BEARING HIGH PRESSURE OIL
SYSTEM START INTERLOCK/FAILURE A
RECTIFIER 63 T MAIN TANK OVER PRESURE SWITCH
TRANSFORMER 63 TX AUXILIARY RELAY
64G GROUND VOLTAGE RELAY - STATOR
25 64F ROTOR EARTH FAULT RELAY
47
TO P.T. 65SN SOLENOID SPEED NO LOAD
65SL SOLENOID SHUT DOWN
59 71QBH/L BEARING OIL LEVEL(HIGH/LOW)
THYRISTOR STATIC 86 EA LOCKOUT RELAY ELECT. GROUP "A"
BRIGES EXCITATION LOCKOUT RELAY ELECT. GROUP "B"
86 EB

SYNCH.
VOLTAGE
REGULATOR 86 MA LOCKOUT RELAY MECH. GROUP "A"
AND CONTROL 86 MB LOCKOUT RELAY MECH. GROUP "B"
87G GENERATOR DIFFERENTIAL RELAY
S.S.
FROM EXCITOR 2 87T TRANSFORMER DIFFERENTIAL RELAY
F F SYNCHRONISING
TO 86 EB EXCITERS

. VAR.COMP
L
SOCKET

L
27
V
31
41G
EXCITATION RELAY
GENERATOR FIELD BREAKER
FROM BATTERY

PT PT 51 EX INSTANTANEOUS TIME OVER

CURRENTRELAY
EQUIPMENT

59 OVER VOLTAGE RELAY

31

FLASHING

..
S.S.
LDC EX. V V
64F
86 EX
LCD
GROUND VOLTAGE RELAY - FIELD
LOCKOUT RELAY
LINE DROP COMPENSATION
FIELD

CONTROL
RUN INC OER OVER EXCITATION RELAY

.. S.S.
KWH
F F
PAR COMP PARALLEL COMPENSATION

METERING

.. S.S.
38THT
THERMOSTAT
R.T.D.
38QB
60

BLOCKS 50/51V
& 40 ON LOSS
OF RELAY
FM

KVAR
SYN

MANNUAL SYN. PANEL

A
FM
RECT
AMMETER
FREQUENCY METER
TEMPERATURE MEASURING
AND RECORDINGINSTRUMENT
71QBH/L GENERATOR GUIDE POTENTIAL SUPV. SUPERVISORY
& THRUST BEARING TZ TRANSDUCER
V VS KW
63 FIRST V VOLT METER
QTH SURGE STAGE VARM VAR METER
12 39V 63T
63FG 26G ARRESTOR ALARM VS VOLT METER SWITCH
V A 33AB RECT PF WHM WATT HOUR METER
63TX WM WATT METER
41G
G CT MISC 27L
66 K.V. SYSTEM
A3 38 63 48 UNDERVOLTAGE RELAY
64F 30
12G TRIP 52-1, & 41G ANNUNCIATOR RELAY
50/51DN DIRECTIONAL OVERCURRENT
TURBINE SHUT DOWN
AND GROUND FAULT RELAY
26AO/AI 59
26GS AND ALARM 51 H INSTANTANEOUS TIME OVERCURRENT
OER TURBINE 86 MA PHASE RELAY
33CW/80CW GUIDE BEARING 62 TIMING RELAY
R.T.D. 51V 46 40 32 62L
38TG -DO-
TO 64T H.V. SYSTEM STAND BY GROUND FAULT
38QB 86 MB 81H HIGH FREQUENCY RELAY
86 EB TRIP 52-1 & 41 G
71QBH/L TURBINE SHUTDOWN 81L LOW FREQUENCY RELAY
87G 86H LOCKOUT RELAY
, PENSTOCK GATE 87GT GENERATOR TRANSFORMER
PS DIFFERENTIAL RELAY
CT CLOSURE AND ALARM
94 GENERATOR TRIP RELAY
5P 10 38-2 12 12G MISC 52-1 66 K.V. BREAKER
CT TRIP 52-1 & 41 G
TURBINE SPEED
CT 86 EB
NO LOAD
AND ALARM

LINK 86 EA
TRIP 52-1 & 41 G
RELEASE CO2,
TURBINE SHUT
2
1

DOWN WITH ALARM

DISTRIBUTION 64G
TRANSFORMER

FIG. 2.3.2 TYPICAL UNIT METERING SINGLE LINE DIAGRAM

1
2

RESISTOR
RATED 15 SEC.

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and automation of SHP Oct. 2009  
 Figure 14

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and automation of SHP Oct. 2009  
4.6 GENERATOR CONNECTED IN PARALLEL TO GRID

Whenever generators are running parallel to grid, a comprehensive auto synchronizing &
Grid islanding scheme will be required. This scheme will help in synchronizing the generator to
the bus and opening the incomer breaker of the plant whenever there is a severe grid disturbance,
thus protecting the generator from ill effects of disturbed grid.

• Grid disturbances
9 Under-voltage / Over-voltages
9 Under-frequency/Over-frequency
9 Rapid fall/ rise of frequency (df / dt),
9 Grid failure or other faults

Generator may not be able to operate below a certain power-factor. At low power-factor,
reverse reactive power flow may damage the generator.

• Grid fault detection

9 Over current and directional earth fault,
9 Rapid fall/ rise of frequency (df/dt),
9 Vector surge relay,

4.7 GENERATORS CONNECTED IN PARALLEL ON A COMMON BUS

Whenever more than one generator is operating in parallel, it is necessary to see that the
plant load is equally shared by the generators in parallel. If there is unequal sharing, there would
be sever hunting amongst the generators and eventually this will lead to cascaded tripping of all
generators, causing a total black out. Specific load sharing relays are available in the market
which provides the most effective, online load sharing system for generators in parallel.

4.8 PROTECTION GROUPS

The protective relays and devices of generator and turbine are proposed to be grouped
into following four categories for an orderly shutdown of the affected unit with the remaining
generating units and auxiliaries continue to operate.

4.8.1 CONTROLLED ACTION SHUT DOWN

Controlled action shutdown will be initiated by any of the following conditions

• Generator thrust bearing pads temperature very high
• Generator guide bearing pads temperature very high
• Turbine guide bearing pads temperature very high
• Governor OPU oil level low stage-II

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 • Governor OPU oil pressure low stage-II

4.8.2 EMERGENCY SHUT DOWN

Emergency shutdown will be initiated by any of the following conditions.

• Sped 115% and deflector/ guide vanes/ runner blades apparatus not moved to closing
• Deflector etc. fails to close in preset time
• Unit over speed (electrical) > 140%
• Unit over speed (mechanical)>150%
• Stop push button on control panel in control room is pressed

Emergency shutdown system will perform following functions:

• Trip generator breaker

• Stop turbine by governor action
• Trip generator field circuit breaker
• Operate trip alarm in control room
• Energizes emergency solenoid valve in governor cubicle to stop the turbine by bypassing
governor
• Close main inlet valve

4.8.3 IMMEDIATE ACTION SHUT DOWN

Immediate action shut down will be initiated by any of the following conditions

• Generator differential protection operates

• Generator stator earth fault protection operates
• Generator field failure protection operates
• Generator transformer stand by earth fault protection operates
• Over current in stator
• Over current instantaneous protection in the excitation circuit

The immediate action shut down perform following function

¾ Trip generator breaker

¾ Trip field breaker
¾ Initiates controlled action shut down stop turbine by governor action
¾ Trip annunciation in control room

4.8.4 ELECTRICAL SHUT DOWN

Electrical shutdown system will be initiated by any of the following conditions

• Over current in the excitation circuit

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• Generator back up protection operates
• Generator over voltage protection operates
• Excitation failure protection operates
• Reverse power protection operates
• Generator T/F IDMT over current, over current instantaneous & earth fault protection
operates

Electrical shut down system will perform following functions

• Trip generator breaker

• Trip field breaker
• Governor brings the unit to spin at no load

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 ANNEXURE-I

COMPUTERISED AUTOMATION AND REMOTE CONTROL OF SMALL HYDRO

POWER PLANT

Er. S. K. Tyagi, Consultant,

AHEC, IIT, Roorkee

1.0 INTRODUCTION
1.1 Purpose
This Guide is intended to assist in preparation of technical specification for
finalizing automation scheme for control, monitoring and data acquisition of a small
hydro power plant. The guide includes different type of control, control locations,
automation schemes, system architecture, system protocols, network protocols, type of
networks, PLC based, computer based SCADA system, user and plant interfaces, remote
control & power source etc.

1.2 References & Codes

Latest edition of following standards & codes are applicable:
• “IEEE Guide for Control of Small Hydroelectric Plants” ANSI / IEEE standard
1020:1990.
• “IEEE Guide for Control of Hydroelectric Power Plants” ANSI / IEEE standard
1010:1991.
• “Communication Protocol” IEEE Tutorial course 95-TP-103 IEEE Press, NY 1995.
• “Hydro Plant electrical Systems” by David M Clemen.
• IEC: 62270-2004-Hydro-electric power plant automation-Guide for computer based
control.
• IEEE-1048-Guide for distributed digital control and monitoring for power plants
(ANS).

2.0 AUTOMATION AND REMOTE CONTROL OF SHP

In a modern hydroelectric power station almost all apparatus are connected with
the plant control system to perform all operations in either manual or automatic mode.
Most of the major apparatus (e.g. generator, turbine and spillway gates) are equipped
with electrically actuated control elements allowing to operate automatically. Many
power stations are controlled from remote locations and these automatic control systems
facilitate unattended plant operation.

2.1 Manual Operation Control

In manual control it is the responsibility of operator to manually perform control
and data acquisition tasks. The quality of data acquisition has been subject to the
limitation of available staff and human error.
AHEC/MNRE/SHP Standards/E&M Works – Guidelines for monitoring, control, protection 49
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 The manual control can be local (control located on panel nearest to the
equipment or on equipment) or/and centralized (with in plant at some other place).

This system is not found sometimes to be as efficient, accurate, safe and

consistent as required by the system.

2.2 Semi Automatic Control

For many years, relay logic type automatic control systems were provided. These
systems were limited to unit control sequencing (start/stop) and were not easily changed,
once installed. Plant operators were responsible for manually performing control and data
acquisition tasks. The quality of data acquisition has been subject to the limitations of the
available staff and human error.

2.3 PLC, Computerised Automatic Control

Automation of hydroelectric power plant operations has made it possible to
accomplish data acquisition and control activities like unit startup& shut down sequence,
which were previously performed by relay logic. Computer based control and data
acquisition systems have made it possible to acquire and process more data than in past,
so generated reports can keep Plant Engineer apprised of total plant condition.

Computer based automation system also permit operation of power plant,

switchyard and outlet works (spillway gates, bypass gates, valves, fish ways, fish ladders
etc.) from a single control point that can be local, centralized or remote. The single
control point system has many advantages, including reduction of staff, consistent
operating procedures and capability to have all control and data available for reference
during normal and abnormal conditions.

2.4 Control Locations

2.4.1 Local
Controls are located on the equipment or with in the sight of equipment for all
auxiliary equipment. For generating unit control is located on unit control system
interface governor control panel. Local control is synonymous to most basic control.

2.4.2 Centralized
In this system controls for all units are brought to a centralized control room
located in the plant itself on control panels. Control of all important auxiliary equipments
are also brought to the control panels installed in the control room. All protection,
metering, synchronizing panel and outgoing lines control panels are located in this
centralize control room.

2.4.3 Off site (remote)

An off site control location is one that is external to plant. It could be located at
switchyard, another place or at some other remote location. The type of control is
characterized by a greater degree of sophistication in the control them selves. The off site

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 control of hydro power stations is inter connected via communication link in lieu of hard
wired point to point control. Relationship between all these three control location is
shown in Figure-I.

3.0 AUTOMATION OF HYDROPOWER PLANT

3.1 Control Requirements
Basic control requirements are as follows:
• Gathering process information
• Controlling the process
• Protecting and supervising the process
• Monitoring the process

3.1.1 Gathering process information:

Process information can be gathered continuously or periodically and consists of
control parameter statics information or feed back signal.

Presentation can be visual, recorded, audible or combination of all, strips charts

recorders, analog / digital indication instruments, video display unit (VDU), lamp
indicators and liquid crystal display are some visual information formats. Audible
presentation may be in the form of bell, gong or tone alerting the operator to an alarm
condition / information.

Process consists of turbine, generator, common auxiliaries unit auxiliaries, D.C.

distribution system, low voltage power, medium voltage power, switchyard, intake bye
pass and draft tube gates etc.

3.1.2 Controlling the process:

Process information gathered serves two purposes:

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 i) It is used by automatic control system to perform appropriate control actions
ii) It allows the operator to operate the plant in safe reliable, secure and economical manner.
The operator should however, be properly trained to start, stop, load, unload and monitor
the generating units and to control the plants auxiliaries including switchyards, water
control system and other ancillary features associated with the project.

3.1.3 Protecting and supervising the process

The protection system is divided in two subcategories:
(a) Electrical protection system covering major plant electrical apparatus and essential
electrical auxiliary systems (e.g. generator, step up transformers, station service electrical
system). Protective systems have progressed from specific purpose electromagnetic
relays to specific purpose electronic analog relays to contemporary multipurpose digital
relays.
(b) Mechanical protection is confined to generating units hydraulic turbine, generator and
major plant mechanical systems (e.g. turbine, draft tube, air depression system).
Protection of “Non electrical” apparatus and systems in the plant are normally assigned to
the plant control system. The control system generally provides tripping signal required
for input to the plant protection system in case any of the mechanical systems or
apparatus require removal from service.

The supervisory process involves comparing plant and equipment operating

values against designed /set limits. This involves monitoring equipment status as well as
limits. For example ‘on’ or ‘off’, ‘open’ or ‘closed’ position may be incorporated into the
supervisory process with consequential control action.

3.1.4 Monitoring the process

Operating and control parameters can be monitored using display devices at their
respective control board (e.g. turbine, governor mechanical cabinet board). Analog and
digital instruments, VDUs and other devices as mentioned above are used as monitoring
equipment. Some display units also permit manual control via touch screens.

4.0 AUTOMATION SYSTEM ARCHITECTURE

4.1 System Architecture
System architecture defines the structures and relation-ships among the components of
hydroelectric power plant automation system, including its interface with operational
environment. Architecture includes hardware components, software components
networks, performance, reliability concepts and maintainability of the automation system.
System architecture for hydroelectric power plant also consider such factors as number,
size, types of turbines and generators in the plant, the plant auxiliary system. A wide
range of hardware components, networks software, component and database alternative
are available to configure cost effective architectures to meet the automation system’s
design goals.

Open system architecture offers the advantages in case of expansion, ability to

accommodate changing technologies and immunity to premature obsolescence.

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 While in proprietary system architecture, taken as part of turnkey automation
from some vendor, flexibility as explained above is not available.

4.2 System classification:

Advances in computer technology provide users with the choice of variety of
system architecture for configuring hydroelectric automation systems. This guide focuses
on systems currently employed or envisioned to find future use in hydroelectric plant
automation applications.

There are two general classification of system architecture used in hydroelectric

plant automation systems:

(i) This class uses proprietary hard wares and software and makes little or no provision for
interoperations with other hardware and software. These are called as closed systems
also.
(ii) The other system class is an integrated system, with all plant control and monitoring
components having a common data communication hardware & software structures.

These are the open systems which relates to its ability to replace hardware,
modify software and expand system capability without a wholesale reconfiguration of the
control system. Attributes of open systems are interconnectivity of hardware and
software, possibility of software and interoperability of application and system. From
practical point of view neither fully closed nor truly open system exists, rather a
combination of systems exist with some ability to communicate or function with other
systems.
Examples of applications and majors components of above two general system
classes along with traditional supervisory control system are as under:
(i) Traditional supervisory control system
These are hardwired supervisory control systems. Major components are:
• Master station
• Non programmable remote terminal unit.
(ii) Closed system
There are stand alone systems (proprietary, single function controllers) Major
components are:
• Proprietary controllers
• Proprietary operator’s console
(iii) Open System:
The application examples are:
• Hydroelectric plant controllers (systems)
• Large scale energy management systems,
• SCADA systems (Microprocessor based)

Major components are:

• Programmable logic controllers
• Networked PCs or work station

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 • End user programmable remote terminal units
5.0 SOFTWARE CONFIGURATION:
5.1 Customized software (Proprietary)
In the customized software there are several options which are as follows:
(a) Dedicated – The software changes are closed to the end user
(b) Configurable – The software has features that can be changed by the user’s software
maintenance personnels. These changes are normally of the form of turning on or off
a feature that is already in the software through a software key or password.
(c) Programmable – The software has features that can be changed or added by the user’s
software maintenance personnel.

These software are normally available as part of turnkey automation system and as
such sometimes are called proprietary softwares.

5.2 Commercially available (open sources) softwares

These softwares can be purchased as a part of turnkey automation system or
directly from open source by plant owner. In later case the owner will have to make
provisions for the installation and configuration of the software. Spread sheets, data base
managers, operators interface software packages are some examples of such softwares
being used as part of the power plant automation system.

These softwares provide flexibility and has many options. In such case owner
may have support from original vendor, other users or possibly other vendors. The most
common options are as follows:
(a) User configurable: The user has all the documents necessary to change the software
operation or to add new code that is linkable to the rest of the software. The user has
the ability to add features or change options, but can not change features in the
original code with out the help of original vendor.
(b) User programmable: The user has the source code as well as the documentation for
the software and can modify it as needed or implement his own software to be added
to the system.
(c) Full graphic: The user has the ability to generate pixels and / or vector graphic image
on the displays in any form. The software has sophisticated art work generation and
real time display of these images under system control. Often full graphics are
implemented in a window operating environment.
(d) On line configurable: The features mentioned can be done by authorized person
sitting in front of the online and running system. That is authorized person can change
the configuration of the running system as they wish.

6.0 NETWORKS
6.1 Control level data networks
Control data network are communication structures that conveys data through out
the system. These networks are used for transmitting time tagged measurements and
status input signals to update live databases. The application program outputs, consists
typically of control commands and alarms are then transmitted in turn, over the network

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 to other data stations that interface directly with the process or that display or report
information to the plant operators.
The control data communication network is also used for transmitting sequence of
event data with specified time resolution. The data is recorded or displayed for trend and
plant diagnostic analysis. The automation hierarchy, the intra plant network services the
unit and functional group levels. Subnetworks and field buses service the instrumentation
and local control levels.

The control data network should be able to support transfer of long messages (e.g.
file transfer) as well as short messages for data acquisition, reporting and control
commands.

The network should be able to reduce operators, technician’s burden to operate

and maintain the over all control and monitoring system. Hot and cold system
initialization should be achieved automatically or manual command from the control
console.

Power plant Engineer should be able to assess the current status of network, to
locate bottlenecks and other problems and to plan action accordingly.

The network should also be able to transmit specific diagnostic and maintenance
trouble shooting data for status display.

6.2 Device level Data Network

Device is an operating element such as relay contactor, circuit breakers, switch or
valve used to perform a given function in the operation of electric equipment logic.

Field wiring for contact interrogation or control devices

• Hard wired
• Fiber optic cables

Hard wired system should be protected against ground potential rise (GPR), for
which proper shielding of cables is to provided while for fibre optic cables such
protection is not required. Field wiring however, should be protected such that a fault on
these cables does not cause loss of more than a minimum tolerable functionality of the
system.
With the advent of programmable logic controllers (PLC) number of wires needed
for connection is reduced by 80% which improved the reliability and availability of
functionality of the system.

6.3 Network Protocol

The protocol implies the methods for packing messages data in the form of bit,
bytes, blocks & packets to communicate between the devices. Just sharing bits & bytes
will not allow devices to communicate successfully. Some situations may require

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 multiple protocols to be run on the same physical media. This is a common situation with
plant LAN.
IEDs (Intelligent electronic device) know what data values are in the message and
where they are placed in data stream. This is part of protocol specification that is
performed by the software that assembles and dissembles the message stream.

6.3.1 Proprietary and standard based protocols and networks:

A proprietary network consists IED connected via some media (standard or
proprietary) using a vendor specific proprietary protocol that will only interoperate with
similar IEDs running the same protocol, proprietary protocols are intended to be “stand
alone”. There may be no need for IEDs on these networks to inter operate with IEDs on
other networks. A gateway IED is required to connect proprietary network to other
portion of the plant network, should such a connection is needed.
IEDs can typically communicate on a standard serial communication bus by
virtue of sharing a common messaging protocol such as Modbus, Modbus plus and
DNP3. There are few other protocols that have been implemented by some users with the
help of specific suppliers. These IEDs may be compatible but may not inter operate.
Often one IED in the network can interoperate with all IEDs and serves as a gateway.
IEDs that support Ethernet can be connected in the same Ethernet network even when different
protocols are used. This is different from standard serial or proprietary networks where all IEDs
on the same network use the same protocol. IEC 61850 is usually considered a protocol that runs
on Ethernet networks.
Local area networks (LANs) should be configured to IEEE 802.3 (Ethernet)
standard.
Commercially available software should be used as far as possible.

6.4 Network topology

Network topology is either logical or physical. A logical topology is a way that
data passes over a network from one IED to the next without regard to physical IED
interconnection. The physical topology of network maps the IEDs of the network and the
connections between them. There are two major groups of topologies:
i) Point to point: Point to point connection only connects two IEDs together.
ii) Point to multipoint: These networks have several major network topologies for
communications.
• Bus Topology
A bus topology has each IED connected to the same physical media as
shown in Figure below:

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and automation of SHP Oct. 2009  
 IED IED IED IED

FIG. 2 : BUS TOPOLOGY

• Star Topology
In a star topology such as Ethernet, each IED is connected to special node
at the centre that can be passive, providing a path for message to traverse or
active regenerating electrical signals. Hub simply repeat and message on all
ports. More intelligent hubs are switches which route the message to the port
where target IED is connected. The arrangement is shown in figure below:

IED IED IED IED

HUB OR SWITCH

FIG. 3: STAR TOPOLOGY

• Ring Topology:
In ring each IED is connected to next with entire network forming a closed
circle. Each IED is isolated from all but two IEDs. Ring networks are less
efficient because data travels through more IEDs before reaching the
destination.

6.5 Type of Networks

Network permit passing messages between end points over a wide range of
distances and provides a messaging service that is independent of message content. Any
number of different media supports network messaging, network design should be such
that it retains critical function in case of a network failure.

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6.5.1 Wide Area Network (WAN)
A wan provides long-distance transmission of data, voice, image and video
information over a large geographical area. A WAN can be owned by utility or WAN
services can be leased from telecommunication providers. WAN permits enterprise
access to all modes on the WAN. Normally connections to a WAN are made through
router, bridge or firewall to control access to distant nodes such as power plants,
substation etc.

6.5.2 Local Area Network (LAN)

A LAN is normally designed for limited geographical area such as power plant,
utility substation or an office area. A LAN is considered to be part of facility and is
owned by utility owners.
It is capable of transmitting data, voice, image or video information. On a plant
there may be one or more LANs to logically group devices and functions as well as
control loading and security.
• It is passive, similar to slave in master slave communication
• It waits requests from clients
• Upon receipt of requests, it process them and then sends a response.
The characteristics of a client are as follows:
• It is active, similar to the master in master slave communication
• It sends requests to servers
• It waits for and receivers server replies

Master slave and client server communications are similar. The biggest difference
is that generally there is one master, where as there can be multiple clients.

7.0 Communication relationship models:

7.1 Master slave
Master slave communication is when the master controls all of the traffic on the
channel. There are two different types – dedicated master and token passing masters.
• Dedicated: Polling scheme involve no network contention because access medium is
granted in orderly fashion with energy device taking its turn. With centralized polling
all IEDs are addressable and the master IED will send out messages only addressed to
single slave. Each device has different address as defined in the protocol being used.
The master communicates to each IED one at a time so as to prevent communication
collisions.

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 MASTER
IED

IED-1 IED-2 IED-3

FIG. 4: CENTRALISED POLLING

• Token Passing
Each IED acts as repeater of message called a token and each IED can be both a
master (requesting data from other) and a slave (sending requested data to other IED).
The token may contain some data that is copied by the receiver. If token contain no
data, then an IED can use it and fill in its information in the token.

PLC communication and some other control system use token passing scheme to
give command to IEDs along the bus.

7.2 Client-server model

This is the most popular model for network application. Each IED on the network
is either client and / or server. The characteristic of server are as follows:

7.3 Peer to Peer Model

There is growing trend in IED communications to support peer to peer messaging.
Here each IED has equal access to the physical media and can message any other IED.
Thus each IED is both client and server. This is substantially different than master slave
communications even when multiple masters are supported. A peer to peer network to
provide a means to prevent message collisions or to detect them and mitigate the
collision. On this configuration each IED can communicate to each other in an
unsolicited manner.

8.0 SCHEMES OF AUTOMATION

Following schemes are normally considered for automation of small hydro plants.
• Conventional control system
• Computerized conventional control system
• Programmable logistic controller (PLC) system
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 - Single PLC with manual backup
- Redundant PLC
• PC with PLC based control system
• Computer based SCADA system (Microprocessor controller with SCADA)

Regard less of degree of automation desired, control sequence can be divided in to

following parts:
• Pre-start checks
• Auxiliary start
• Unit run, synchronize and load
• Running control
• Unit shutdown
• Emergency shutdown in abnormal conditions
Recommendations:
A. 5 KW to 100 KW Data logger with PLC load controller

B. 100 KW to 5000 KW
(i) 100 KW to1000 KW PC based integrated system for governing and plant
control
(ii)1000KW to 5000 KW PLC integrated controller and SCADA with PC

C. 5000KW and above PLC digital governor with plant controller and
SCADA with redundant PC
8.1 Conventional Control
The hardware need to perform above functions in a conventional centralized
hardwired control system which is generally similar to that used for individual local unit
control. This consists of equipment such as control panels with discrete control alarm and
indication devices, dedicated data logging, load and voltage control equipment and
anunciators. This equipment interfaces to the units in parallel to the local unit control or
through the local unit control board. Control circuits are with appropriate inter locks.

8.2 Computerised conventional control system

This type of control systems are used for control of hydroelectric units because of
the speed and flexibility needed to run the real time control algorithms and to manage the
associated data.

The computer system interfaces to the plant and to the conventional control
system via input / output (I/O) interface equipment suitable for operation in the harsh
power plant environment. This interface may be parallel to the hardwired control system
and may operate conventional hard wired control circuits.

It may be desirable to furnish a programming and training console that permits

software development and operator training while providing back up hardware for
alternate use when the normal operator interface is out of service. Inter locking may be
provided to permit only one console to be in control at time.

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 Special consideration must be given to the design of the computer system power
supply, grounding and shielding in view of harsh power plant environment and generally
sensitive nature of computer equipment. Protection from electro magnetic and radio
frequency interference should be provided. Computer equipment may be located in
controlled environments such as control rooms. However they may be located in plant
where extreme of temperature, humidity and moisture is absent.

Batteries of uninterrupted power supply (UPS) are commonly used to provide

reliable power for control system. The capacity and duration requirements are dependant
on the shutdown and operation procedures and critical nature of the unit.

Software development and purchase must be considered easily in the design so

that the hardware will be compatible, software will perform desired control and the
human requirement IEEE Std. 1249 may be referred for greater details on the subject of
computer based control.

8.3 Programmable logistic controllers (PLC) based control system

8.3.1 PLC
As a result of fast progress in technology, many complex operation tasks have
been solved by connecting PLC and control computer besides connection with
instruments like operating panels, motors, sensors, switches valves and such possibilities
for communication among instruments are so great that they allow high level of
exploitation and process coordination, as well as greater flexibility in realizing a process
control system. In automated system PLC controller is usually a central part of a
processor control system. With execution of program stored in program memory, PLC
continuously monitors status of the system through signals from input devices. Based on
the logic implemented in the program, PLC determines which action needs to be executed
with output instrument. To run more complex process it is possible to connect more PLCs
to a central computer.

8.3.2 Control Panels

In conventional control relay logic is utilized and these were connected using
wires inside control panels. The disadvantages of such panels are as follows:
• Too much work in connecting wires
• Difficulty in making changes or replacements
• Difficulty in locating error requiring skillful workforce.
• When problem occur hold up time is indefinite, usually quite long.
With intervention of Programmable Logic Controllers, much has changed in how
a process control system is designed. Advantages of PLC based control panels are as
follows:
• Compared to conventional process control system, number of wires needed for
connections is reduced by 80%.
• Power consumption is greatly reduced because a PLC consumes less than a bunch of
relays.
• Diagnostic functions of a PLC controller allow for fast and easy error detection

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 • Change in operating sequence or application of a PLC controller to a different
operating process can easily be accomplished by replacing program through a console
or using PC software (not requiring changes in wiring, unless addition of some input
output device is required)
• Needs fewer spare parts
• It is much cheaper compared to conventional system, especially where large number
of I/O instruments are needed and when operational functions are complex
• Reliability of PLC is greater than that of an electro-magnetic or static analog relay.

8.3.3 Process Control System

Function of process control system is watched by input devices (switches sensors)
that gives signal to PLC controller. In response to this, PLC controller and signals to
output devices (viz. solenoids, electro magnetic valves, relays, magnetic starters, as well
as light and sound signalisers) that actually control how system functions in assigned
manner. Program for sequence of operation is also entered in PLC memory.

8.3.4 Automation schemes

The two control schemes utilized for small and medium hydro stations are:
(i) A single PLC with provision of manual operation as back up system
(ii) A redundant PLC for back up system and other PLC for main control

There are various modification of these two basic schemes which depend on the
individual plant requirement and owners preference. The singe PLC system offers the
advantage of low cost and simplicity and is typically backed up by hard wired system.
With redundant PLC system back-up control and memory are provided by second PLC.
The advantages and disadvantages of both systems are given in following table.

S. Single PLC with manually operated Redundant PLC

No. backup
1. In manually operated backup system for 10% Backup for CPU. The CPU includes
control the unit output is set at operator’s the processor, system memory and system
discretion. An operator usually keep safety power supply. Head water level and
margin of approximately 10% in headwater discharge control is taken care of by
or discharge level to avoid problem such as redundant PLC whenever the PLC is
drawing air into the system. As a result disabled. With this system maximum
maximum generation (KWH) for the machine expected generation can be achieved.
is not realized in manual operation.
2. Less expensive as compared to redundant The cost of second PLC exceeds the cost of
PLC manual system.
3. Non-uniform spare parts, spare parts would Uniform spare parts. Only on set of I/O
have to be arranged for both PLC system as cards need to be maintained. Items such as
well as manually operated system. But spare relays and control switches associated
manual system being simpler in construction with hard wired system are not required.
few spare parts would be required
4. Operator’s familiarity with trouble shooting Trouble shooting is complex for SHP
hardwired relay system operator may not be trained for PLC system
trouble shooting (some of the complexity is
offset by the PLC and 1/0 card self
diagnostics now available)

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 5. Less chance of common mode failure • Some time instantaneous surges may
because the hardwired system is less prone to causes failure of both PLC
surge – induced failure and more tolerant to simultaneously owners must insist for
inadequate grounds good surge protection system and
effective grounding.
• More over if software is non-standard,
software problems will be common to
both.

In control system all unit protective relays should be independent from

programmable controllers. The independence will allow protective relay system to
function even if PLC fails ensuring the safety of unit & personnel.

For a single PLC scheme with a manual operated back up system it is usually
preferable to have and independent RTD (Resistance temperature detector) monitor and
annunciation panel functionally operative during manual operation of the unit. It is also
recommended in single PLC scheme, it may have redundancy for power supply in the
same PLC.
Redundant PLC for supervisory control only can also be considered in case it
meets the requirement of the system.

8.4 PC with PLC based Control System

Modern control systems utilize PCs in conjunction with PLC control. The PCs are
utilized with man-machine interface (MMI) software for control display graphics
historical data and trend displays, computerized maintenance management systems
(CMMS) and remote communication & control. PLC programming software usually
reside on the PC eliminating need of separate programming terminal to implement or
change the PLC software coding. PC can also be used for graphical displays of plant data
greatly enhancing operational control. Standard Microsoft based graphical display
software packages are available for installation at standard PC. These displays include
control display with select before use logic informational displays for plant RTD
temperatures or historical trending plots of headwater, tail water and flow data.

Modems with both dial out and dial in capabilities can be located in either PC or
PLC or both to provide offsite access to plant information. These modems may be
utilized to control the plant operation from a remote location.
For plants having capacity up to 1000 KW PLC having integrated governor and
plant control system with a PC is recommended while for plants having capacity more
than 1000 KW unit control PLC with SCADA is recommended.

8.5 Computer based SCADA System (Microprocessor controller with SCADA):

The complex operating system at bigger power stations require a computer based
SCADA system – computer in place of PLC. Some elements of this complexity are
multiple units, complex reservoir or run-off-river water level algorithms and operation of
number of intake gates, inlet valve, spillway gates, sluice gates and draft tube gates in
conjunction with unit start/ stop sequence for flood conditions. The DCS (Distributed
Computer System) is appropriate for this type of operation because it has ability to handle

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 large quantities of inputs and outputs quickly, providing operator with real-time
information.
8.5.1 System:
Computer based SCADA system use microprocessor based control technology
physically distributed through out the power house. The separate microprocessor units are
linked together by a number of digital communication paths to form a completely
integrated control system. The distributed system offers several advantages over a
centralized main frame computer type system:
• Improved system performance, as the various distributed microprocessors perform
dedicated software functions or tasks at the same time (parallel processing)
• Reduced software complexity, with each microprocessor performing its own
dedicated task.
• Modular elements, make the system easily expandable and simplifying component
replacement

Increased system reliability because of reduced complexity and modular structure

which allows most of system to function through the failure of one or more components.

Supervisory control and data acquisition (SCADA) is system operating with

coded signals over communication channels so as to provide control of remote equipment
and to acquire information about the status of remote equipment for display or for
recording functions.

8.5.2 Control Parameters:

SCADA system should be complete with primary sensors, cables analysers/
transmitters, monitors, system hardware/ software and peripherals etc. to monitor/ control
the following parameters.
• Generator stator and rotor winding temperatures
• Generator and turbine bearing temperature
• Lubrication oil temperatures
• Status of generator cooling system
• Governor control monitoring of turbine speed
• Generator terminal voltage current KW, KVAR, KVA, KWH, Hz, PF, field
voltage and field current.
• Annunciation for violation of permissible limits of above parameter
• Turbine guide bearing temperature detector
• Generator guide & thrust bearing temperature detector
• Guide and thrust bearing oil level indicator
• Generator winding temperature detector
• Turbine speed
• Generator speed
• Governor oil pumps, oil pressure indicator and low pressure indicator and low
pressure switch
• Cooling water pumps, section and discharge pressure switch / gauge.
• Inlet pressure gauge at inlet of turbine
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 • Level indicator for level in fore bay

8.5.3 Requirements of SCADA System

SCADA should provide monitoring of parameters listed above. The list may have
additional parameters as per requirement of individual plant. It should be able to control
in grid mode or isolated mode as the case may be. In case of off site control it should be
able to provide remote monitoring and control. It should have following features.
• Reliable safe control of unit with very high availability
• Automatic start up, on load control and shut down of units by the control system
• Control of auxiliary equipment
• Remote monitoring of all plant status and alarm information
• Remote normal startup on load control and shut down of machines by control
system as well as by operator.

8.5.4 Specifying response time

The processing speed of the computer or computers used in control system
determines the over all response time which is very important especially during
emergency situations therefore, when specifying a control system, the plant owner should
take care to define response time speed of control system clearly. Some of the times
related to the response time of computer system are:
• Time duration required to update a graphical display from the instant a field
contact changes state
• Time duration from the instant a control is activated at the operator station until
the command is implemented at the field device; and
• Over all time duration to process and log an alarm once it is received at the
computer.

The specification should define the acceptable time durations for each of the
above events in both normal leading and high activity loading scenario. Penalty should be
included in specification if vendor can not meet the response time defined. The computer
system response times should be verified at the factory acceptance test to confirm the
system will operate as required by specifications.

8.5.5 SCADA should have following controllers:

• Unit controller
• Common plant controller/ supervisory control
• Remote supervisory control

8.5.5.1 Unit Controller:

It is microprocessor based / PLC based and is required to perform all functions as
below. It is required to have capability to implement closed loop PID function for
governing and to perform all monitoring, control, protection and recording functions that
a power plant required independently.
(a) It should monitor and control items

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 • Turbine wicket gate
• Turbine/ Generator RPM
• Generator power out put
• Generator excitation
• Generator breakers
(b) Automatic unit control modes should include following:
• Unit automatic start sequence
• Unit automatic shutdown sequence
• Unit automatic synchronizing
• Unit wicket gate set point control
• Unit load set point control
• Unit flow control
(c) The unit should include digital governor with proportional, integral and derivative
gains. The governor be with in a position loop controlled by speed loop and capable
of 0-10% droop. A manual position control should be provided. Following governing
functions should be provided.
• Speed evaluator
• Speed control
• Speed set point adjustment
• Gate limiter
• Start up and shutdown control of turbine
• Position controller for guide vanes with power amplifier for control of servo
valve.
(d) Unit Auto synchronization
The controller should be capable of synchronizing the generator to the bus by
reading the slip frequency (generator-bus) and adjusting the governor speed set point
until the correct slip frequency is obtained while sending voltage raise/lower pulses to
the voltage regulator to match generator voltage to bus voltage. When the slip
frequency is obtained and the generator and bus voltage are equal, the controller
should send a close breaker command when the generator voltage and the bus are in
phase. An additional external sync check relay should also be provided to supervise
the controller close breaker command and the manual close breaker command. The
controller should follow synchronization limits in terms of breaker closing angle and
voltage matching condition specified by generator manufacturer.

(e) Shutdown sequence

The shutdown sequence provided by controller should be such that the turbine
generator set from any moving state to a complete standstill with all auxiliaries
correctly shutdown. The unit controller should automatically shut down if the control
system detects turbine mechanical system faults; generator electrical faults or specific
shut down conditions are generated with in system. Following three types of
shutdown to be performed on the turbine/generator set should be provided by the
controller.

(i) Normal shutdown

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 A normal shutdown should be initiated by a shutdown command that has
been issued by an operator either from the panel mosaic or the supervisory
system locally or remotely. This sequence should allow the plant to be
shutdown in a standard orderly manner. After the plant has completely
shutdown it should return to a state in which it can be restarted again on the
issuing of a startup command.

(ii) Emergency shutdown

An emergency shutdown should be initiated if a failure occurs in a critical
item of plant, which is likely to cause unsafe operation of plant such as an
electrical trip. The plant should quickly and safely shutdown with lockout to
avoid damage to plant or injury to personnel. The plant should be blocked
from restarting again until the fault is rectified and acknowledged by the
operator from either the panel mosaic or the supervisory system.

(iii) Rapid shutdown

A rapid shutdown is initiated if a safety trip occurs on the plant. The plant
is rapidly shutdown taking care not to cause unfavorable effects such as
pulsations, backwater surges and suction waves. The plant is blocked from
restarting until the fault is rectified and acknowledged by the operator.

(iv) Unit start-up sequencing

The controller should allow the unit to be started manually (if all
permissive are met) and bring generating unit speed to synchronous speed.
Alternately if automatic start up mode is selected either locally or remotely
then unit should automatically start provided all the start up permissive are
met. The unit controller should allow parameters of the start-up sequence to
be configured to match the turbine generator.

(v) Lockout
The controller should include a generator lockout function. Whenever the
lockout function is on it should inhibit the generator from starting. Any alarm
should be configurable as a lockout alarm. The lockout should be reset with a
command entered on the keyboard. When the lockout is on, it should be
displayed on the screen annunciator.

(vi) Auto restart

The controller should be capable of automatically restarting the turbine
after certain shutdowns if so enabled and if the lockout is not set. The time to
wait for a restart and the enabling of the restart function should be
configurable.

(vii) Automatic power control modes

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 The unit controller when the unit is not under plant control mode should
be capable of several forms of automatic power control. The operator should
be able to select automatic power control modes at any time and enter a new
set point at any time. .The available power control modes should meet the
requirements of system.
• Gate position should be automatically controlled to match the wicket gate
to a position set point.
• Gate position should be controlled to match the kW output of the
generator to a kW set point. Regardless of the kW set point, the generator
output should be limited by a maximum kVA limit specified during
configuration.
• Gate position should be controlled to match a flow set point that is
calculated by the controller from a flow versus gate position curve for the
operating head which is entered during the configuration process.

(viii) Override control

• The controller should provide at least two override controls that when
enabled will take over turbine control from the Automatic Power Control
mode when certain set point limits are reached. When these interim
conditions return to normal, the controller should automatically revert to
the primary automatic power control mode.
• The controller should modulate the turbine output so that the measured
generator stator temperature (hottest of the three phases) does not exceed
the Temperature Control set point.

(ix) Reactive power control

The controller should have four reactive control modes, one manual and
three automatic. The generator capability curve should be entered into the
controller during configuring. All automatic reactive power control modes
should be limited by the generator capability curves. If an operator enters a set
point, that will take the generator outside its capability curves, the reactive
power control program should control reactive power to get as close to the set
point as possible, but remain within the generator's capability.
• Manual:
The controller should provide operator capability, using "raise/lower" keys
on the VDT keyboard and the "raise/lower" switch on the manual control
panel to control voltage and reactive power.
• Automatic VAR control:
The controller should automatically control the generator output to that
VAR set point set by operator. The generators voltage limit and capability
curve should not be exceeded regardless of the VAR set point.
• Automatic PF Control:
The operator should enter power factor set point from the keyboard and
The controller should automatically control the generator output to that
power factor (leading or lagging) set point set by operator. The generator

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 voltage limit and capability curve should note be exceeded regardless of
the power factor set point.
• Automatic voltage control:
The controller should automatically control the generator output to match
that voltage set point set by operator. The generator's voltage limit and
capability curve should not be exceeded regardless of the voltage set point.
• Alarm Annunciation
There should be two types of alarms used by the controller. One type
should be the external alarms from contacts fed into the digital inputs of
the controller and the second, the internal alarms generated by the
controller. All alarms, whether internal or external, should be capable of
being configured to cause different sequences.

Unit controller should be capable of providing audible and visual alarms

in the event of faults occurring in the power plants. The instant the fault
occurs the relevant fault indicator is activated. All faults have to be
acknowledged by the operators and can only be reset when the fault has been
resolved. On the occurrence of following faults audible warning should be
activated to attract the attention of the plant operators.
(x) Manual control panel
The unit controller should have a manual control panel that bypasses the
processor and allows the generator to be operated manually. The manual
control panel should include start relay circuitry that is station battery
powered. Manual switches to trip and close the breaker, turn the field on and
off, start and stop the turbine and raise and lower the voltage should also be
included. The gate should be capable of manual operation by a potentiometer
that is located on a manual control panel and should be calibrated to position
within 0.1 percent.
(xi) Unit Protection
The protection system should be based on the use of discrete
microprocessor based relays with the following features:
• Continuous self monitoring
• Online display of actual values
• Should be capable to communicate with supervisory system through unit
controller. The tenderer may also quote for multifunctional numerical
relay.

8.5.5.2 Supervisory Controller

It should monitor and control the status of power plant, provide automatic
unmanned operation, log data, display the process through a mimics, supervise water
levels of reservoir, startup and shutdown of units, control manually control auxiliary and
alarm monitoring. All such control should subject to password-bases security system.
Depending on the station requirements, the operator should be able to enter set points for
power output, voltage and power factor. It should also have online documentation and
expert diagnostics, efficiency management and plant management.
(i) Operating Regimes:
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 The plant should be controlled either manually or automatically under different
operating regimes. Following operating regimes may be provided.
(ii) Plant efficiency control mode:
In this mode of operation, the automatic control system should maximize the
plant's energy production for a given headwater level and river flow. To achieve
this, the system should automatically select the optimum number of units to run in
combination with the most efficient unit loading point to dispatch all available
water for a particular gross operating head. The operator should be able to specify
the order in which units are to be started and stopped by the control system.

(iii) Plant load sharing mode:

In this mode of operation, the control system should automatically adjust the
output of each unit by an equal percentage of rated power output in response to
fluctuations in reservoir level. Load sharing should be the default mode used in
conjunction with automatic reservoir level control.
(iv) Reactive power control mode:
In this mode of operation, the control system should automatically adjust the
excitation field current to maintain the output power factor or VARs within a
defined range (i.e., leading or lagging). The operator should be capable of
entering a set range that the power factor or VARS must fall within for each unit.
The control system should maintain the unit's output power factor or VARs within
this set range unless limited by the generator capability curve or the exciter output
current capability. The system should verify that the VAR set point is an identical
percentage of rated output for all units when used in conjunction with automatic
load sharing control.
(v) Operator Interface Requirements:
The controller should use a video display terminal or PC as the main operator
console. It should have powerful graphical user interface to the operators. The
operator should be able to completely operate the plant by typing
commands/function key on the keyboard or by push button on control panel. All
information required to operate the plant should be shown .on the screen. A
printer should be used to print out plant information. Symbols and colours
specified in the international standard IEC 204 should be used for display.
(vi) Screen display:
The screen display should include all metering, indication and annunciator
information normally displayed on a typical power plant control panel. This
should include all metered data such as three phase generator volts and amps,
generator watts, VARS, power factor, speed and frequency. This display should
also show generator stator and bearing temperatures, breaker status, line volts,
line frequency, and kilowatt-hours. The time and date should also be displayed
with time to the minute.

Screen data should be updated promptly whenever actual data changes. Alarm and
status information should be updated within one second of actual changes. Analog
data should be updated within two seconds of a change. Calculated value such as

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 temperature, watts, VARS, and power factor should be updated within five
seconds of an actual change.

All DC analog readings on the screen display should have configurable scale
factors. All except speed should have configurable labeling on the screen.

The AC scaling should be configurable by specifying WYE or DELTA and

maximum AC voltage and current.

Data shown on the display should have the following minimum accuracies.
AC Voltage 1% of full scale
AC Current 1% of full scale
Frequency ± 0.005 HZ
DC Inputs 25% of full scale
KW, KVAR, PF 25% of full scale
Temperatures + 5 degrees C

(vii) Annunciator display:

A portion of the screen should be dedicated for an annunciator. Alarms should be
displayed in order of occurrence with the oldest alarm at the top of the screen. The
sequence of alarms should be distinguishable if alarms are more than 1/60 th of a
second apart. The display should include space for a least 23 alarms. When an
alarm clears, the alarm below it should move up to fill in the blank space keeping
the sequence. No alarms should be lost. Any alarms that do not fit on the screen
should be save until these is room. Alarms should flash until the acknowledge key
on the keyboard is presses. If the alarm is still on after it is acknowledged, it
should stop flashing but remain on the screen. If the alarm has cleared, it should
disappear from the screen when the acknowledge key is pressed.

The annunciator should display both alarms that are internally generated by the
controller and alarms that are sensed external to the controller. The controller
should be capable of generating a contact closure (option) on selected alarms for
use with a horn or telephone dialer.
(viii) Control status display:
The display should include an indication of the status of the turbine i.e., starting,
stopped, synchronizing, etc...
(ix) Automatic control status display:
The display should show the current automatic control mode, its set point, turbine
gate limit, and any overriding control modes.
(x) DT Keyboard:
The keyboard should be a standard keyboard with upper and lower cases, ten key
numeric pad and at least ten function keys. The function keys should be assigned
important functions.

The operator should be able to start and stop the turbine from the keyboard using
simple commands. The operator should be able to enter set points via keyboard,

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 select any one of automatic power control modes and select any one of reactive
power control modes
(xi) External Interface
Supervisory Controller should have a number of protocol modules which should
provide connectivity to other devices including remote terminal units and
programmable logic controllers.

(xii) Event Recording and Data Logging

(a) Data logging
Their should be a provision for a data logging printer at the plant to provide data
logging at adjustable intervals, trouble logs and operator comments entered
manually at the keyboard. The data logging interval for each printers should be
adjustable by the operator in increments of one minute.
(b) Alarm and status logging
All alarms annunciated on the screen should be recorded on the data log, time-
tagged to 1/60 of a second resolution. Plant status or operational changes should
also be recorder on the data log, time-tagged to 1/60 of a second resolution. The
operator should be able to enter comments on the log manually through the
keyboard.

(c) kWH logging

Plant watt-hours should be accumulated and recorded on the data log at both daily
and monthly intervals. The integrated power generation controller should have the
capability to accumulate these data by one of two methods: internally, by a
calculation method based on direct monitoring of generator CT and PT inputs, or
externally, by receiving and totalizing counts from pulse initiator output from an
external watt-hour meter.

8.5.5.3 Remote Supervisory Controller

In case of off site (remote) control, identical desk top computer based supervisory
controller should be installed at offsite station. This controller should provide identical
set of screens to that of station itself. The same information is displayed at this controller
almost simultaneously with it appearing on the Supervisory Controller at the power
station. The same level of control is also provided on this remote controller. Using the
detailed screens for the startup and shutdown sequences, remote operator should monitor
exactly what is happening in the power station. A big screen should also be installed at
some sutable wall of the remote control center displaying on line data. In case some
generating facility is to be added at later date it should be ensured that there is no
problem in protocol matching.
The controller should have following features from safety and security point of
view:
• It should ignore all unsafe commands.
• Only one operator is able to control the unit at any point of time.
• Multiple authorization levels allow different operators access to different levels of
control.
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 (i) Communication Link
To interface Remote Supervisory Controller located at offsite location to plant
Supervisory Controller at centralized control of plant proper communication
system should be installed and commissioned.

The equipment to be supplied should have the facility of transmission of speech

and data simultaneously. Data transmission speed should be 9600 bps.

(ii) Software Requirements

The operating system:
The software should run in a priority interrupt driven, multitasking operating
system. The system should provide each task with dedicated random access
memory to allow preemptive scheduling of tasks without loss of information.

(iii) Programming language

The controlling programs should be written in a high level compiled language
whenever possible for ease in maintenance, with the exception of time critical
tasks which should be written in assembly language. The code should be re-
entrant and employ mutual exclusion techniques to prevent deadlock of resources.

(iv) Standardization
The software should reside in non-volatile EPROM memory, which should not
require reloading for routine power interruptions to the controller.

(v) Configurability
Configuring of the control software should be accomplished via a menu driven
user-friendly program that will be run on an IBC PC or compatible computer. The
configuring should be able to be accomplished at an area remote from the
controller and should not prevent operation of the controller during configuring
except during the transfer of the configuring information to the controller.

(vi) Functions
The software should allow the operator to examine and modify those parameters
of the control software that will specify the operating conditions and restrictions
of a particular plant. These features should include but are not limited to:
- Timings
- Decision paths
- Set points
- Equation coefficients
- Enabling functions
- Plant description information

The software should also allow for specifying particular contact inputs, analog
inputs and analog outputs. The software should allow user designation and titling
of contact inputs. Analog scale factors should be set via the configuring program.

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 (vii) Communications
The configuring information should be communicable with the controller via
standard RS-232C communications protocol. The communication should have the
ability to be via voice grade telephone communication as well as a direct
connection with the controller.

(viii) Security
The configuring software should provide a means of preventing unauthorized
access to the configuring information. Further it should provide a means of
differentiating three or more security levels of configuring information to create
three or more depths of configuring accessibility.

(ix) Human interface

The configuring program should be "user-friendly" in that it should be menu
driven and should be operable by non-technical personnel.

8.6 Physical and Environmental

(i) Physical
The equipment should be constructed on a modular basis, using plug-in
connection. The controller should be suitable for mounting in a standard 19-inch
wide rack, with a minimum depth of 24 inches. Input/output termination cabinets
should be internally labeled, to permit ready identification of the incoming and
outgoing wiring. The equipment should be of self protecting against surges that
may be generated on power supply bus by contact operation, circuit resonance,
etc. External connections should utilize modular screw terminal blocks which
should be should be suitably mounted and readily accessible. Each terminal
device shall suitably identify all conductors. All wiring should be clearly marked
and so designated on the drawing to permit identification for maintenance. Wire
not colour coded should be identified by a wire number marker on each end. All
cables and jacketing material should be oil, moisture, and heat resistance
thermosetting compounds under operating conditions. Controller AC power
connection should be a standard NEMA PI5-5 plug configuration.

(ii) Environmental
The controller and video display should be capable of withstanding the
environmental conditions of the site of plant during air condition failure.
(iii) Power Requirements
The controller should use standard wall outlet AC power, however an inverter
should be supplied that is powered from the station battery to provide AC power.
The controller including VDT, DTC, printer, and modem other peripheral
equipment should operate from a 250 VA inverter.

9.0 USER AND PLANT INTERFACES

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9.1 User interfaces
The most critical interface for a power plant automation system is the User
Interface (UI). The plant interfaces discussed later in this clause are important to the
automation system in order to perform effective monitoring, annunciation, control, etc.,
but the UI is crucial to the success of the system. If the operator is not able to use the
system easily and conveniently, the system will never be used properly or cost
effectively. The operator's needs are critical to the successful operation and use of a
power plant automation project. UIs offering the look and feel of a personal computer
may be desirable to reduce special training.

In order to make the system acceptable to the operations personnel, care must be
taken in the selection of the hardware and software used. The hardware options are
numerous for input and output devices as well as the workstations to be used.

9.1.1 Input devices

Input devices are not mutually exclusive and may be combined to incorporate desired
features. Typical devices include the following:
a) Trackballs. Pointing devices for menu driven software. Trackballs are normally
used in conjunction with a standard ASCII keyboard and/or numeric keypad and
occupy very little desktop space.
b) Mice. Similar to track balls, they are normally used in conjunction with an ASCII
keyboard arid/or numeric keypad. A mouse requires more desktop space than a
trackball since the mouse must be moved in order to move the cursor on the
screen.
c) Light pens. A pointing device for menu-driven software. Light pens normally use
an ASCII keyboard and/or a numeric keypad for data entry and require no desktop
space.
d) Keyboards. Normally installed on all workstations for data input and system
control. Desirable features for keyboards and numeric keypads include standard
key layouts and tactile feedback. They need to be well constructed to withstand
continuous use. They should be waterproof and dustproof. Keyboards using
layouts similar to the familiar PC will minimize the chance for confusion arising
from the use of a nonstandard keyboard.
e) Touch screens. Useful for cursor positioning but not well suited for data entry.
f) Speech recognition. This input technique is a leading edge technology. It has
many disadvantages at present such as speaker dependency, large error or
misinterpretation rates, large memory needs, and extensive processing time.

9.1.2 Output devices

As with input devices, various output devices may be combined to incorporate
desired features. Some typical devices are as follows:
a) Printers. These devices range from dot matrix units to letter-quality line printers
in both black and black-plus-color models. They are used for hard copy output of
the computer data for reports or historical records.

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 b) CRT screens. These output devices are on most UI systems and are the primary
output device for the computer. They range from small monochrome units to large
color units with millions of color combinations.
c) Speech synthesis. Provides the operator with a phonetically-based audible
message output.
d) Mimic boards. Graphical displays or map boards used to represent the
configuration and data of the plant or system. Mature technology units range from
manual displays with movable parts to fixed displays with lights to indicate
equipment status. New technology units include displays of system data in
graphical form and large projection screens with computer generated displays.

9.2 Plant Interfaces

The plant to computer-based control system interfaces are important to the
success of the automated hydroelectric power plant's control system. There are many
types of hardware interfaces, each with specific requirements that must be addressed as
the system is designed, installed, and tested.

9.2.1 Types
Examples of plant interfaces include analog transducer signals, dry contacts (i.e.,
contacts without sensing voltages) and digital data. This clause covers several generic
types, however, installations may have special application requirements to meet unique
concerns. This discussion addresses the analysis process for any plant interface.

9.2.1.1 Digital, contact, and pulse inputs

Digital or contact inputs should meet minimum criteria for operations at the
voltages and current loads anticipated. The current required to drive the input circuitry
should be adequate to ensure false indication changes do not occur due to noise. The
current should be as low as possible to conserve power and reduce heat generation.
Wetting voltages (e.g., those voltages required to sense the status of dry contacts) may be
provided by the control system or the field device.

Contact bounce in the input signal can cause erroneous data in the system. Digital
inputs should have filters to detect only sustained input signals. These filters may be in
the hardware or the software. Filters must be selected in accordance with time tag
accuracy. Simple low-pass filters can introduce undesirable delays. Voltage levels for
logic detection should be sufficient to prevent erroneous readings.

Digital inputs may also serve the functions of pulse accumulators or counters.
This function is normally in software or firmware at the I/O. Accuracy, counting, and
pulse accumulation rates should be sufficient for the intended use.

Another variety of digital inputs comes in the form of a parallel (e.g., binary
coded decimal) data. The quantity of wire conductors, noise immunity, and hand shaking
requirements should be considered when making accommodations for these inputs.

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 Serial digital inputs (e.g., EIA RS232, RS422) are frequently used as an interface
to newer transducers.

Digital input status indicators, often LEDs, may be provided. These indicators
ease I/O and control circuit troubleshooting.

9.2.1.2 Digital and contact outputs

Digital or Contact outputs provide data and control contacts for external circuits.
These contacts must have sufficient current and voltage rating for the external load.
These ratings must often be considered in total for a given card or group of I/O as well as
for individual circuits. Wetting voltage is typically provided by the external circuit. The
ability of the solid-state devices in the output circuitry of the I/O to absorb the required
current (without thermal instability of the devices) is a function of temperature (heat
generation).

Where higher current ratings are required, interposing relays are typically
installed. The current ratings are then those of the interposing relays.

Digital outputs may be latched, momentary, or maintained. These functions may

be implemented in software or in the output relay. Digital output status indicators—
usually LEDs – may be provided, similar to those on input I/Os.

The failure state of digital outputs should be defined and specified. Digital output
failure may be critical in some applications.

9.2.1.3 Analog inputs

Analog inputs may be low-level (e.g., 0-1 mA dc, 4-20 mA dc, 1-5 V dc, etc.)
current or voltage, resistance, or thermocouple signals. Resistance or millivolt
(thermocouple) inputs may be scaled to engineering units by the I/O processor, or a
separate RTD or thermocouple to current or voltage converter located with the I/O.

The I/O is often capable of providing the loop power supply for analog inputs.
Voltage, tolerance, stability, and loading should be considered.

Scaling accuracy, resolution, deadband, and thermal stability should all be

specified to meet the needs of the applications. Thermocouple and RTD replications
should meet the standard accuracy for these devices. Open thermocouple detection is
often desirable. Common and differential mode rejection ratios should also be specified.

When multiplexing technology is used, the multiplexing hardware should be

solid-state and not electromechanical. Multiplexing schemes must be fast enough to
ensure that the most recent values are available when required for all control loops.

9.2.1.4 Analog outputs

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 Analog outputs are typically low-level voltage or current. Accuracy, resolution,
deadband, and thermal stability should all be specified. Similar to digital outputs, the
condition or value of analog outputs upon failure may be critical in some applications.

9.2.1.5 Analog-to-digital/digital-to-analog conversion

The accuracy of any analog input or output depends on the conversion between
the computer's digital data system and the analog information. The conversion is typically
performed by multi-bit A/D converters. Conversion accuracy and resolution are a
function of the number of A/D converter bits and I/O amplifier design. Further, the
accuracy is affected by temperature-induced drift. Thus, A/D resolution, input accuracy,
and temperature stability should all be specified.

9.2.1.6 Field devices and field bus standards

Another major source of interface signals are those originating from intelligent
electronic devices (IED) and intelligent field devices (e.g., a field device capable of
measuring more than one parameter and transmitting the measured parameters over one
pair of wires.

9.2.2 Sources
The sources of information to be interfaced to control systems are numerous and
not all are covered in this clause. The most common ones are highlighted, as follows:
a) Digital Input Signal Monitoring.
Usually accomplished by sensing the state of relay contacts using the station
battery or a voltage supply to detect the opened or closed status of the contact.
The output devices are normally solid-state or electromechanical relays that are
energized or de-energized by the control system.
b) Analog Input Devices.
Normally transducers that convert potential transformer (PT) and current
transformer (CT) signals to quantities such as megawatts or megavars. In existing
plants, control system analog outputs may drive display panels or strip chart
recorders for operator observation.
c) Parallel Input Devices.
Usually shaft encoders or digital panel meters. The output devices are digital
panel meters or process controller modules. These interface sources are in many
cases bidirectional, i.e., they are both input and output devices.
d) Serial Sources.
Normally bidirectional devices with built-in intelligence, providing both input and
output capability. The devices consist of smart watthour meters, shaft encoders,
temperature transducers, etc.

9.2.3 Input/output protection

All inputs and outputs should be specified to withstand the Surge Withstand
Capability (SWC) test, -as described in IEEE C37.90.1-1989, without any false
operations. The SWC test has proven to be a reliable means to identify noise problems
similar to those found in a hydroelectric powerhouse.

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9.2.4 Collection process
The data collection process involves all of the aspects discussed above as well as
some considerations that are internal to the control system as opposed to the interface
itself.

9.2.4.1 Scan rate

The scan rate deals with the rate at which the data is moved from the interface to
the data base or from the database to the interface.
9.2.4.2 Archival rate
The archival rate of the control system is normally the rate at which data is stored
for long-term, historical purposes. This rate varies dependent on data type, in order to
save storage space, retrieval time, and analysis efforts. For example, the archival rate for
temperature data does not need to be as often as that for electrical data.

10.0 REMOTE CONTROL OFF SITE CONTROL

Remote control of hydroelectric plant means controlling activities of a plant from
off site control centers. Personnel at such control centers are responsible of operating
several power plants and substations. Some of the control functions performed from such
control centers are:
• Periodic MW & MVARs adjustments to maintain power system operation in
accordance with grid requirements as per guide lines of system control.
• Maintain generation reserves to assure power system stability as per guidelines of
system control.
• Energy interchange scheduling
• Automatic generation control, including time error control and frequency control
(in coordinative with area system control centre).
• Hourly load forecast
• Transmission line loading (system power flow)
• Power export control adjustments.

Remote control can be automatic or manual with duplication of local controls at

remote location for desired operation at that site control logic system can be provided by
hardwired relay logic programmable logic controllers, microprocessor based system or a
combination of these. Interlocks are required at the local site to prevent improper remote
manual operation. Remote control and indications may be established by the use of
“supervisory control” equipment, using one of the modern communication means totally
automatic start & slop initiation is possible from remote location. However unattended
operation requires that special attention be given to fail safe characteristic of control
system.

10.1 Control requirement:

Initiation and control functions are listed below. The items installed will vary
according to size of plant, method of system operation and economics.
• Start and stop sequence initiation
• Breaker operation – open/ close

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 • Motorized excitation or voltage regulator setting rheostat to allow remote setting
of field current and generator terminal voltage.
• Governor control and flow control device position (guide vanes, blade angle or
nozzle or valve)
- speed – no load
- Best efficiency
- Position (guide vanes, blade angle, nozzles or valve)
- Unit auxiliary system
-
10.2 Instrumentation requirements:
• KW output per generator
• KVAR output per generator
• KWH output per generator field voltage and current synchronoscope indication
• Generator voltage, current and frequency
• System voltage
• Head water level
• Tail water level, when required
• Turbine flow control devices (guide vanes, blade angle, nozzle or valve)
• Status of bye pass, sluice or spillway gates
Transducer or signal transmitters are provided either at the control board or at the
equipment.

10.3 Status / Alarms requirement:

• Ready to start
• Breaker position (No alarm if manual operation only)
• Intrusion alarm
• Fire alarm
• Emergency station alarm (immediate response)
• General station alarm (can be differed for some time)
• Trash rack differential pressure alarm
• Unit stop when not required
• Unit turning when not required
• High bearing temperature
• Loss of lubrication or cooling or both
• Low hydraulic system oil pressure
• High or low water levels
• Incomplete start or stop sequence loss of power

10.4 Communication Links:

Following communication methods are used for implementing control from Remote site:
• Hardwired communication
- Telephone type lines
- Fiber optical cables
• Leased telephone lines

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 • Power line carrier communication system (PLCC)
• Point to point radio at approved frequency
• Microwave system
• Satellite

For items of 1 & 2 arrangements of special protection for equipment and personnel
against ground potential rise & lightening surges are essential.
It is seen that optical fiber cable, PLCC, Satellite communication links are the most
preferred options as these are more reliable.

11.0 SITE INTEGRATION FOR AUTOMATION OF EXISTING PLANT

Before taking up automation of existing plant it is necessary to study site
conditions and ensure that interfaces and other circumstances are compatible with proper
operation of the automation system some features requiring study for automation are as
under: -

11.1 Existing contact output:

Most automation systems include large numbers of contact status point inputs. These
contact can be found in:
- Protective relays
- Manually operated control switches
- Level switches
- Position switches
- Other devices.

The contacts should be used directly as inputs to automation system. It is

advisable to avoid input through auxiliary relays. Sometimes contacts in protective relays
are connected in parallel with annunciation equipment. In such case care should be taken
to avoid any sort of interference between automation system and annunciation equipment.

In case one side contacts is connected to power source from station battery, the
automation system should provide electrical isolation between the inputs to prevent sneak
paths between inputs when either side of the battery is disconnected from one of them.

11.2 Existing Transducers:

An automation system can be configured to adapt to any electrical signal as input
but it is preferable to have standardized inputs. The accuracy of existing transducers
should be studied to ascertain that they most system accuracy requirements. The most
commonly used transducers provide O - + port) signal as an output but transducers
providing 4-20 mA signal are also used by manufacture different transducer outputs
require different input circuits on the automation system. It is therefore, preferable to
have minimum transducer outputs to have less complexity in automation system. It will
make it easier to add or reconfigure the inputs after the equipment.

11.3 Existing control output points:

The functions of output points are:
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 - Close /trip
- Raise / lower
- Start / slop

The characteristic of each output point supervised should be determined. The old
break trip circuits, speed level motors require high level inductive current to be switched
as such output circuits must be capable of reliably switching this current through out the
life of automotive system alternatively interposing auxiliary machine tool type relays can
be used on such outputs.

11.4 Grounding
Each equipment rack of automation systems is required to be separately
connected to the power house ground mat. During power system fault conditions, a large
potential rise can occur between different locations with in power house due to large
current flowing through ground.

This potential rise will appear between different components of equipment

communication circuit connecting different components must with stand this potential
rise as such with stand value of maximum potential rise for links must be specified. The
use of optical fiber cable as communication link between equipment is one way of
solving this problem. Shield ties on transducer end are used on communication cables
between transducers and automation system.

11.5 Power Source

11.5.1 Battery set with charger
Normally a battery set with automatic float rectifier type battery charger powered
by station AC is provided to feed critical load such as protection and control circuits and
devices as D.C. source is more reliable.

An evaluation (as described in IEEE Std 485-1983) should be performed to ensure

that station battery is having enough capacity to operate automation system along with all
other D.C. loads for specified time periods (half an hour is considered adequate in case of
station AC failure). The chargers must be capable of supplying D.C. system load while
charging up the battery. If the evaluation shows that larger batteries or chargers are
required, consideration should be given to it for improving automation system efficiency.
Reducing other D.C. load is other option.

Some components of automation system operate on AC power since AC power

source available at power house is not considered very reliable providing inverter to
convert power from D.C. station battery to A.C. power is considered reliable option.
Some automation features like sequence of event recording operating on A.C. are vital
and can not be afforded to be missed as such provision of inverter become inescapable.
Inverter, however, should include a bump less static switch with automatic transfer of
power source for the automation system to the station A.C. power source in the event of
inverter failure. Also the inverter should be designed to produce an A.C. output with
wave form deviation and wave form characteristics consistent with the requirement of

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 supplied load. Appropriate failure detection and alarming should be specified in the
investor.

In case of large power stations two sets of batteries of full required capacity are
required to make availability of D.C. more reliable.

UPS of proper capacity are preferred for SHP as these require less maintenance
and are considered more reliable.

11.5.2 Uninterruptible Power Supply System (UPS)

Uninterruptible Power Supply System in SHP are required to provide electricity for
computerized control and data acquisition system, communication system etc. when
normal plant power system fail. As per IEEE: 944 – Recommended practice for
application and testing of uninterruptible power supplies for power generating stations;
UPS systems are used to provide electricity for essential loads when normal plant power
system fails. Loss of power to such loads as the plant computers, communication
networks, security system and emergency lights.
DC BATTERY (48/110V)

FUSE
FLOATED BOOST
CHARGER

AC FROM
STATION
SERVICE

D.C. BUS
TO COMPUTER
CONTROL SYSTEM

FEEDER
MCB BREAKER TO
EMERGENCY
SUPPLY

UPS SYSTEM

D.C. FEEDERS

AC-220V FROM
STATION SERVICE

Fig. 3.3 Typical DC system for SHP up to 3000 kW

UPS system is defined as one designed to automatically provide power without delay or
transient during any period when normal power supply is in capable of performing
acceptably.

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 On line static (solid state) UPS system with sine wave output are required. An off line
system take about 25 ms for transfer to DC which may impair critical control by
computer system. Normal range of sizes for hydro plant up to 25 MW uninterruptible
power supplies is given below:

Plat size (MW) UPS size (kVA) Remarks

5 - 25 MW 1 – 5 kVA
0.1 to 5 MW 1 or less kVA
Micro Hydel i) Electronic load i) Use power line conditioner
controller (ELC) may (power supply system)
use its on converter and ii) May use standard single PC UPS
conditioned Dc supply
system from UPS or
otherwise
ii) If remote controlled
PC may be used with its
own UPS

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 ANNEXURE-II

LIST OF GENERATOR PANEL INDICATION AND RELAYS

Sl. Designation Inscription Colours

No.
1 L1 DC Supply on Yellow
2 L2 AC Supply on Red
3 L3 Generator Circuit Breaker Close Red
4 L4 Generator Circuit Breaker Open Green
5 L5 Generator Circuit Breaker Trip Amber
6 L6 Generator Circuit Spring Charge Blue
7 L7 Trip Coil Healthy Yellow
8 L8 DC Supply Failed Red
9 L9 Spare Red
10 R R Phase Bus Healthy Red
11 Y Y Phase Bus Healthy Yellow
12 B B Phase Bus Healthy Blue
13 IPB Immediate Action Trip Push Button Red
14 PB1 Controlled Action Shut Down Push Button Green
15 PB2 Spare Push Button Red
16 TS Temperature Scanner
17 DMF Digital Multi Function Meter
18 H Hooter Black
19 ANN Annunciator Black
20 T Test Push Button Black
21 A Accept Push Button Yellow
22 R Reset Push Button
23 BAPB Bell Accepted Push Button
24 27 Under Voltage Relay
25 32P Reverse Power Relay
26 51V Voltage Controlled Over Current Relay
27 59 Over Voltage Relay
28 60 PT Fuse Failure Relay
29 64S Stator Earth Fault Relay
30 46 Negative Phase Sequence Relay

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31 40 Loss of Field Relay
32 95 Trip coil Supervision relay
33 87G Generator Differential Relay
34 52G Generator Circuit Breaker
35 KWTR Kilowatt Transducer
36 BL Electrical Bell
37 86G1 Master Trip Relay
38 86G2 Master Trip Relay
39 86G3 Master Trip Relay
40 86G4 Master Trip Relay
ANNEXURE-III

LIST OF PROTECTION ELEMENTS IN MICRO PROCESSOR BASED RELAYS

Symbol Description
21 Under Impedance
24 Over Fluxing
26 Field Winding Temp
27 Under Voltage
27NT 100% Stator E/F
32 Reverse Power
38 Bearing Temp
40 Loss of Field
46 Negative Phase Sequence
49 Stator Winding Temp
50BF Breaker Failure
50P Instantaneous Phase Over Current
50N Instantaneous Neutral Over Current
50/27 Unintentional Energisation at Stand Still
51P Time Delayed Phase Over Current
51N Time Delayed Neutral Over Current
51N Voltage Controlled Over Current
59 Over Voltage
59N Residual Over Voltage
64R Restricted E/F
78 Pole Slipping Protection
81 Over/ Under Frequency
87G Generator Differential
CTS Current Transformer Supervision
VTS Voltage Transformer Supervision

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 Version 2

STANDARDS/MANUALS/
GUIDELINES FOR
SMALL HYDRO DEVELOPMENT

Electro-Mechanical Works–
Selection of Auxiliaries for SHP Stations

Sponsor: Lead Organization:

Ministry of New and Renewable Energy Alternate Hydro Energy Center

Govt. of India Indian Institute of Technology Roorkee

May 2011
 CONTENTS

Sl. No. Items Page No.

1.0 GENERAL 1
2.0 GENERAL CONSIDERATION FOR SELECTION OF
ELECTRICALAND ECHANICAL AUXILIARIES 1
2.1 General Design Considerations Electrical Auxiliaries 1
2.2 General Consideration for Mechanical Auxiliaries 7
3.0 ELECTRICAL AUXILARIES 9
3.1 Auxiliary Power Supply System 9
3.2 D.C. Auxiliary Power System 14
3.3 Uninterruptible Power Supply System (UPS) 19
3.4 Power and Control Cables 20
3.5 Lighting System 26
3.6 Grounding System and Lightning Protection 30
3.7 Communication System 32
3.8 Transformer Oil Purifier 34
4.0 MECHANICAL AUXILIARIES 34
4.1 E.O.T. Crane 34
4.2 Cooling Water System 34
4.3 Dewatering and Drainage System 36
4.4 Compressed Air System 38
4.5 Fire Protection System 40
4.6 Ventilation and Air Conditioning 49
4.7 Water Level Sensing 54
 Guide for Selection of Auxiliaries
for SHP up to 25 MW
1. GENERAL

Electrical and mechanical unit and station auxiliaries integrity is important for successful
operation of hydro station. Major considerations for selection and provision of auxiliaries
in SHP station are: i) economic viability, ii) lack of skilled operators iii) unattended
operation. Provision and selection of auxiliaries in SHP upto 25 MW capacity is
discussed as follows:

a) Selection of auxiliaries and system for SHP above 5 MW and upto 25 MW unit
size
b) Auxiliaries for SHP above 100 kW to 5 MW
c) Micro hydels upto 100 kW

1.1 Auxiliary System and Equipment

1.1.1 Electrical Auxiliaries

• Auxiliary Power system – Electrical auxiliaries including aux. Power supply

system equipment; Comprising of auxiliary transformer; AC LT Switchgear and
control gear for unit and station auxiliaries
• DC system – DC equipment and power supply system; Comprising Dc batteries
and Dc switchgear and charging equipment for unit and station auxiliaries
• Uninterruptible power supply (UPS)
• Power and control cables and cabling
• Lighting System – including emergency lighting
• Grounding System – covers ground mat below power house and switch ground
and equipment earthing network
• Communication system
• Transformer oil purifier

1.1.2 Mechanical Auxiliaries

• Powerhouse and auxiliary cranes

• Cooling water system
• Dewatering and drainage system
• Compressed air system
• Fire protection system
• Ventilation and air conditioning system
• Water sensing (forebay and tailrace)

2. GENERAL CONSIDERATION FOR SELECTION OF ELECTRICAL AND

ECHANICAL AUXILIARIES

2.1 General Design Considerations electrical auxiliaries

All component of the electrical items of Works of the auxiliary systems should be of
reliable design.

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 Ratings of main electrical works should generally include a safety margin of 10%. Short
circuit calculations, de-rating factors, etc. should be carried out and taken into
consideration for design.

Short-circuit calculations should be evaluated and every electrical component should

withstand the maximum stresses under fault conditions, for fault levels and durations
obtained under the worst conditions, e.g., upon failure of the corresponding main
protection device and time delayed fault clearing by the back-up protection device.

The equipment should be suitable for the prevailing climatic conditions and insensitive
to any signals emitted by wireless communication equipment.

Clearances: The layout of the equipment in the power house should provide ready access
for operation and maintenance whilst the remaining sections of equipment are alive.
Working clearance provided between isolated equipment and nearest live metal work should
be as per Indian Electricity rules & Standards.

2.1.1 Electrical Supplies for Auxiliary Equipment: The electricity supplies available
for various auxiliary equipment are :

(i) 415 V, ± 10%, 3-phase 50Hz, 4-wire for A.C. power supply,
(ii) 230 V, ±10%, single phase, 50 Hz for lighting, indication, and anti-condensation
heaters,
(iii) DC for essential indication, controls, protection, alarms and circuit breaker closing
and tripping supplies, emergency power supply system
(iv) UPS system for computerized controls and SCADA

2.1.2 Alternating Current Supply Practice: All mains supplies should be through
MCBs of appropriate rating. Double-pole switches should be used to break single-phase
A.C. mains supplies. For multi-phase supplies, each phase should be switched simultaneously
and the neutral should preferably not be switched.

2.1.3 Direct Current Supply Practice: Power supply bus bars in cubicles should be
carefully routed and each bus bar should be shrouded. It should not be possible to
inadvertently short bus bars either between themselves or to earth. It should be possible to
remove/replace cards from/to electronic equipment without damage and without interfering
with the operation of the rest of the equipment or system.

2.1.4 Electric Motors

2.1.4.1 General: All motors should conform to IS 325 induction motors with suitable
eyebolts. AC motors should have squirrel cage type rotors. The insulation of all the
motors should be of class F but temperature rise during operation should be limited to
class B insulation. It should be suitable for operation in damp locations and for occasional
contact with corrosive gases/vapors.

2.1.4.2 Ventilation and Type of Enclosure: All motors should be of the totally
enclosed fan-cooled type, protection class IP 54 according to IEC Recommendation 144.
Cable termination points should be of class IP55. Vertical motors should be provided
with a top cover to prevent the ingress of dirt and droplets etc.

2.1.4.3 Terminal Boxes and Earthing: The terminals, terminal boxes and associated
equipment should be suitable for terminating the power cables. The terminal boxes should
be of ample size to enable connections to be made in a satisfactory manner. For earthing

AHEC/MNRE/SHP Standards/E&M Works – Guide for Selection of Auxiliaries for                     Page 2 

SHP up to 25 MW
 purposes, each motor should have adequately sized bolts with washers at the lower part
of the frame. In addition, each terminal box should contain one earthing screw.

2.1.4.4 Motor Voltages and Power Ratings: The service voltages and corresponding
power ratings for electric motors to be used should be as follows:

Motors up to 1 kW
− Service voltage : single-phase a.c. 240 V, 50 HZ
− Mode of starting : condenser
Motors above 1 kW and up to 75 kW
Service voltage : 3-phase a.c. 415/240 V, 50 HZ
Mode of starting : direct-on-line up
Motors intended to work on the D.C. System
− Service voltage : As per battery voltage
− Mode of starting : resistor

2.1.4.5 Rating: The rating of the motors should be adequate to meet the requirements of
its associated driven equipment. The service factor, being the ratio of the installed motor
output to the required power at the shaft of the driven machine at its expected maximum
power demand, should be applied as follows:

Power Demand of Driven Machine Service Factor

Up to 5 kW 1.2
More than 5 kW 1.1

A.C. motors should be capable of operating continuously under rated output conditions
at any frequency between 95% and 105% of the rated frequency and/or with any volt-
age variation between 90% and 110% of the nominal voltage. A transient over voltage
of 130% of the nominal voltage should be sustained.

The motors should be capable of maintaining stable operation when running at 70%
nominal voltage for a period of 10 seconds. The pullout torque for continuously loaded
motors should be at least 160% of the rated torque and for intermittently loaded motors
200% of the rated torque.

D.C. motors should be capable of operating continuously under rated output conditions
at any voltage between 90% and 110% of the nominal voltage with a fixed brush setting
for all loads. The speed drop between no-load and full-load should not exceed 10% of
no-load speed.

2.1.4.6 Starting: A.C. motors should be designed for direct on-line starting. They
should be capable of being switched on without damage to an infinite busbar at 110% of
the nominal voltage with an inherent residual voltage of 100% even in phase opposition.
For starting the motors from the individual main and auxiliary busbars, a momentary
voltage drop of 20% referred to nominal voltage should be taken into consideration. With
85% of the nominal voltage applied to the motor terminals, each motor should be capable
of accelerating its associated load to full speed with a minimum accelerating torque of 5%
of full load torque.
The maximum starting currents (without any tolerance) should not exceed the following
values:

AHEC/MNRE/SHP Standards/E&M Works – Guide for Selection of Auxiliaries for                     Page 3 

SHP up to 25 MW
 − 5 times of rated current for L.V. motors rated 100 kW or above
− 2 times of rated current for D.C. motors (by means of starting resistors)

Generally, all motors should be able to withstand five cold starts per hour, equally
spaced. Each motor should be capable of withstanding three successive starts under the
same conditions or once every fifteen minutes without detrimental heating. Motors for
frequent automatic starting should have an adequate rating.

2.1.4.7 Bearings

As far as possible, the motors should have sealed ball or roller bearings lubricated for
life. All other motors with ratings of about 1 kW and above should be equipped with
lubricators permitting greasing while the motor is running and preventing over-lubrica-
tion. Additionally, the bearings should be fitted with grease nipples permitting the use
of a universal grease gun. Vertical motors should have approved thrust bearings.

2.1.4.8 Terminal Boxes and Earthing

The terminal leads, terminals, terminal boxes and associated equipment should be suit-
able for terminating the respective type of cables as specified in these General Tech-
nical Specifications and in the Particular Technical Specifications.

2.1.4.9 Noise-Level and Vibrations: Under all operating conditions, the noise level of
motors should not exceed 75 dB (A) at any place 1.0 m away from operating equipment.
All motors should be statically and dynamically balanced. The vibration amplitude
should not exceed values specified in IS 4729.

2.1.4.10 Tests: Each motor should be factory tested and should undergo a test at site. The
following tests should be performed under full responsibility of the Contractor.

Workshop Tests :

− Measurement of winding resistances

− No-load and short-circuit measurements
− Measurement of starting current and torque
− Efficiency measurement (type test)
− Heat test run
− Dielectric test
− Measurement of insulating resistance

2.1.5 Starters and Contactors

A.C. motors should be designed for direct on-line starting. They should be capable of
being switched on without damage to an infinite busbar at 110% of the nominal voltage
with an inherent residual voltage of 100% even in phase opposition. For starting the
motors from the individual main and auxiliary busbars, a momentary voltage drop of
20% referred to nominal voltage should be taken into consideration.

With 85% of the nominal voltage applied to the motor terminals, each motor should be
capable of accelerating its associated load to full speed with a minimum accelerating
torque of 5% of full load torque.

AHEC/MNRE/SHP Standards/E&M Works – Guide for Selection of Auxiliaries for                     Page 4 

SHP up to 25 MW
 The maximum starting currents (without any tolerance) should not exceed the following
values:

− 5 times of rated current for L.V. motors rated 100 kW or above

− 2 times of rated current for D.C. motors (by means of starting resistors)

Motor starters and contactors should be equipped with short circuit protection and local
disconnecting devices. The control circuit voltage should be obtained from a 415/240 V
isolating transformer with primary circuit breaker and secondary fuse. The secondary
winding of this transformer should be grounded. The operating coils of the contactor
should be connected between the grounded side of the transformer and the control
contacts.

Starters and contactors should comply with IEC 292.1 or National Electrical
Manufacturer Association USA standard NEMA IC 1 and be suitable for direct on-line
starting, uninterrupted electrical duty, and capable of 30 operations per hour. They should
be installed in ventilated enclosures for indoor installation and weatherproof enclosures
for outdoor installation. The enclosures should be complete with locks, cable sealing
boxes, conduit entries, cable gland plates, bus bars, internal wiring, terminal boards, etc.
as required by the duty of the starter.

Thermal type overload and phase failure relays should be supplied with starters for
motors of 7.5 kW or greater. For motors of less than 7.5 kW, suitable rated 3-phase
thermal overloads may be provided. Ammeters to read current in one phase should be
provided for motors above 7.5 kW.

2.1.6 Moulded Case Circuit Breakers

All moulded case circuit breakers should be of 2 or 3-pole type as required, with requisite
short time rating having thermal time delay and instantaneous trips with "On-Trip-Off",
indicating/operating mechanism. Circuit breakers used in combination type motor starters
or contactors should have the operating mechanisms interlocked with the starter or
contactor cover so that the cover cannot be opened unless the circuit breaker is open.

2.1.7 Cubicles and Control Panels

Cubicles and control panel enclosures should be of sheet steel with minimum thickness of
1.5 mm, vermin proof, rigid self-supporting construction and supplied with channel bases.
Cubicles should be fitted with close fitting gasketted and hinged doors capable of being
opened through 180 deg. The doors of all cabinets/panels should be provided with similar
integral lock.

2.1.8 Instrumentation And Control Equipment

Design Criteria

Shielded cables should be provided for the control and supervisory equipment where
required.

Measuring Systems: Electric measuring signals of 4-20 mA should be transmitted to the

control room for essential or regulating circuits. Measuring signals for indicating
purposes will be 4-20 mA. Measuring ranges of indicators, transducers, etc. should be
selected in such a way that the rated value of the measured magnitude covers approx.
75% of the range.
AHEC/MNRE/SHP Standards/E&M Works – Guide for Selection of Auxiliaries for                     Page 5 
SHP up to 25 MW
 All local instruments should, as far as practicable, be mounted vibration free to allow
good reading. Wherever required, damping elements should be used. Corresponding
systems should be grouped together in local panels.

2.1.9 Pressure Measurements

Pressure gauges should be shock and vibration-proof (preferably by filling with

glycerine) and the movement should completely be made of stainless steel. The casings
should be dust and watertight and be made of stainless steel. The adjustment of the
pointer should be possible by means of an adjustment device without removing the
pointer from its axle.

Each gauge, pressure switch and transmitter for absolute or differential pressure should
be equipped with a pressure gauge isolating valve including a test connection of the
screwed type M20 x 1.5 mm so that such device can be removed without any distur-
bance of the plant operation. If the pressure is pulsating, the devices concerned should
be connected via flexible tubes or other pulse-absorbing means.

The error for pressure transmitters should be limited to ±0.5%.

2.1.10 Level Measurements

The liquid level measurements in reservoirs and tanks with atmospheric pressure should
be made by means of capacitance measurement type. The errors should not exceed ±
1.0% of the total measuring range.

2.1.11 Electrical Measurements

All Electrical instruments should be of flush mounted design, dust and moisture-proof.
A.C. ammeters and voltmeters should have digital type system of not less than 1.5
accuracy class. D.C. measuring instruments should also be digital type of the same
accuracy. Wattmeters should be suitable for unbalanced systems and accuracy of energy
meters should be of 0.2 % accuracy class.

All indicating instruments should generally withstand without damage a continuous

overload of 20% referred to the rated output value of the corresponding instrument
transformers. Ammeters should not be damaged by fault-currents within the rating and
fault duration time of the associated switchgear via the primaries of their corresponding
instrument transformers. All instruments and apparatus should be capable of carrying
their full load currents without undue heating. Means should be provided for zero
adjustment of instruments without dismantling.

When more than one measured value is indicated on the same instrument, a measuring
point selector switch should be provided next to the instrument and should be engraved
with a legend specifying each selected measuring point.

All instruments mounted on the same panel should be of same style and appearance.

2.1.12 Position Measurements

AHEC/MNRE/SHP Standards/E&M Works – Guide for Selection of Auxiliaries for                     Page 6 

SHP up to 25 MW
 Position transmitters for continuous position indication and measuring transducers
should have an output current of 4-20 mA and aux. supply voltage (if required) 24 V
D.C.

2.1.13 Limit Switches

Limit switches should be mounted suitable for easy adjustment and for rigidly locking
in position after being adjusted. They should be of heavy-duty rating and have two
changeover contacts suitable for station DC voltage operation.

2.2 General Consideration for Mechanical Auxiliaries

2.2.1 General

The mechanical items of Works of the auxiliary systems electrical including

installations should generally fulfil the requirements as given below. All components
should be of reliable design.

Bolts, Screws, Nuts etc.: All bolts, studs, screws, nuts, and washers should be as per
ISO metric system. Mild steel bolts and nuts should be of the precision cold forged or hot
forged type with machined faces parallel to one another. All bolts and studs which will
be subject to high stress and/or temperature should be of high tensile material with nuts of
appropriate material.

Fitted bolts should be a driving fit in the reamed holes and should have the screwed portion
of a diameter such that it will not be damaged during driving. They should be properly
marked in a conspicuous position to ensure correct assembly at site.

All parts (other than structural steel work) bolted together, should be spot faced on the
back to ensure that nuts and bolt heads bed down satisfactorily. Mild steel nuts and bolts
should be zinc or cadmium plated. Stainless steel bolts, nuts, washers and screws should
be used for holding renewable parts in water or when exposed to high humidity.

Seals : Rubber seals should be made of synthetic rubber suitable for particular application
and should be designed in such a manner that they are adjustable, water tight and readily
replaceable. Seals should be manufactured by molding process and not extruded. All
adjusting screws and bolts for securing the seals and seal assembly should be of non-
corrosive stainless steel.

Oils and Lubricants : Different types of oils, lubricants, etc. should be subject to the
written approval of the Engineer. Unless otherwise stated in the Particular Technical
Specifications, the oil or grease for bearings, pressure oil systems, transformers, etc.,
including the necessary quantity for flushing and quantity for first oil change with 20%
extra should be obtained.

2.2.2 Piping, Fittings, Valves and Gates

General : All required piping should be furnished complete with flanges, joints,
expansion joints, gaskets, packing, valves, drains, vents, pipe suspensions, supports, etc.
Flanged joints or connections should be provided only as required for transport,
installation or for dismantling and reassembly. Standard metric flanges and connections
should be used for all pipe works. Adequate clearance should be given to parallel pipes
to allow for easy maintenance without disturbing other lines. All overhead piping
should have a minimum clearance of 2.1 m from operating floors and platforms.

AHEC/MNRE/SHP Standards/E&M Works – Guide for Selection of Auxiliaries for                     Page 7 

SHP up to 25 MW
 All pipes should be supported/restrained/anchored in order to prevent any undue localised
stress and deflection/sagging anywhere along the piping length due to the applied
forces/moments. For the above purpose standard support attachments such as clamps, saddle
plates, braces, angles/cleats, guides etc. and support components such as hangers, rods, turn
buckles, spring boxes etc. should be used.

Materials of Pipes & Fittings : Water, air and drain piping less than 25 mm nominal
bore should be of galvanised heavy grade to IS-1239, Part-I or equivalent standards steel
pipe. Pipes equal to or greater than 25 mm nominal bore should be galvanized heavy
grade to IS-1239, Part I/IS-3589 or equivalent.

Oil piping greater than 25 mm nominal bore should be of seamless high quality steel pipe
conforming to IS 1239 or API-5L GR.B or equivalent grade as per process requirement,
whereas pipes less than 25mm bore should be of stainless steel.

Steel pipes of diameter 100 mm and above for a pressure upto PN 10, may be used in
welded type. The minimum wall thickness of pipes should be the "normal" or "standard"
wall thickness as per applicable standards.

Pipe Work Fabrication: Steel pipe work smaller than 25 NB and for operating pressure
more than PN 10 should be joined by screwed fittings and pipe work for 25 NB and over
should be joined by welded flanges. Pipe work for operating pressure upto PN 10 may be
joined by screwed fittings upto 50 NB size. Tig welding must be used for fabricating pipe
work.

Pipe work Cleaning: Oil pipe work internal bores should be chemically cleaned and
passivated prior to use.. Water, air and drain piping should be blown through with high
pressure air and flushed with water prior to use.

Pressure Testing: All pressure piping should be pressure tested at a pressure 50% greater
than maximum operating pressure after erection and cleaning but before painting at site. The
test pressure should be maintained without loss for half an hour.

Painting: All steel piping should be painted on the exterior to prevent rusting. The paint
treatment should be of the same system as used for the turbine exterior. Colour coding of
pipe work should be adopted as per applicable Indian Standard. Paint damaged during
erection and commissioning should be repaired prior to handing - over the plant.

Protection for Transport and Storage: Oil piping should have a protective coating
applied to prevent corrosion occurring during transport and storage. The ends of the pipe
lengths should be plugged to prevent ingress of water.

Valves & Gates: Generally, valves should be leak-proof in either flow direction
(except for non-return valves) when the nominal pressure is applied. All valves with
design pressures higher than PN 10 and diameters larger than DN 100 should be
workshop-tested for tightness and soundness of materials. Valves should close
clockwise and be provided with position indicators/marks on hand wheel. The drive
units of motor-driven valves should also be provided with hand wheels for manual
operation. To facilitate operation, large valves and gates should be provided with by-
pass lines for pressure balancing, if required. Valves spindles and pins should be of
stainless steel, spindle nuts and bushes of bronze, the body of cast steel. No valve in
cast iron body will be accepted.

AHEC/MNRE/SHP Standards/E&M Works – Guide for Selection of Auxiliaries for                     Page 8 

SHP up to 25 MW
 All pressure reduction valves; safety valves and similar components should be workshop-
tested.

2.2.3 Mechanical Instruments: All mechanical parts of instruments should be

suitably protected against shocks and vibrations, heat, humidity and splash water, etc.
Pressures gauges should be provided with a damping liquid, e.g., glycerin, to compen-
sate vibrations. Pressure gauges without damping means should not be normally
permitted.

Pumps : Materials of the main parts of pumps should be :

− Casing Cast steel

− Impeller stainless steel
− Shaft stainless steel
− Sleeves stainless steel
− Wear rings bronze
− Keys stainless steel
−
The capacity of the driving electric motor should be 15 % higher than the maximum
power required by the pump at any operation point. The overall pump-motor efficiency
for the specified rated head and discharge should not be less than 60%. The pumps
should withstand corrosion and wear by abrasive matters within reasonable limits. Shafts
sealed by packing glands should be fitted with sleeves. Pump seals should be replaceable
without extensive dismantling of the pump. Leakage water should be directed to suitable
drainage facilities.

Miscellaneous Metalwork

Except where otherwise indicated elsewhere in the Particular Technical Specifications,

the Contractor should supply the following:

• All platforms, ladders, guards, handrails of tubular construction and hatch

covers necessary for easy and safe access to Works.
• Safety guards at each point where normal access provision would permit
personnel to come within reach of any moving equipment.
• All covers for pipe work, cable trenches and access hatches, required for
completing the floors around and over the equipment will be supplied and
installed. Unless otherwise approved, floor chequered plates should be of an
angular pattern.

3. ELECTRICAL AUXILIRIES

3.1 Auxiliary Power Supply System

3.1.1 General

Station service power supply system capacity includes supply of power to following

• Unit and station auxiliaries i.e. governor oil pumps, cooling water pumps,
transformer cooling fan, sump pumps, air compressors, battery chargers,
ventilation and air conditioning equipment
• Dam/weir byepass etc. auxiliaries

AHEC/MNRE/SHP Standards/E&M Works – Guide for Selection of Auxiliaries for                     Page 9 

SHP up to 25 MW
 • Lighting of the project and adjacent area
• Colony lighting (if required)
• Uninterrupted power supply

3.1.2 Design Criteria

a) Station service power supply system should have a minimum of two full capacity
redundant power sources
b) Service should not be interrupted by system disturbances.
c) Service continuity be maintained under all conditions.
d) There should be provision for starting the station from cold.
e) First cost, maintenance cost and operating cost should be low.
f) Safety of personnel, simplicity of operation and ease of maintenance be ensured.
g) Provision of black start in emergency
h) Source of Power

• Transformer connected to generator leads

• Main station buses through house transformers
• Direct supply from another station
• House station service generator – Diesel generator for black start in emergency

3.1.3 Auxiliary Power Supply System for SHP Interconnected with the Grid

The design of the auxiliary power supply system of small hydroelectric power plants may
vary significantly depending on consideration of a combination of factors including, but
not limited to :

a) The degree of importance of the generator or generators

b) The number of main transformer to be installed
c) The number and availability of power sources to the plant
d) The availability of necessary electrical and mechanical auxiliary systems

3.1.4 Auxiliary Power Supply System for SHP

A Single Power Supply System : This is recommended for a single unit plant non-
critical plant whose loss of generation can be tolerated, and which would suffer no harm
due to loss of auxiliary systems. A typical single line diagram is shown in figure 3.1.
When the unit is feeding power into the power system, it also feeds plant ac station
service. If the generator in Fig. 3.1 is out of service, station service can be fed from the
transmission line. If the main transformer is out of service, station service may be fed
from the generator, with the isolating switch open, provided the generator is synchronous
type and hydraulic conditions permit stable operation at low loads.

The flexibility for restoring auxiliary ac supply can be of prime importance if there are
critical loads that must be energized quickly. Examples of such loads are sump pump,
spillway gates, and headgate motors. The need for rapid restoration of station service
power may justify a stand-by source such as a small diesel engine generator or a separate
feed from the utility.

Multiple Auxiliary Supply System : In the case of plants with multiple auxiliary
supplies, the single line diagram would typically be as in fig.3.2 (Mukerain Stage-2).
Emergency power supply is obtained from grid s/s at Dasuya. Figure 3.3 shows Auxiliary
power supply for Dhoba SHP in Bihar, where two units are shown feeding station service.
The second supply could alternatively be obtained from a separate utility connection
AHEC/MNRE/SHP Standards/E&M Works – Guide for Selection of Auxiliaries for                     Page 10 
SHP up to 25 MW
 rather than a second generator. Another possibility for station service supply is by
provision of an emergency generator connected to the plants distribution system. The
station service supply configuration will depend on the degree of reliability of station.

For Micro hydel auxiliary power refers Micro hydel standard issued by AHEC.

3.1.5 Selection of Auxiliary power AC Switchgear and Control Gear

3.1.5.1 General Design Consideration

The electrical items of Works of the auxiliary systems including mechanical

installations should generally fulfil the requirements as given in Para 2. All components
should be of reliable design.

The power supply and control cables should be laid up to the common terminal blocks.
Various control/protection devices and instruments should be uniform, interchangeable
and connected as per system requirement.
TO TRANS LINE

MAIN
TRANSFORMER

SWITCH OR
SOLID LINK

STATION
SERVICE MAIN
BREAKER
STATION SERVICE BUS

FUSE DISC 5W
STATION
SERVICE
TRANSFORMER
GENERATOR
BREAKER

SURGE STATION SERVICE FEEDERS

ARRESTOR

GENERATOR

Fig. 3.1 Typical System for Single Unit/Mini SHP

AHEC/MNRE/SHP Standards/E&M Works – Guide for Selection of Auxiliaries for                     Page 11 

SHP up to 25 MW
 11 kV LIN E
FR OM DASU YA
GR ID S/S
LEGEND
11-3

TR IPS 11-1 TRIPS 11-2 MC C B

CT 30/5 TR IPS C T 30/5
D -1, 52-1 & U N IT CT 30/5 D -3, 52-2 & U N IT
5P 10 SPEED N O LOAD 5P 10 11-3 & D 2 5P 10 SPEED N O L OAD
50/51 63 50/51 50/51
63 LIGH TN IN G ARR ESTER
63 500 K VA 11/0415 K V 500 K VA 11/0415 KV 500 KVA 11/0415 K V
UN IT AU X. T/F-1 STATION T/F U N IT AUX. T/F-2 AMMETER
A

KWH ENERGY METER

5P 10 TR IPS 5P 10 TRIPS 5P 10 TR IPS VOLTMETER

D1 D2 D3 V
51/64 51/64 51/64
C T 800/5 C T 800/5 C T 800/5 VOL TAGE SELECTOR
KWH 27B Vs
KWH 27B 3 KWH
3 3
C LASS 1 CLASS 1 C LASS 1 C OMBIN ED OVER CU R R ENT AN D
A 51/64 EAR TH FAU LT R ELAY
A A

OVER C UR R EN T R ELAY W ITH

50/51 IN STAN TAN EOU S ELEMEN T
Vs Vs Vs
B UC H H OL Z RELAY
63
V V V
27B 47 27B UN D ER VOLTAGE R ELAY
D2 D3
D1 TRAND
SEE N OTE 1 47 PHASE SEQU ENC E R ELAY
ELEC TRIC AL
IN TER LOC K ELECTRIC AL
(SEE N OTE 1 & 5) IN TERLOC K H .V. B REAK ER
415 VOLTS BUS (SEE NOTE 1 & 5) L. T. BOARD
D4 D5 11 K V LIN E SW ITCH

D7 D 11
D6 D 10 D 13
SPARE SPAR E C UR R EN T TRAN SFOR MER
D12

CON TR OL TR AN SFOR MER

ELEC TR IC ALLY OPER ATED C IR CU IT

B R EAK ER

ELEC TR IC AL POW ER SW ITC H

IN TER LOC K

SER IES OVER LOAD AN D SH ORT

CIR C U IT TRIP

D8 NOTE
1 BR EAKER S D 1, D2, D 3 SH ALL N OR MALLY B E 'ON '

2 BR EAKER S D 4, D5, D 8 AN D D 9 SH ALL

NOR MALLY BE 'OFF'

3 ELEC TR IC AL IN TER LOC KIN G OF B REAK ER D 1 W ITH

SPAR E SPAR E GEN . H IGH SPARE SPAR E GEN . H IGH D4, D 3 W ITH D 5 SHALL B E PR OVIDED TO AVOID
PR ESSU RE GOV. OIL
COOLIN G GOV. OIL COOLIN G PR ESSU R E PU MPS PAR ALLEL ING OF U N SYN C HR IN IZED SOUR C ES
GEN . CON TR OL PU MP OIL PU MP PU MPS C ON TROL PUMP OIL PU MP
D E-HU MID IFYIN G T/F T/F
MECH ANIC AL 4 ELECTRIC AL INTER LOCK OF B REAK ER D6 AN D D11 W ITH
EQU IPMEN T GEN . GEN . GEN .
SPARE

SPARE
GEN . IN TER LOCK B R EAK ER D 8 SH ALL B E PR OVID ED SO AS TO AVOID
B LOW ER D E- H UMID IFYIN G B LOW ER GEN . PAR ALLELIN G OF UN SYNC H R ON ISED SOU RC ES
SPAC E
HEATER S EQUIPMEN T SPACE
TU R B INE B EARIN G H EATERS
TUR B IN E B EAR IN G 5 W H EN D3 IS OFF D 5 W ILL B E ON W H EN D1 IS OFF D 4
LU BR IC ATIN G LU B R ICATIN G
PU MP W ILL B E ON
C ON TR OL CON TR OL PU MP
POW ER POW ER 6 ALL CIR C U IT B R EAK ER S AR E AIR B R EAK , D R AW OU T TYPE
SUPPL Y SUPPLY AN D FITTED W ITH SER IES OVER LOAD AN D
IN STANTAN IOUS SHOR T C IR C UIT PR OTEC TION
UNIT DISTRIBUTION BOARD-1 UNIT DISTRIBUTION BOARD-2 7 TH E D R AW IN G IS TEN TATIVE ON LY FOR TEND ER
PU R POSE

D9 R EVISION 1 - N OTE
C HAN GES IN IN TERLOC K IN G AND N OTES 2 TO 5

DR AF T IN LET SPARE D RAIN AGE AIR COMPR - A/C AND POW ER SPARE
VEN TILATION
CAN AL TU BE GATE D EW ATER ING PU MP ESSOR
SYSTEM
DR AINAGE OU TLET LIGHTIN G IN LET D RAFT
C AN AL
H OIST LIGH TIN G PUMP TU B E

P/H CRANE
HOIST PU MP B ATTER Y CK T. GATE
P/H CRANE

RAD IAL POW ER POW ER R AD IAL

GATE MOTOR MOTOR C H AR GERS H OIST H OIST
SU PPLY SU PPLY MOTOR GATE
HOIST MOTOR H OIST
DE- W ATER ING
PU MP
C OLONY SW ITC H SW ITC H COLON Y
POW ER YAR D YAR D POW ER
POW ER A/C AN D TR EATED TR EATED POW ER
SU PPLY W ATER SUPPLY
C K T. VEN TILATION W ATER CK T.
SYSTEM PU MP PUMP

STATION SERVICE BOARD

AHEC/MNRE/SHP Standards/E&M Works – Guide for Selection of Auxiliaries for                     Page 12 

SHP up to 25 MW
 Fig. 3.2: Typically Auxiliary Supply System for Multiple SHP

LIGHTNING ARRESTOR

LINE ISOLATOR WITH

EARTHING BLADE

CURRENT TRANSFORMER

1Rx3Cx185sq.mm,3.6kV AL.AR. POTENTIAL TRANSFORMER

XLPE CABLES

100k V A,3.3/0.433k V CIRCUIT BREAKER

STATION
TO SYNCH. PANEL TRANSFORM ER
ELECTRICALLY OPERATED
CIRCUIT BREAKER
5P10,10VA 50/51 64
CT 175/1-1A SURGE CAPACITOR
CL0.5,10VA k Wh As A FUSE
F

Vs V MCCB
DG SET
60k W
MCB

CONTACTOR

5P10,10V A 50/51 64
CT 120/1-1A

CL0.5,10VA k Wh As A

Vs V
G-2 G-2

INTERLOCK ACB
200A 400A,45k A
CONTACTOR

400A,45kA LT BOARD

M CCB

GROUNDING GROUNDING
TRANSFORM ER TRANSFORM ER

UNIT-2 UNIT-2
(SAME AS UNIT-1) (SAME AS UNIT-1)

Fig. 3.3 : Dhoba Mini Hydro Scheme (2 x 1000 kW)

(Auxiliary Power System)

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SHP up to 25 MW
 Ratings of main electrical works as selected or proposed, whether originally specified
or not, should generally include a safety margin of 10%. Short circuit calculations, de-
rating factors, etc. should be carried out and taken into consideration for design.

Short-circuit calculations should be evaluated and every electrical component should

withstand the maximum stresses under fault conditions, for fault levels and durations
obtained under the worst conditions, e.g., upon failure of the corresponding main
protection device and time delayed fault clearing by the back-up protection device.

All Works should be suitable for the prevailing climatic conditions and insensitive to
any signals emitted by wireless communication equipment.

3.1.5.2 Switchgear

The high voltage switchgear in power station for 3.3, 6.6 and 11 kV is almost universally
specified as air-break switchgear. High degree of safety of air-break switchgear, suitable
performance characteristics and high degree of availability combine to make it so
acceptable for the job. The fire fighting equipment can therefore be dispensed with.
Further absence of current chopping reduces the overvoltages in the system and
minimizes outages due to insulation failures. Withdrawable type, cubicle mounted,
solenoid operated from the battery is usually specified to be provided. A total opening of
approx. 5-8 cycles is usually satisfactory for protection of equipment and for maintenance
of system stability under fault conditions.

3.1.6 Auxiliary Transformers

Epoxy cast/resin encapsulated air cooled transformer are recommend. These can be
located inside the powerhouse. Oil filled auxiliary transformer will be required to be
placed in outside switchyard alongwith main transformers requiring long cables; fire
protection arrangements etc. for fire hazards.

Standards

IS: 11171-1985 – Specification for dry type transformers

IEC: 35415– Specification for dry type transformers

3.2 D. C. Auxiliary Power System

3.2.1 General

Direct current system in hydro generating stations and step up sub station is one of the
most crucial electrical system in a hydro plant because it provides power to critical
controls, protective relays and uninterruptiopn power system (UPS) associated with
computers that control plant operation and is provided for following functions.

a) Supply to trip coils and closing coils of switchgear for switching operations.
b) Indication: Indicating lamps, facial, semaphores, alarm and annunciation etc. For
energizing the holding and operating coils in control and interlock schemes, and
in protection schemes.
c) Supervisory control and data acquisition system (SCADA)
d) For power supply to communication equipments
e) Emergency lighting

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SHP up to 25 MW
 f) Generator exciter field flashing – may use rectified station service AC supply
system

The system consists of a storage battery with its associated eliminator type chargers,
providing the stored energy system required to ensure adequate and uninterruptible power
for critical power plant equipment. The battery and battery circuits should be properly
designed, safeguard maintained, and the requirements should be carefully estimated to
ensure adequate battery performance during emergencies.

AC supply from station service or generator leads can be used for this purpose if the cost
of DC system cannot be justified.

3.2.2 Batteries and Battery Chargers

3.2.2.1 Type

Table 3.2.1 list commonly used battery types and their normal expected life, approximate
number of full discharges, ampere-hour range, approximate cost range, frequency of use,
advantages and disadvantages. Latest applicable Indian standard specification mentioned
in the table 3.2.1 and be referred for confirmation.

Type of battery or batteries generally used in hydro generating stations are of the lead-
acid type in vented cells or a sealed cell.

Following types of lead acid batteries are commonly used in power plants.

• Tubular positive plate with pasted negative plate: and

• Plante positive plate with pasted negative plate.

Plante positive plate batteries are costly and preferred for large hydro station above 5 MW
as they have longer life and these cells are suited for applications requiring supply of
large currents for short durations as required in unattended stations whereas the cells with
tubular positive plates are suitable for the supply of smaller currents for medium to long
durations. Use of glass containers is preferable over the other types as these facilitate
checking up of sedimentation, electrolyte level, condition of plates, separators etc.

3.2.3 Standard

a) Plante Cells – IS : 1652-1984

b) Tubular Cells – IS: 1651-1979
c) IS: 8320 – General requirement and method of tests
for lead acid storage batteries.
d) Ni Cd battery specification – IS: 13300 (for air craft batteries)

3.2.4 Construction Features

Each battery should have a static battery charger, rated to fully recharge the battery from a
completely discharged condition in not more than ten (10) hours in boost charging mode.
Each battery charger should be capable of float charging the batteries while supplying at
normal voltage. Voltage regulators shall have following facilities.

(a) Manual selection facility for battery charging mode i.e. whether trickle or boost.

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SHP up to 25 MW
 (b) Automatic and manual control of output voltage and current. Selector switch should
be provided for auto/manual selection. Auto to manual changeover should not result
in any harmful surges.
(c) Effective current limiting feature and filters on both input and output to minimise
harmonics, RFT, EMT etc.
(d) When on automatic control mode during trickle charging, the charger voltage should
remain within 1% of set value for maximum permissible voltage, frequency and
combined voltage and frequency variation on feeding system and dc load variation
from zero to full load.
(e) Degree of protection should be IP:42. For chargers located in air conditioned areas,
same may be IP:31.
(f) The rectifier shall utilise diode/thyristors and heat sinks rated to carry 200% of the
load current continuously. Temperature of heat sink shall not be permitted to exceed
85 deg. C duly considering the maximum charger panel inside temperature.
(g) Rectifier fuse and RC surge suppressor should be provided
(h) Ripple content to be limited to 1% peak to peak.
(i) All inter cell connectors and terminals should be fully insulated/shrouded.

3.2.5 Battery Room

3.2.5.1 SHP Plant above 5 MW

A separate room with lockable doors provides adequate protection against accidental
contact or malicious tampering. The room or area should be ventilated in such a manner
that exhaust air from the room does not enter any other room in the plant. If necessary,
heat should be provided to obtain full rated performance out of the cells. The cells should
be mounted in rows on racks permitting viewing the edges of plates and the bottom of the
cells from one side of the battery. The tops of all cells should preferably be of the same
height above the floor. The height should be convenient for adding water to the cells.
Tiered arrangements of cells should be avoided. Space should be provided permitting
removal of a cell from its row onto a truck without reaching over any other cells. The
lighting fixtures in the room should be of the vapor-proof type, with the local control
switch mounted outside by the entrance to the room. Battery charging equipment and
controls should not be located in the battery room.

3.2.5.2 SHP Plant Upto 5 MW

At plants smaller than 3 MW, a ventilated battery room is not always required except for
a flooded liquid electrolyte (lead acid) battery, because the small ampere-hour size means
that the battery produces a minimal amount of hydrogen gas during charging.
Furthermore, typically only qualified personnel (usually the operators) have access to the
powerhouse. Therefore, a separate battery rooms is not required.

Owners of plants smaller than 5 MW should perform a “hydrogen produced” calculation

to verify whether a ventilated battery room is necessary. Elements of this calculation are:

i) Air volume in the powerhouse

ii) Number of air changes per hour based upon the heating, ventilating, and air
conditioning (HVAC) system design; and
iii) Amount of hydrogen gas released during charging. (This amount is based upon
the
ampere hour size of the battery, the float charging voltage selected, and the type
of battery to be charged)

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SHP up to 25 MW
 This calculation should confirm that, in the worse case scenario, the hydrogen production
of the batteries will be less than 1 percent of the total air volume in the powerhouse.
Normally, a minimum of 3 percent hydrogen by volume is required before any explosive
mixture is possible.

For very small SHP and micro hydel station AC may be used.

3.2.6 Battery Voltage and Number of cells

Rated voltage of the DC control supply for electrical installations can be selected out of
the fairly standardized values of 110, 48 and 24 volts. Higher voltage leads to more
economical configurations as the total load of the DC system, lengths of circuits and
number of DC cables increases. Usually 110 V turn out to be the optimum choice for SHP
above 3 MW capacity. For smaller plant 48 V may be provided. For micro hydels
interconnected with grid –12V UPS system may be sufficient for emergency lighting and
PC.

The voltage of a lead acid cell being 2 volts per cell, the number of cells in the battery
would be half of the rated DC voltage adopted.

A separate battery for communication equipment is normally provided. The choice of

communication battery, voltage has to be made according to voltage rating of the
communication equipment already existing or that to be installed. In the absence of any
precedent 48 volts is normally found to be optimum for most installations.

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SHP up to 25 MW
 Table 3.2.1 Percentage Commonly Used Battery Types in Hydroelectric Plants

Sl Type Normal Approximat Ampere Hour Relative Advantages Disadvantages Remarks

No. Expecte e Number of capacity Cost of
d Life1 full range in SHP battery
Years discharge
Flooded Liquid Electrolytic
1. Lead Acid Flat 1000 – 1200 6 -4000 Base Capable of providing a Frequent water addition, Only recommended
pasted cells significant number of full high hydrogen emission, for SHP below 5 MW
IS: 6304 discharges over 20-year life needs monthly in separate ventilated
equalizing charge rooms
2. Lead Acid 50 – 100 6-4 1.2 x Low water consumption, low Recommended for
Tubular base hydrogen emission, no SHP upto 5 MW
IS: 1651 See monthly equalizing charge
3. Lead Acid Plante note -1 1000 – 1200 2.0 x Can function at room Recommended for
IS: 1652 base temperature higher than the SHP above 5 MW
standard 250C
4. Nickel Cadmium 1200 2.5 – 1000 3 x base Low maintenance; longer life, Higher cost and at 1.2 Recommended for
Alkaline (NI- IS: 13300 performs well in low volts cell, requires a SHP at high altitudes
CAD) covers only 24 temperatures, not damaged by greater quantity of cells and small unattended
IS: 13300 V and upto 40 freezing, low self-discharge to attain a rating of 125 SHP
AH batteries rate, will not deteriorate in volt DC. Little historic
discharged condition, no operation experience
release of corrosive fumes
5. Nickel Iron 5000 – 2.5 - 500 3 x base Performs well in low Not used in
Alkaline 10,000 temperatures, not damaged by powerhouse; most
freezing, low self-discharge common use is motive
rate, will not deteriorate in power application
discharged condition, no
Sealed maintenance free
release of corrosive fumes
batteries
6. Lead acid/special 300 200 – 4000 1.4 x Does not require water Little historic May in use
alloy base addition, no hydrogen experience in powerhouse below 5
Sealed emission powerhouses MW when separate
maintenance free room is not made
batteries
1
-Lifetime estimates can vary substantially depending on cell/plate construction

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 3.2.7 One or Two Battery System

Selection of a one-or two – battery system will depend not only on comparative costs of different
battery sizes and combinations, including circuits and charging facilities, but consideration of
maximum dependability, performance, and flexibility during periods of plant expansion.

3.2.8 D.C. Loads Classification

Recommended procedure for determining battery rating is outlined in following standards /

publications.

a) CBI & P Technical Report No. 79 entitled specification of sub station battery, charging
equipment and DC switchyard.
b) IEEE 485 – IEEE recommend practice for sizing lead acid batteries

These standard classify the system load into following categories.

i) Momentary loads
• Continuous load
• Emergency light load: Duration of light load may be required for duration of 1 –

12 hours. Modern computerized control system require uninterruptible power supply (UPS)
system and emergency power is supplied from these UPS system (see Para 3.5).

For hydro stations the following durations are assumed for computation of battery capacity (as
per CBI &P Manual) for attended stations.

Where standby battery is Where standby battery is

provided not provided
Steady and continuous load 3 hours 6 hours
Emergency light loads 1 hours 2 hours

For unattended stations duration may be suitable increased.

3.2.9 Battery Accessory are Generally as follows:

i) Cell testing voltmeter

ii) Hydrometer
iii) Thermometer
iv) Acid jugs for topping up of the cell
v) Rubber gloves
vi) Rubber apron
vii) Tool box
viii) Battery log books
ix) Bridging clamps for cutting out individual cell in the event of defect
x) Protective goggles

3.2.10 Safety Consideration

Standard rack performance criteria should be evaluated to ensure compliance with plant
requirements. Seismic considerations and other factors may dictate the need for special racks and
special anchoring needs.

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SHP up to 25 MW
 3.2.11 Battery charging Equipment

Static charger sets are preferred for battery charging service. Two sets should be provided so one
will always be available. The charger capacity should be sufficient for float operation as well as
boost charging capability.

3.2.12 Float Operation Term

This term applies to the method of operation in which battery remains connected to the load and
the charger continuously. Voltage of charger is substantially constant and just higher than open
circuit voltage of the battery. To keep the battery in a fully charged condition, the charger sends
through the battery charging current of a few mili amperes at a voltage which is sufficient to
compensate for local action and leakage losses. The magnitudes of the charging current and the
voltage should be recommended by the battery suppliers. The charger also supplies the entire DC
load under normal condition.

3.2.13 DC Switchgear

For reliability and flexibility, a dc distribution board with several outlets is preferable as this
board provides connection of battery and charger to the various load circuits. Each circuit beaker
is protected by a fuse and controlled by a switch or circuit breaker which should be suitable for
making and breaking inductive loads at voltages upto the maximum floating voltage and not
merely the rated voltage. Cartridge fuses are recommended to be used as back up even when
circuit breakers with protective releases are installed. The breakers and fuses should be carefully
chosen from the consideration of recovery voltage after interruption of faults. The fuses where
used should be properly coordinated to ensure operation even for the farthest faults and each
circuit should be properly segregated. The dc switchgear should have short circuit rating equal to
about 10 times the maximum rated current if the associated equipment, without the current
limiting feature on, and about 1.1 times, with the current timing feature ‘on’. However, with the
available standard dc switchgear usually having much higher short circuit ratings (4 kA), the
above requirement poses no problem.

3.2.14 A typical single line diagram with single battery system is shown in Fig. 3.3 which can be
used on smaller unit. Fused disconnecting switch may be used instead of circuit beakers. For
larger unit above 5 MW 2 batteries may be provided.

3.3 Uninterruptible Power Supply System (UPS)

Uninterruptible Power Supply System in SHP are required to provide electricity for
computerized control and data acquisition system, communication system etc. when normal plant
power system fail. As per IEEE: 944 – Recommended practice for application and testing of
uninterruptible power supplies for power generating stations; UPS systems are used to provide
electricity for essential loads when normal plant power system fails. Loss of power to such loads
as the plant computers, communication networks, security system and emergency lights.

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SHP up to 25 MW
 DC BATTERY (48/110V)

FUSE
FLOATED BOOST
CHARGER

AC FROM
STATION
SERVICE

D.C. BUS
TO COMPUTER
CONTROL SYSTEM

FEEDER
MCB BREAKER TO
EMERGENCY
SUPPLY

UPS SYSTEM

D.C. FEEDERS

AC-220V FROM
STATION SERVICE

Fig. 3.3 Typical DC system for SHP upto 3000 kW

UPS system is defined as one designed to automatically provide power without delay or transient
during any period when normal power supply is in capable of performing acceptably.

On line static (solid state) UPS system with sine wave output are required. An off line system
take about 25 ms for transfer to DC which may impair critical control by computer system.
Normal range of sizes for hydro plant upto 25 MW uninterruptible power supplies is given
below:

Plat size (MW) UPS size (kVA) Remarks

5 - 25 MW 1 – 5 kVA
0.1 to 5 MW 1 or less kVA
Micro Hydel i) Electronic load i) Use power line conditioner (power
controller (ELC) may use supply system)
its own converter and ii) May use standard single PC UPS
conditioned Dc supply
system from UPS or
otherwise
ii) If remote controlled PC
may be used with its own
UPS

3.4 Power and Control Cables

3.4.1 Power and Control Cables

Standards

IEC: 60502 Extruded solid dielectric insulated power cables for rated voltages from
1.00 kV up to 30 kV.
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SHP up to 25 MW
 IEC: 60331 Fire resisting characteristics of electric cables.

IS: 1554 (Part-1) PVC insulated (heavy-duty) electric cables for working -1988
voltage up to and including 1100 V.
IS: 1554 (Part-11) PVC insulated (heavy-duty) electric cables for working 1988
voltage from 3.3kV up to and including 11 kV.
IS: 7098(Part-11) Cross-linked polyethylene insulated PVC sheathed cables 1985
for working voltages from 3.3 KV up to and including 33 kV.
IS: 3961 Recommended current ratings for cables.
IS: 8130 -1984 Conductors for insulated electric cables and flexible cords.
IS: 5831- 1984 PVC insulation and sheath of electric cables.

3.4.2 Duty Requirements/Design Criteria

A. The cables should be suitable for installation in a tropical monsoon area having a hot
humid climate. The reference ambient temperature to be considered for the purpose of
this specification is 500C (depend upon site).
B. The derating factor for the various conditions of installation including the following
should be considered while choosing the conductor size:

• Maximum ambient air temperature.

• Maximum ground temperature,
• Depth of laying wherever applicable
• Grouping of cables.

C. The allowable voltage drop at terminals of the connected equipment should be maximum
1.0% at full load for choosing the conductor size. In case of squirrel cage induction
motors, the cable size should be so chosen that the motor terminal" voltage does not fall
below 90% of the rated voltage, at the time of starting, if the motor is started with a
D.O.L. starter.
D. The maximum continuous conductor temperature and the maximum allowable conductor
temperature during short circuit are taken as 700C and 1600C respectively in case of PVC
insulated cables and 900C and 2500C respectively in case of XLPE insulated cables.
E. The minimum size of all 11 kV grade power cables and 415 V power cables connected to
circuit breakers are chosen taking into account the following factors.

• Fault level due to system contribution.

• Fault contribution of running motors.
• Expected time up to which motor contribution to fault current persists.
• Maximum time for fault clearance (i.e. operating time of the backup protection relay
plus the time of operation of the circuit breaker.)
• Full load current of the circuit.

G. The cables should in general comply with the requirements of the latest revision of
IS:7098 (part-11) for the 11 kV grade XLPE insulated cables and IS-1554 (part-1) for the
L.T. PVC insulated power and control cables or the relevant IEC Standard. The design,
manufacture, installation, testing and performance of the cables, should comply with the
latest revisions of IS/IEC/ NEMA/ASTM standard.

H. For 11 kV cables, conductor screen and insulation screen should both be extruded semi-
conducting compound and should be applied along with XLPE insulation in a single
operation by triple extrusion process. Method of curing for 11 kV cables should “Dry
curing/gas curing/steam curing". 11 kV cables should provided with copper metallic screen

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SHP up to 25 MW
 suitable for carrying earth fault current. For single core armoured cables, the armouring
should constitute the metallic part of screening. For 11 kV cables, insulation should be
XLPE, while for other cables it should be PVC.

I. Calculations should be made for selection of cables showing type of cable and conductor
size selected voltage drop, temperature rise, under rated load and short-circuit conditions,
to meet the design requirement.

J. Cable schedule showing the various interconnections and also the routing diagram giving
details of various openings are requirement to be prepared.

K. For the sake of reliability, it is required to use only copper conductor cables for the
following services :

• Excitation systems (Single Core)

• Battery and battery chargers (Single Core)
• Inverters
• All control systems
l. As far as feasible, separate cables should be provided for circuit of different plant and
auxiliaries, for circuits of different voltages, and for circuits used separately. To the
extent feasible Power, control and instrumentation circuits should invariably be taken
through different routes, which should not be laid together on the same cable tray,
otherwise necessary measures should be implemented to avoid the undesirable effects.

3.4.3 Range Of Cables

i. Generator- Generator transformer/ Bus Bar connections (used in small hydro plants) should
be by armoured power cables of copper conductors with unearthed grade EPR insulation
Non PVC jacket HD – HOFR (high density, heat, oil and flame retardant.

ii. 11KV system - Power cable

The cable should be 11 kV grade, heavy duty, stranded, aluminium conductor, XLPE
insulated, provided with conductor screening and insulation screening, galvanised steel
wire/strip armoured, flame retardant low smoke (FRLS) extruded PVC of type ST 2 outer
sheathed.

iii. 415 V System

The cable should be 1.1 kV grade, heavy duty, stranded aluminium conductor, PVC type.
An insulated galvanised steel wire/strip armoured, flame retardent low smoke (FRLS)
extruded PVC of type ST1 outer sheathed. Cables may be either single or multi-core or
both.

iv. Control cables

The cable should he 1.1 kV grade, heavy duty, stranded copper conductor, PVC type-A
insulated galvanised steel wire/strip armoured, flame retardant low smoke (FRLS) extruded
PVC of type- ST1 outers, sheathed Cables may be multi-core; depending upon the circuit
requirements or both.
Size of control cables should not be smaller then:

a. Control circuits 2.5 mm 2

b. PT circuits for energy measurement 2.5 mm 2
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SHP up to 25 MW
 c. CT circuits 2.5 mm 2
v. Co-Axial Cable
Coaxial cable should be steel armoured and should be FRLS type. The cable should have
braided tinned copper conductor. The capacitance of the cable be low so as to minimise
attenuation in the carrier in the carrier frequency range. The impedance of the cable should
be so as to match with the output impedance of the terminals and secondary impedance of the
coupling units. The cable should be insulated to withstand a test voltage of 4 kV. Following
type of H.F. cables are generally used.
1. Co-axial H.F. cable with 75 ohms impedance (unbalanced)
2. Test voltage in KV – 4 KV RMS for 1 minute
3. Size of conductor – 7 strands/0.4mm
The maximum attenuation at various frequencies is generally as follows
Frequency in KHZ Attenuation in db/km
60 1.4
300 3.3
500 4.7
3.4.4 Cabling
Scope

The complete cable support system should enable proper laying of all power, control,
instrumentation and telephone cables, and should provide necessary mechanical protection,
ventilation and segregation for them. All hardware and anchoring arrangement should be provided.
All steel members should be hot dip galvanised.

Cabling from powerhouse to hydro-mechanical equipment e.g. intake and draft tube gates and gates
for power & control from power house. Power and control panels to control panels of hydro
mechanical equipment should be properly provided.

Design

Detailed design and calculation should be carried out.

General requirements

No sub zero level cable vault/trenches should be provided below control building/switchgear rooms
in main plant and switchyard areas.
Interplant cabling for main routes should be laid along overhead trestles/duct banks/directly buried.
However, for tap-offs, same can be through shouldow trenches. Directly buried cable, if essential,
should not have concentration of more than four (4) cables. Cables in switchyard area from main
plant to switchyard control room are laid in duct bank/cable trenches. In switchyard area, cables are
laid in RCC concrete trenches.

Cable entry from outdoor underground/cable routes to the buildings, if any should be above the
finished floor level inside the building. PCC flooring of built up trenches should be sloped for
effective drainage with sump pits and sump pumps.

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SHP up to 25 MW
 Cable trays, support system and pipes.

a) support system for cable Prefabricated out of sheet steel and fully galvanised flexible type
trays consisting of channels, cantilever arms and associated brackets &
hardware, installed at site by bolting or clamping. These should be
rigid enough to withstand max. possible loads during and after
installation.
b) Type of cable trays Cable trap for power cables are perforated. Separate trays are
provided for control instrumentation cables.
c) Material of cable trays Rolled mild steel, min. 2 mm thick for trays and 3 mm thick for
coupler plate.
d) Finish of cable trays Hot tip galvanised.
e) Duct banks (if provided) Heavy duty GI pipes/heavy duty PE pipes (10% spare of each size,
subject to min 1) with suitable water-proof manholes. For corrosive
areas, pipes should have anti-corrosion coating both inside &
outside.
f) Pipe size Suitable with 40% fill criteria
Junction and Pull boxes Hot dip galvanised sheet steel of 2 mm thickness.
Cable glands Nickelchromium plated brass, heavy duty, single compression type
for unarmored, and double compression type for armoured cables
conforming to BS: 6121.
Cable lugs Solderless tinned copper crimping type. For HT cables, lugs should
be as per DIN 46329/IS
HT cable terminations and Proven design and type tested as per VDE 0278. Elastimold or
joints equivalent fully insulated moulded terminations are preferred.
Cable Laying
a) Identification tags for To be provided at all terminations, on both sides of wall or floor
cables crossing, on each conduit/duct/pipe entry/exit, and at every 20 m in
cable trench/tray or buried run.
b) Cable tray numbering To be provided at every 10 m and at each end of cable way &
branch connection.
c) Joints Joints for less than 250 m run of cable should not be permitted.
d) Buried cable protection With concrete slabs; Route markers at every 20 m along the route
& at every bend.
e) Road crossings Cables to pass through buried RCC hume pipes.
f) Transformer yard Handling RCC trenches to be filled with sand after cable laying
area
g) Separation At least 300 mm between HT power & LT power cables, LT
power & LT control/instrumentation cables.
h) Segregation All cables associated with the unit should be segregated from

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SHP up to 25 MW
 cables of other units. Interplant cables of station auxiliaries and unit
critical drives should be segregated in such a way that not more
than half of the drives are lost in case of single incident of fire.
Power and control cables for ac drives and corresponding
emergency ac or dc drives should laid in segregated routes. Cable
routes for one set of auxiliaries of same unit should be segregated
from the other set. Segregation means physical isolation to prevent
fire jumping or minimum one hour fire rating.

In switchyard, control cables of each bay should be laid on separate

racks/trays.
i) Cable clamping To be suitably clamped/tied to the tray; For cables in trefoil
formation, trefoil clamps as provided required.
j) Fire protection Fire proof cable penetration seals rated for one hour when cable
passes through walls and/or floors. This can be by suitable block
system using individual blocks with suitable framework or by
silicon RTV foaming system. In case foaming system is offered,
damming board, if used, should not be considered for fire rating
criteria. Any of the system used should be of proven type as per
BS: 476 (Part-8) or equivalent standard.

A. Cables should be laid on overhead cable trays and supports, pulled through conduits/GI
pipes and on racks in built up cable trenches and vertical race ways and clamped with
aluminium clamps on walls, ceiling and structures and may be directly buried in ground.

B. Cable laying should include termination of power and control cables (i.e on both ends of
the cables), at equipment terminals, switchgear, control panels etc. All electrical
equipments after installation are completed with cable terminal boxes, cables glands,
cable trays, lugs and terminal blocks.

C. All power and control cables are provided with aluminium tag of an approved type,
bearing cable reference. Cable routing is done in such way that cables are accessible for
any maintenance and for easy identification. Power and control cables are laid in
separate cable racks/trays, power cables being on upper most racks/trays. Asbestos sheets
are laid beneath power cable where they are running over control cables

D. The racks/trays, in general, are supported at a distance of 1500 mm on horizontal and

vertical run.

E. Straight through jointing of cables is avoided. Terminations is done by crimping.

Termination kits for the 11kV XLPE insulated cables are heat shrinkable polymeric or
tapex type.

F. Buried cables are avoided as far as possible but if necessary it is covered with alternate
layer of bricks and sand for mechanical protection. Steel markers are provided at every
20 meters along the cable route.

H. All cables laid on trays/racks are neatly dressed up and clamped/tied to the tray/rack.
Suitable Trefoil clamps are provided for single core cables.

Galvanising

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 All cable trays and their fittings are hot dip galvanised after fabrication according to IS: 2629
(1968) or relevant IEC. The galvanising should be uniform, clean, smooth, continuous and free
from acid spots.
Support and supporting structures

Angles, flats, channels, hangers, brackets clamps, nuts, bolts and other anchorage material are
used for the installation of cables, cable trays, race ways and conduits. All steel members are
suitably treated and galvanised or painted with 2 coats of approved paint.

3.5 Lighting System

3.5.1 General Requirements

A comprehensive illumination system should be provided in the entire project i.e. all areas within the
plant boundary. The system should include lighting fixtures, distribution boards, lighting panels,
junction boxes, lighting poles, receptacles, switchboards, cables and wires, conduits, poles and
masts, etc. The system should cover all interior and exterior lighting such as area lighting, yard
lighting, street lighting, security lighting, etc.

3.5.2 Standards

IS : 3646 Code of Practice for interior illumination (illumination glare index)

IS : 694 Wires
IS : 732 Wiring installation conditions
IS : 9537

3.5.3 Illumination Design Criteria

3.5.3.1 General

The illumination system should be designed on basis of best engineering practice to facilitate normal
operation and maintenance activities as per IS: 3646 part-II and should ensure uniform, reliable,
aesthetically pleasing, glare free illumination. The design should prevent glare/luminous patch seen
on VDU screens, when viewed from an angle.
Table 3.5.3.1 gives the recommended values for different parts of power house and switchyard.
Table 3.5.3.1: Recommended Illuminator Values
SI. No. Particulars Average illumination level Limiting Glare Index
'Lux'
1. Control rooms:
Vertical control 200 to 300 19
panels 150 19
Rear of control panels 300 19
Control desks 150 25
2. Battery room 100 -
3. Carrier room 300 -
4. Offices and reception 300 19
5. Cloak rooms 100 -
6. Workshop/Repair bay 300 25
7. Test room 450 19
8. Outdoor switchyard 20 -
9. Stairs 100 -
10 Corridors 70 16
11 Approach roads 20 -
12 Pathways 20 -

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 13 Car parks 20 -
14 Conference room 300 19
15 Store room 100 -
16 Cable gallery/floor 70 -
17 AC plant/DG set 150 -

Out door switchyard average illumination level shall be 50 lux on main equipment and 20 lux on balance
area of switchyard. In the out door switchyard, the area covered by transformer/reactor should have 50 lux.

3.5.3.2 The lighting system of a particular area whether outdoor or indoor should be designed in
such a way that uniform illumination is achieved. As far as possible any dark spots should be
avoided. This requires careful placing of the luminaries, selection of proper mounting heights and
provision of sockets in the marshalling kiosks and mechanism boxes of circuit breakers/disconnect
switches for providing supplementary lighting wherever required. In outdoor switchyards, only the
equipment/bus bar areas are illuminated. In outdoor area, luminaries should be directed as far as
possible towards transformers, circuit breakers/disconnect switches, their mechanism boxes etc.,
where some operations may be necessary during emergency at night.

3.5.3.3 There are several classifications of the types of lighting such as direct, indirect, semi-
indirect, diffusion, etc., The types of lighting or the combinations should be so chosen as would
provide adequate level of glare-free illumination without creating undesirable shadows.

3.5.3.4 Direct lighting system is the most commonly used and it employs open dispersive reflectors,
silver glass reflectors and angle reflectors. The simplest form of general diffusion fitting is the plain
sphere of opal glass. The spherical form may be modified and any form, which the designer can
think of may be used. The efficiency of the general diffusion fitting depends partly on shape but
much more on the properties of the diffusing material used.

3.5.3.5 The choice of lamps, i.e., incandescent, fluorescent, mercury vapour, sodium vapour
halogen etc., depends mainly on the nature of work, the number of hour of utilization annually, the
cost of energy and the power available for illumination. Table 3.2 gives different types of lamps and
fittings that may be used in different area of a substation.

3.5.3.6 Flood light fittings are in essence, projectors with parabolic reflectors. There are two types
of floodlights: the wide beam type and the narrow beam type. Wide beam type is suitable where
accurate control is not necessary and the light is projected only over a short distance. The harrow
beam type is used where light is required to be projected over longer distances.

3.5.3.7 The foremost criterion in the design of illumination system of indoor area such as control
room, workshop, repair bay, offices, etc., is that illumination at the working height throughout the
area should be as uniform as possible so as to avoid eye fatigue. In practice, complete uniformity of
illumination is difficult to achieve and a ratio of the minimum intensity to the maximum equal to
about 70 percent is usually nsidered acceptable.

3.5.3.8 Energy conservation requirement. has to be kept in view while selecting type of lamp and
type of fitting. While designing the lux level requirement Utilization coefficient factor may be
considered to take care effect of dust, pollution etc. on reflectors used in the lighting fixtures.

The night time lighting of exterior areas is necessitated by operational requirement, security or
decorative purposes or a combination of these. It is used for illuminating outdoor switchyards
transformer yards, approach roads to substations, etc., Use of flood lights has been in practice for
illumination of switchyards. However, floor lights generally cause glare, if not properly positioned
and mounted at proper heights. As the lumen output of mercury/sodium vapour lamps is quite
appreciable as compared to incandescent lamps, flood light units having mercury/sodium vapour

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 lamps with medium and wide angle coverage, mounted at suitable heights are preferred. If the floor
light is mounted at a height of 6 to 10m it would be away from the normal vision angle (8°) of a man
approaching it and therefore, there would be no problem of glare. If the design of the flood lighting
is followed in an orderly fashion, it is easy to obtain uniform illumination in the outdoor switchyard.
The spillover light from flood lights provided in the switchyard is generally sufficient for fence
lighting. Separate fence lighting is provided only in exceptional cases. Light fittings in the
switchyards are mounted on substation structure/lighting masts. Typical lamps and fittings generally
provided in some identified areas are given in Table 3.5.3.2
Table 3..5.3.2 : Typical Lamps & Fittings in Some Identified Areas

SI. Particulars of area Type of lamps Type of fittings

1. Unloading-cum-repair bay Mercury vapour sodium High bay
2. Store rooms, workshops Fluorescent Industrial
3. Control room, offices carrier Fluorescent Decorative
4. Battery room Fluorescent Acid proof, Industrial
5. Compressor room etc., Fluorescent Industrial
6. External lighting on building Mercury vapour sodium Water tight flood light
7. Outdoor switchyard Mercury vapour sodium Water tight flood light
vapour
8. Fence lighting Mercury vapour sodium Post type water tight, flood
vapour light
9. Roads Mercury vapour sodium Post type water tight
vapour street light fittings

3.5.3.9 The purpose of street lighting in substations is to promote safety and convenience on the
approach roads, service roads and side walls inside switchyard, etc., The aim should be to provide
conditions of visibility adequate for accurate, certain and comfortable seeing.

3.5.4 Emergency Supply

Power supply should be fed from 415/240 V normal ac power supply, station service board, and
UPS system for emergency lighting. Lighting panels should be located at different convenient
locations for feeding various circuits. These panels should be robut in construction with lockable
arrangements and MCB for different circuits.

Emergency lighting should be provided in following areas :

a) Generator room - 20 lux

b) Operating floors of turbine hall - 20 lux
c) Switchgear room - 15 lux (min. one lighting fixture
between two rows of switchgear)
d) Control and relay room - 50 lux with one power 5 Amps
e) Cable spreader room - at least 10% of illumination (min. one
lighting fixture at convenient location.)
f) Battery room - at least 10% of illumination
g) Exit points and stair cases - One light fixture
h) All other strategic locations for safe personnel movement during any emergency.

DC lighting should come on automatically on failure of normal ac supply. In off-site areas/buildings

dc lighting is to be provided through self-contained 4-hour duration fixtures located strategically.

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 Lighting panels, fixtures, receptacles, poles, masts, distribution boards, switch boxes, conduits,
junction boxes etc. should be property installed and earthed.

All outdoor fixtures should be weather proof type. Fluorescent fixtures, installed in other than
control room areas should have electronic ballasts. For control rooms, the ballasts should be copper
wound inductive, heavy duty type, filled with thermo-setting insulating moisture repellent polyester.

All luminaries and their accessories and components should be of the type readily replaceable by the
available Indian makes. All fixtures and accessories should be of reputed make and non-corrosive
type. Acrylic covers/louvres should be of non-yellowing type.

The constructional features of lighting distribution boards should be similar to AC/Dc distribution
boards described elsewhere. Outgoing circuits in PLS should be provided with MCBs of adequate
ratings.

Wiring should be by multi-stranded PVC insulated colour code cable laid in GI conduits. Wiring for
lighting circuits of ac, and dc systems should be run in separate conduits throughout. Minimum size
of the wire should not be less than 1.5 sq.mm copper. Wire should conform to IS: 694 and wiring
installation should be as per IS: 732.

Conduits should be of heavy duty type, hot dip galvanised steel conforming to IS: 9537. In corrosive
areas, conduits should have additional suitable epoxy coating.

At least one 5/15A, 240 V universal socket outlet should be provided in offices, stores, cabins, etc.
15A 240 V ac industrial type receptacles should be provided strategically in all other areas. All these
receptacles should be 3 pin type and controlled with a switch. Suitable numbers of 63 A, 3 phase,
415 V ac industrial type receptacles with control switches should be provided for the entire plant for
welding purposes, particularly near all major equipment and at an average distance of 15 m. At least
one 63 A receptacle should be provided in each off-site building.

Suitable number of ceiling fans in areas not covered by air-conditioning and ventilation system
should be provided.

Street lighting should be with swaged/steeped tubular steel poles of swan new construction. The
poles should be coated with anti-corrosive treatment and paint.

Area lighting should be with suitable lighting masts. Masts of adequate height should have lattice
structure with ladder, cage and top platform. Alternatively they should have lantern carriage of
raise/lower type with electrical winch provided inside the tubular mast.

3.5.5 Illumination Levels And Type Of Fixtures And Luminaries

Location Average Type of Fixture

Illumination
level (Lux)

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 a) Turbine Hall Operating floor 200 HPSV high/medium bay
Industrial trough type
fluorescent
b) Switchgear rooms 200 Mirror optics with anti-
glare feature
c) Control room, computer room 300 Decorative mirror optics
type
d) Offices, conference rooms etc. 300 -Do-

e) Battery rooms 100 Totally enclosed corrosion

resistant / vapour proof.
HPSV flood light, weather
f) Switchyard 10(general) proof
50 (on equip.) HPSV medium
g) Compressor room, pump house, etc. 150 bay/industrial trough type
fluorescent
h) Turbine, auxiliaries like OPU etc. Flame proof fluorescent
150 fixtures suitable for
hazardous area
i) Cable galleries Industrial trough type
50 fluorescent
j) Street lighting roads HPSV street lights
20
k) Outdoor storage handling HPSV flood light, weather
20 proof.
l)Permanent stores Industrial trough type
150 fluorescent
m) Workshop, general work bench Mirror optics fluorescent
150
n) Laboratory - General Corrosion resistant, vapour
-Analysis area 150 proof fluorescent
o) Garage/Car parking 300 Industrial trough type
70 fluorescent

3.6 Grounding System and Lightning Protection

3.6.1 Grounding System

Earthing system consisiting of ground mat and equipment earthing. The grounding conductor
consists of galvanised mild steel trips for ground network and mild steel rounds for ground rods and
shall be designed as per IS: 3043 and IEEE: 80. Earthing system network/earthmat shall be
interconnected mesh of mild steel rods buried in ground in the plant. All off-site areas shall be
interconnected together by minimum two parallel conductors.

Enclosures of all electrical equipment as well as all cabinets/boxes/panels/etc. should be earthed by

two separate and distinct earth connections. Metallic pipes, conduits, cable tray section, etc. should
be bonded to ensure electrical continuity and earthed at regular intervals as well as at both ends.
Metallic conduits, pipes, etc. should not be used as earth continuity conductor. All hinged doors
should be earthed by flexible braids of adequate size.

All steel structures should be duly earthed. Metallic sheaths and armour of all multicore cables
should also be earthed at both equipment and switchgear end.

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 Earthing conductor should be buried at least 2000 mm outside the fence of electrical installations.
Every alternate post of the fences and all gates should be connected to earthing grid by one lead.
Earthing conductor embedded in the concrete floor should have at least 50 mm concrete cover.

Earthing connections with equipment earthing pads should be bolted type with at least two bolts, and
joint surfaces should be galvanised. The connections should be painted with anti-corrosive paint
after testing and checking.

Neutral of power transformers should be directly connected to two rod electrodes in treated earth
pits, which in turn should be connected to station earthling grid.

The earthing terminal of surge arresters and voltage transformers, and lightning protection down
conductors shall also be connected to station earthing grid through separate rod electrode.

Other requirements for Earthing system

a. Standard/Code IEE-80, IS: 2309

b. Earthing system life expectancy 40 years
c. System fault level kA for 1 second 33kV 66kV 132kV
(based on short circuit rating 20 31.5 31.5
of circuit breaker)
d. Soil resistivity Should be measure at site
e. Min. steel corrosion rate 0.25 mm per year.
f. Depth of burial of main earth 600 mm below grade level; where it crosses
conductor trenches, pipes, ducts tunnels, rail tracks, etc., it shall be at
least 300 mm below them.
g. Conductor joints By electric arc welding, with resistance of joint not less
than that of the conductor. Welds to be treated with red
lead for rust protection and then coated with bitumen
compound for corrosion protection.

The minimum conductor size for earthing system shall be as follows:

Equipment Buried Conductor above ground & in trenches
conductor
Main station grid 25 mm dia MS 50x6 mm GS flat
rod; 50 x 6 MS
flat
Switchgear/MCC -- 50x6 mm GS flat
415 V distribution boards -- 50x6 mm GS flat
HT motors -- 50x6 mm GS flat
LT motors above 125 kW -- 50x6 mm GS flat
LT motors - 25 to 125 kW -- 25x6 mm GS flat
LT motors - 1 to 25 kW -- 25x3 mm GS flat
Fractional HP LT motors -- 8 SWG GS wire
Control panel & control desk -- 25x3 mm GS flat
Push button stn. & Junction box -- 8 SWG GS wire

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SHP up to 25 MW
 Cable trays, cols. & structures -- 50x6 mm GS flat
Bus duct enclosures -- 50x6 mm GS flat
Rails & other metal parts -- 25x6 mm GS flat
Eqpt. earthing for switchyard -- 50x6 mm GS flat and 50x6 mm GS flat
equipment

3.6.2 Site Soil Resistivity Measurements and Installation

These may be carried out by standardisation instruction issued by AHEC.

3.6.3 Micro Hydels

Two 20 mm dia GI rods or 40 mm dia pipe may be provided. For details refer micro hydels
standard.
3.6.4 Lightning Protection

The lightning protection system should be designed as per IS: 2309. It should cover all buildings and
structures in the plant, and switchyard areas. It should comprise horizontal/vertical air terminations,
down conductors, test links and earth connections to the station earthing grid. All conductors should
be of minimum 25x6 mm size and should be of galvanised steel only.

The down conductors of lightning protection system should have a test joint at about 1500 mm
above ground level. Each down conductor should be connected to a 40 mm dia, 3 m long mild steel
earth electrode as well as station earthing grid.

The lightning protection system should not be in direct contact with under ground metallic service
ducts and cables, and should not be connected above ground level to other earthing conductors. All
joints in the down conductors should be of welded type.

Hazardous areas handling inflammable/explosive materials and associated storage areas should be
protected by a system of aerial earths as per IEEE: 142.

3.7 Communication System

Reliable communication system is required for operation of power plants as follows:

i) Voice communication
ii) Dedicated communication system for SCADA, circuit types of line protective relaying
and telemetering etc.

Available communication media is as follows:

i) Leased telephone lines

xi) Metallic cable power
xii) Power line carrier
xiii) Radio frequency communication
xiv) Micro wave (MW) communication system
xv) Fibre optics
xvi) Satellite communication

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 3.7.1 Fibre Optic cable

Communication between the central or distributed processor and the to other computer system
(remote control stations) is a main function in system performance. Fibre optic cable is preferred
because of fast transmission speed best noise immunity. In case of difficult terrain – radio
communication can be considered.

In larger powerhouse or these controlling remote stations or a group of stations internal telephone
system may be provided.

Selection of communication media for transmission lines interconnecting powerhouse with grid can
be chosen based on site limitation cost etc. Fibre optic cable is preferred.

Voice communication between powerhouse and interconnected receiving station may be PLCC;
radio frequency; communication; Landline (leased) based telephone line or mobile network based
dedicated line.

3.7.2 Code Standards

• ANSI/IEEE 1010 – 1987

• US Army of Engineers Engineering Manual
• Relevant National / International Standards

The contractor shall furnish detailed design and calculation for approval by purchaser.

3.7.3 Regulatory Requirement

Govt. regulatory requirement and sanctions for the communication system shall be obtained by
Contractor. Necessary assistance will be provided by Purchaser.

3.7.4 Internal Telephone System

An electronic telephone exchange suitable for 10-15 subscribers should be provided in the
powerhouse above 3 MW. The subscribers shall be located at various vulnerable positions to
facilitate the communication. Standard PVC cables should be laid for these subscribers. Some of the
important locations for subscribers may be as follows.

i) Control room
ii) Switchgear room
iii) Turbine pit
iv) Machine hall
v) Unloading/erection bay
vi) Cable spreading room
vii) Drainage/dewatering motor starter panel
viii) Switchyard
ix) Compressor room near switchyard.
x) Fore Bay
xi) Bye pass gates control room
xii) Pump house
xiii) Security gates
xiv) Offices

3.8 Transformer oil Purifier

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 Normally a portable transformer oil purifier of a capacity to purify the largest transformer in 3 to 4
hours for all power houses having transformer of 1000 kVA and above.

For small transformer portable transformer oil purifier may be provided for cluster of nearby
powerhouses as feasible.

4. MECHANICAL AUXILIARIES

4.1 E.O.T. crane

Cranes are used in the power house for operational function and for maintenance and repair.
Power house bridge crane (electrical over head traveling crane EOT) is the principal overhead
traveling crane for turbines, generators and auxiliaries in typical surface power house.

The crane comprises of main hoist consisting or one or more cranes with combined capacity to
lift the heaviest assembly of the generating units. An auxiliary hoist of much lower capacity is
provided for handling smaller parts.

Number of Cranes: The choice of providing one or two cranes with a lifting beam is an
important consideration in power house because of following reasons especially in power house
with large number of units (generally 5 units or more).

i) power house structural costs

ii) construction and erection advantage
iii) 2 cranes with lifting beam will need additional crane clearance and increase in height of
power house.
iv) Value of down time

In small hydro stations for the range under discussion only one crane is sufficient.

Crane Capacity: Crane capacity is SHP is based conventionally on estimated load -weight
heaviest part to be lifted with about 25% overload capacity. The rated load capacity of the main
hoist should be capable of lifting the heaviest assembly specified and not less than weight of the
generator rotor assembly including poles, shaft and turbine runner.

Standard: IS: 3177 – 1999 –Code of practice for Electrical Overhead Traveling Cranes and
Gantry Cranes
IS: 807 – Structural design of crane

For very small powerhouses, manual monorail hoist may be used. In micro hydel range EOT
crane is not provided. Erection may be done by chain pulley block, mobile crane or manually.

EOT Cranes Specification – Refer guidelines for E & M works entitled ‘specification for
procurement of auxiliary for SHP.

4.2 Cooling Water System

Cooling water system may be required in a powerhouse for the following.

i) Generator air coolers and bearing coolers.

ii) Turbine bearing coolers, wearing rings and gland. Turbine glands and wearing ring
require water of suitable quality.
iii) Transformer cooling

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 4.2.1 Water Requirements:

(i) The water flow requirements are determined by generator and turbine suppliers but are
dependant on water supply temperature and should take into account extremes in climate
conditions for the site. Flow requirements are usually large and require dependable
sources. Purity requirements are moderate permitting non potable supplies with limited
silt content.
ii) Gland and wearing ring requirements are obtained from turbine supplier. Quality
requirements are nominal requiring the removal of abrasive material.
iii) Transformer Cooling: Most plant in the SHP range under discussion utilize air cooled
transformer.

4.2.2 Sources

(1) Spiral Case – For units with heads upto about 75 m, the preferred source of cooling water is
a gravity supply from an inlet in the spiral case spiral case extension. In multiunit plants, an inlet
is provided for each unit with a crossover header connecting all units to provide a backup water
supply to any one unit. Cross-overs between pairs of units only are not regarded as adequate
since there would be no emergency source from an unwatered unit. The spiral case source is
usually satisfactory for unit bearing coolers, as well as the generator air coolers, and can be
adequate for gland and wearing ring use with proper filtering and adequate head.

(2) Tailwater – For higher head projects, above 76 m, the usual source of cooling water is a
pumped supply from tailwater. This normally provides water of essentially the same quality as
the spiral case gravity system.

(3) Other sources – It is unlikely that other suitable sources will be available or required for
cooling requirements, but alternate sources should be considered for gland requirements. Silt or
other abrasive material is usually present in varying degrees in reservoir water, at least
seasonally, and since abrasive material is injurious to glands, an alternate source or additional
treatment is usually required. The potable water system is normally the best alternate if the
supply is adequate or could be economically increased. This would usually be in the case of a
tube well supply requiring little chlorination. Where potable water is used, cross connections
from the cooling water source, with backflow protection, should be provided for emergency use.

4.2.3 Head requirements

Normally the cooling water supply should provide a minimum of 68.9-kPa differential across the
connection to the individual cooler headers. Available gravity head, cost of a pumped supply,
and cost of coolers all enter into an optimum cooler differential requirement and require early
design consideration to assure a reasonable figure for the generator and turbine specification.
Gland and wearing ring differential head requirements should be obtained from the turbine
supplier.

4.2.4 Treatment

Water for coolers, glands, and wearing rings will normally require only straining or filtration.
This should be verified from operating experience at nearby existing plants on the same stream.
Where existing plants are remote or the project is on a previously undeveloped stream, a water
analysis should be the basis of determining the likelihood of corrosion or scale deposits and the
need of additional treatment. Typical strainer requirements for coolers permit 3-mm
perforations, but strainer specifications for existing projects should be obtained as a guide to
complete design requirements. Strainers should be the automatic type unless the system provides
other backup provisions for continuous water supply or the p. h. is small. Unnecessarily fine

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 strainers requiring more frequent servicing should be avoided. Filters are required for gland
water unless the supply is the potable water system. The system should provide for continuous
operation when an individual filter requires cleaning.

4.2.5 Pumps

A pumped cooling water supply requires a standby supply for a pump out of service. This can be
provided with two pumps per unit, each of which is capable of supplying cooler requirements, or
one pump per unit consisting of a common pump discharge header to all units and one or more
backup pumps. Other arrangements to provide backup capacity may also be acceptable. Pumps
should be located such that flooded suctions occur at minimum tailwater. Continuously rising
pump performance curves are required, and the pump should not exceed 1,500 rpm.

4.2.6 Piping

i) Design considerations for piping include, velocity, pressure loss, pumping costs,
corrosion allowance, equipment connection sizes and requirement, mechanical strength,
temperature, expansion etc. .
ii) Water takeoffs from the spiral case or the spiral case extension should be within 30 deg
of horizontal center line to minimize debris and air.
iii) A valve should be located as close to the casing as practicable for emergency shutoff.
iv) Balancing valves should be located in cooler supply lines.
v) A removable 0.9-m section of straight pipe should be provided in the generator bearing
supply line for temporary installation of a flow meter.

Cooling Water Systems Specification - refer guidelines for procurement of auxiliaries.

4.3 Dewatering and Drainage System

4.3.1 General

The Dewatering system provides the means for dewatering main unit turbines and their
associated water passages for inspection and maintenance purposes. Drainage system provides
for the collection and disposal of all powerhouse leakage and wastewater other than sanitary. The
safety of personnel and plant is of vital concern in this system and should have continuing
priority throughout the design. It may be noted that following type of turbine will not require
dewatering arrangement because they are set above maximum tail water level and can be
accessed without dewatering.

a) Impulse turbine
b) Vertical Kaplan/Francis turbine with siphon intake

4.3.2 Dewatering System

General. The principal volumes to be dewatered in all powerhouses are the spiral case and draft
tube. In addition, there is usually a considerable volume down stream of the headgates or the
penstock valve.

Dewatering Procedure. Normal procedure after unit shutdown requires: closing of the
headgates or penstock valve; drainage of all unit water above tailwater to tailwater elevation
through the drain; and spiral case or spiral case extension drain; placement of draft tube gates or
stoplogs; and draining the remaining unit water to sump with the sump pumps operating.

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 Dewatering Time. Aside from safety, the required elapsed time for completing a unit dewatering
is the major factor in dewatering system design. Unit downtime will usually be of a value
justifying facilities to perform dewatering in 4 hr. or less. This can mean that in a typical plant all
necessary valve, gate, and stoplog or gate operations should be done in approximately 1 hr and
draining of the pumping system in approximately 3 hr.

Dewatering Sumps. Sump provision in most projects require either joint usage in both the
dewatering and drainage systems, or separate sumps with the dewatering sump serving as a
backup or overflow for the drainage sump. Sumps should be designed for maximum tailwater
head.

Dewatering Pumps. Two dewatering pumps should be provided. Dewatering pump capacity
should permit unwatering in 3 hr or less of pumping time with total capacity divided in two
pumps of the same capacity. Either pump used alone should be capable of accomplishing the
dewatering. Since unit dewatering will not be scheduled under powerhouse design flood
conditions, rated dewatering pump discharge should be for a maximum planned tailwater under
which dewatering will occur.

Pumps of the deep well water lubricated type are normally used. Submersible motor and pump
combinations units mounted on guide rails permitting the pump units to be raised or lowered by
the powerhouse crane have also been used.

Generally float-type controls are used for pump control. Automatic lead-lag with manual
selection of the lead pump is provided.

4.3.3 Drainage System

The drainage system handles three general types of drainage as follows: rain and snow water
from roofs and decks, leakage through structural cracks and contraction joints, and wastewater
from equipment. Discharge is to tailwater either by gravity or by pumping from a drainage sump.
Roof and Deck drainage should normally be directly to tailwater by gravity. Drainage of water
sprinkler fire protection system if used should be included in the drainage system in the design.

In small hydro upto 3000 kW capacity gravity drainage is generally provided.

Float Drainage: Drainage galleries should be provided for float drainage and conduits and pipes
connecting the trenches to the drainage sump should be provided.

Oil Storage or Purifier Rooms: Oil Storage or Purifier Rooms provided with water sprinkler
fire protection system should have chilling drain with a gravel pocket of sufficient capacity to
handle the sprinkling system flow.

Battery Room: Battery room floor and sink drains should be of acid resisting material, have a
minimum 2% slope.

Miscellaneous Area Floor Drains: Miscellaneous floor areas i.e. turbine room, galleries,
machine shop, toilet rooms etc. where leakage rainwater water from disassembly, flushing, etc. is
normally expected should have floors with continuous slope to the drain location. Any drains that
come from a source that can add oil to the water should not drain directly to tailwater but should
first be routed to an oil separator facility.

Pressure wastewater: wastewater from generator air coolers and bearing coolers etc. are
normally piped directly to the tailrace. Some powerhouses also require pressure drains for
transformer cooling water and air conditioning cooling water.

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 Drainage Piping: Drainage piping design considerations should be based on relevant on
standards.

Drainage Sump: The drainage sump or joint unwatering- drainage sump should be located low
enough to provide gravity flow from all drained areas under all dry powerhouse design tailwater
conditions and up to the float-operated alarm, sump water elevation.

Drainage and Dewatering Systems Specification - refer guidelines for procurement of SHP
auxiliaries.

Dewatering and drainage System specification - refer guidelines for procurement of

auxiliaries.

4.4 Compressed Air System

Compressed air system are required in powerhouse for operation and to facilitate maintenance
and repair. Service air, brake air and governor air comprises the three systems needed in all
powerhouses. Reliability, flexibility and safety are prime design considerations. This system is
generally not provided for mini and micro hydro sets upto 1000 kW capacity.

4.4.1 Brake Air System

a. General . The brake air system comprises one or more semi-independent storage and
distribution installation for providing a reliable of supply of air to actuate the generator
braking systems. Air is supplied from the service air system, stored in receivers, and
distributed through the governor actuator cabinets to the generator brake systems.
b. Air Requirement. Air is required in the system to stop all generator-turbine units
simultaneously without adding air to the system and without reducing system pressure
below 520kPa (75 psi). Storage capacity and pressure depends upon number of brake
applications per stop, brake cylinder capacity and volume required for piping and
verified by generator manufacturer.
c. Piping-Receivers. Each subsystem includes a receiver, piping from the service air
system to the receiver, piping from the receiver to the governor cabinets, and piping from
each governor cabinet to the respective generator brake system normally.
d. Control. Control for application of the brakes is normally included in the governor
cabinets and provided by the governor supplier.

4.4.2 Governor Air System

a. General. The governor air system provides the air cushion in the governor pressure
tanks. When the governor system is to be placed in operation, the pressure tank is filled
approximately one-fourth full with oil, and the tank is then pressurized to governor-
operating pressure from the governor air system. Corrections to maintain the proper oil-
air ratio are required at intervals during plant operation. The governor pressure tank size
and operating pressure will be determined by the turbine servomotor volume.
b. Air requirements. i) Quantity: Compressor delivery should be sufficient to effect a
complete pressurization of a governor tank with the proper oil level in 4-6 hr. ii) System
Pressure. The operating pressure should be approximately 10% above the rated
governor system pressure. iii) Compressor. The total air-delivery requirement should be
provided by two identical compressor, each rated at not less than 50% of the
requirement. Compressor should be heavy duty, reciprocating, water or air cooled, and
rated for continuous duty.

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 4.4.3 Service Air System

a) General. The service air system is a nominal 700-kPa system providing air for
maintenance and repair, control air, hydropenumatic tank air, charging air for the brake
air system, and in some cases, air for ice control bubblers.
b) Service Air Requirement. i) Routine Maintenance. Supply 25-40 L/s for wrenches,
grinders, hammers, winches, drills, vibrators, cleaning, unplugging intakes and lines, etc.
ii) Major Maintenance and Repair. Supply 140-190 L/s (300-400 cfm) for
sandblasting, painting, cleaning etc. Normally this capacity should be provided with
portable equipment. For projects too remote from a government or commercial source of
temporary portable equipment, installed capacity be provided. iii) Ice Control Bubblers.
Thjis may be required for SHP located high altitude ice prone areas. Supply 1-2 L/s per
3- width of trashrack with bubblers opaerting on intakes for upto four units
simultaneously (if required). iv) Operational Requirements. Supply 7-12 L/s (15-25
cfm) with individual assumption as follows:

• Brake system charging air 1-2 L/s

• Hydropenumatic tank 3-5 L/s

• Control Bubbler 1-3 L/s

• Leakage 1-3 L/s

v) Standard Provision Basis. It is found that the computed basis will usually require several
arbitrary assumption and service factors to arrive at a total service air requirement. in lieu
of the compound basis, the following standard provisions may be used as the basis of
total air requirement:

• 1 – 2 unit plants 40 L/s

• 3 - 4 unit plants 50 L/s
• Over 4 unit plants 60 L/s

In addition, provide 175 L/s (375 cfm) for major maintenance and repair. If this will be
supplied with portable equipment, add computed ice control bubbler requirement to the
above standard provisions. If the 175 L/s is to be installed, assume that ice control and
major maintenance will be nonsimultaneous requirements, and the 175 L/s will cover the
ice control bubbler requirements.

v) Service Air Pressure. A nominal 700-kPa pressure with system variations from 580-760
kPa is satisfactory.

c) Compressors. Compressors should be heavy duty, water cooled, flood lubricated, and
cooled rotary screw type rated for continuous duty. Normally, aside from major
maintenance, service air should be supplied by two identical compressors each of which
is capable of supplying approximately 75% of the requirement. where ice control bubbler
demand exceeds 12 L/s and there is no installed major maintenance compressor, it will
usually be preferably to supply the bubbler demand from separate compressor. Installed
major maintenance and repair capacity should be provided with a single compressor.
d) Receivers. Each air receiver should conform to design construction, and testing
requirements of the ASME, “ Boiler and pressure Vessel Code.” Receiver capacity
should provide a minimum 5 min-running time with no air being used from the system
for the largest connected compressor on automatic start-stop control. One or more
receivers may be used for the system. However, galvanized receivers are preferred, and
sizes should be checked against galvanizing plant capabilities.

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 e) Controls. The two service air compressors should each be provided with selective
manual or automatic control. They should have pressure switch lead-lag control
automatic selection and conventional load- lag control automatic selection and
conventional load-unload operation for manual selection. A major maintenance
compressor or a separate ice control bubbler comprssor should be on manual control with
conventional load-unload provisions. Cooling water should be controlled to flow only
when the compressor motor is energized. Automatic shutdown should be provided for
low oil pressure, low oil level, and high-discharge air temperature.

4.4.4 For typical procurement specification refer guidelines foe procurement of SHP
auxiliaries.

Compressed Air System speifcation- refer guidelines for procurement of auxiliaries.

4.5 Fire Protection System

4.5.1 General

Arrangement of fire protection in hydro power station and switchyard is normally divided into
following three groups.

i) Fire protection for generators

ii) Fire protection for generator transformers and other equipment in outdoor switchyard
iii) Fire protection of area and equipment and power house not covered under above two
groups.

4.5.2 Codes & Standard

i) IS: 1646 – Code of Practice for Fire Safety of Building (General) Electrical Installation
ii) IS: 2189 – Code of Practice – Selection, Installation and Maintenance of Automatic Fire
Detection and Alarm System
iii) IS: 3844 – Code of Practice for installation and Maintenance of Internal Fire Hydrants
and hose reels on Premises
iv) CBI & P Manual on Transformer
v) IS: 6382 – Code of Practice for Design and Installation of fixed Carbon Dioxide Fire
Extinguishing System

4.5.3 General Consideration for Design of Fire protection System

4.5.3.1 In view of a large number of oil-filled equipments in a Generating Station including

outdoor switchyard, it is very important that proper attention is given to isolation, limitation and
extinguishing of fire so as to avoid damage to costly equipment, reduce chances of serious
dislocation of power supply and ensure safety of personnel. The first step in this direction is
inherent in the design and layout of the powerhouse and substation itself, which should be such
that if fire occurs in any equipment it should be limited and isolated so that it does not spread to
other equipments. For this purpose the following are the general guidelines:

i) The spacing of the equipment should be considered. Extra space is not usually provided
for fire isolation, but the space available is taken into account in deciding other isolation
measures.
ii) Fire isolation walls should be provided between large oil-filled equipments such as two
or more transformers placed adjacent to each other. These should be of adequate strength
and of such size that the adjacent equipment is reasonably safe from the risk due to
burning oil flying from the equipment on fire.

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 iii) In indoor areas automatic fireproof doors should be provided for rooms which house
major oil filled equipment. The rooms should also be constructed with a view to isolating
the fire.
iv) Soak pits or drain pits should be provided below large oil-filed equipment to drain off the
burning oil falling below the equipment.
v) Minor items of oil filled equipment should be placed in beds of gravel or pebbles which
will quench and prevent the spread of burning oil.
vi) Care should be exercised that any prospective fire can be easily approached for
quenching. In closed spaces and buildings attention should also be given to evacuation of
personnel. (Refer IS: 1646).
vii) All oil pipes and cable trenches should be sectionalized by means of cross walls.

4.5.3.2 A well coordinated system of fire protection should be provided to cover all areas of the
power house and substation and all types of likely fires. The details of fire protection have to be
worked out on the basis of size, type and location of the substation, accessibility and degree of
attendance. Care should be taken any fire can be fought from more than one source and
dependence is not placed on single equipment for this purpose.

4.5.3.3 The subject of fire safety involving electrical equipment is exhaustively covered in latest
code and practice mentioned in 4.5.2.

4.5.4 Fire Fighting System in Substation

4.5.4.1 All substations should be equipped with fire fighting systems conforming to the
requirements given in latest IS: 1646 and fire protection manual Part-I issued by Tariff
Committee of Insurance Companies.
4.5.4.2 Trailer pumps where provided should draw their water supply from ground tanks of
suitable sizes, the location and distribution of which shall be such that no item to be protected is
more than about 90 m away from any ground tank.
4.5.4.3 The more valuable equipment or areas forming concentrated fire risk should be covered
by special fire protective systems. In this class are:

i) Generators
ii) Transformers, both indoor and outdoor:
iii) Oil filled switchgear
iv) Oil tanks and oil pumps
v) Oil, grease and paint stores

4.5.4.4 Although the substitution of bulk-oil and minimum oil circuit breakers by SF6 gas circuit
breakers has reduced the risk of fires in electrical installations, considerable risk still exists on
account of transformers, cables etc., which contain combustible insulating materials. Fires in live
electrical equipment, motors, machinery etc. fall in class C according to the tariff Advisory
Committee Classification of Fires. It is necessary to provide efficient Fire Protection Systems in
the electrical installations. Fire protection system consists of the following :

i) Fire prevention
ii) Fire Detection and annunciation
iii) Fire extinguishing

4.5.5 Fire Prevention

4.5.5.1 Fire prevention is of utmost importance and should be given its due if risk of occurrence
of fires has to be eliminated/minimized. The safety and preventive measures applicable for hydro

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 generating stations and substation as recommended by the relevant authorities must be strictly
followed while planning.
4.5.5.2 All fire fighting equipment and systems should be property maintained. Regular mock
drills should be conducted and generating station staff made aware of importance of fire
prevention and imparted training in proper use of the fire fighting equipment provided in various
parts of the substation, control room building etc.

4.5.6 Fire Detection and Annunciation

4.5.6.1 Fire detection if carried out at the incipient stage can help in timely containment and
extinguishing of fire speedily. Detection can either be done visually by the personnel present in
vicinity of the site of occurrence or automatically with the use of detectors operating on the
principles of fixed temperature, resistance variation, differential thermal expansion, rate of rise of
temperature, presence of smoke, gas, flame etc. Fire detectors of the following types are usually
used:

(i) Ionization type

(ii) Smoke type
(iii) Photoelectric type
(iv) Bimetal type
(v) Linear heat detection type

4.5.6.2 Ionization type detectors are used more commonly. However in areas like cable vaults,
lionization smoke and linear heat detection type detectors are used. Smoke type detector is
effective for invisible smoke, and photoelectric type for visible smoke. Smoke type detectors
incorporate LEDs, which start glowing in the event of fire.

4.5.6.3 Detectors are located at strategic positions and arranged in zones to facilitate proper
indication of fire location, transmission of Audio-visual signals to Fire control panels and
actuation of the appropriate Fire Fighting Systems. In the rooms with false ceilings, these are
provided above the ceiling as well as below it. For the detectors located above the false ceilings,
remote response indicators should also be provided.

4.5.6.4 Detectors are provided at the rate of one for a maximum area of 80 m2 in the zones to be
covered by the Fire Protection System

4.5.7 Fire Extinguishing

The Fire Extinguishing Systems used for fire protection of the various equipments/building in
substations are the following:

(i) Hydrant system.

(ii) High velocity water spray system.
(iii) Portable fire extinguishers.
(iv) Nitrogen injection fire prevention method for transformer only

These are described below briefly.

4.5.8 Hydrant System

4.5.8.1 Hydrant System is installed for the protection of the following areas from fire:

(i) Control room building

(ii) L.T. transformer area

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 (iii) Diesel generator set building
(iv) Fire water pump house
(v) Suitable location in the switchyard.

4.5.8.2 Hydrants are the backbone of Fire Fighting System as these can help fighting fires of all
intensities in all classes of fires and continue to be in service even if the affected
buildings/structures have collapsed. These keep the adjoining properties/buildings cool and
thereby save them from the serious effects of fire and minimize the risk of explosions.

4.5.8.3 The Hydrant System is supplied water from Fire Water Pump House. Fire Water Pump
House is located by the side of Fire Water Storage Tanks constructed within the substation
boundary limits. These tanks are made of RCC above ground such that these are easily
accessible. Water from these tanks is pumped into the Fire Hydrant System with horizontal
centrifugal pumps.

4.5.8.4 The Hydrant System essentially consists of a network of pipes, laid both above ground
and underground, which feed water under pressure to a number of hydrant valves located at
strategic locations throughout the substation. Pressure in the piping is maintained with the help of
hydro-pneumatic tanks and jockey pumps. Jockey pumps compensate for minor leakages also.
The hydro-pneumatic tanks are pressurized with compressed air supplied by two air-compressors
of which one is working at a time and other acts as standby.

Adjacent to the Hydrants, hosepipes, branch pipes and nozzles are kept in Hose Boxes. In case of
fire, the hoses with nozzles are coupled to the respective hydrants and water jet is directed
towards the seat of fire.

4.5.8.5 On drop of pressure in the piping network below a preset value, the Hydrant Pump starts
automatically and continues to run till it is stopped manually after fire has been extinguished.

4.5.8.6 The quantity of water to be available for fire protection and the number of fire water
pumps depend on the total number of hydrants which are provided as per guidelines of Tariff
Advisory Committee Manual, according to which substations fall in "Light Fire Hazard"
category. The parameters of Fire Water Pumps as per TAG guidelines are given below.

(a) For the total number of hydrants upto twenty, one no pump of 96 m3/hr capacity with a
pressure of 5.6 kg/cm2 (gauge)
(b) For the total number of hydrants exceeding twenty upto fifty five, one no. pump of 137
m3/hr capacity with a pressure of 7.0 kg/cm (gauge)
(c) For the total number of hydrants exceeding fifty five, upto hundred, one no. pump of 171
m3/hr with a pressure of 7.0 kg/cm (gauge)

4.5.8.7 As per TAG guidelines, the jockey pump should have a capacity of 10.8 m3/hr. and the
hydro-pneumatic tank should have a capacity of 18 m3. The effective capacity of the Fire Water
Tank should be not less than one hour of aggregate pumping capacity, with a minimum of 135
m3

4.5.8.8 All components of the Hydrant System such as piping, valves, fittings, hoses, branch
pipes, nozzles etc. should be of approved make acceptable to TAG.

4.5.9 High Velocity Water (HVM) Spray System

4.5.9.1 This type of Fire Protection System is provided for the following types of equipment:

(i) Power Transformer, both auto and multi-winding

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 (ii) Shunt Reactors

This system is designed on the assumption that one reactor/transformer is on fire at a time. For
this assumption, the largest piece of equipment forms the basis.

4.5.9.2 High Velocity Water Spray System consists of a network of projectors arranged around
the equipment to be protected. Water under pressure is directed into the projector network
through a deluge valve from a piping network exclusively laid for the Spray System. Water
leaves the projectors in the form of conical spray of water droplets travelling at high velocity.

4.5.9.3 The high velocity droplets bombard the surface of oil and form an emulsion of oil and
water which does not support combustion. This emulsion converts a flammable liquid into a non-
inflammable one. However, this emulsion is not of a stable character and therefore shortly after
the water is shut off, oil starts to separate out from water which can be drained away, leaving the
oil behind unimpaired.

4.5.9.4 The rate of burning of a flammable liquid depends upon the rate at which it vaporizes and
the supply of oxygen to support combustion. It is the maximum when the rate of burning of the
flammable liquid is the maximum and the surface of the liquid is near boiling point. The fcjigh
velocity water spray system while forming an emulsion, intersperses cold water with the liquid,
cools it and lowers down the rate of vapourisation which prevents further escape of flammable
vapours. During passage of water droplets through flames, some of the water gets converted into
steam, which dilutes oxygen in the air supporting the fire and creates a smoothering effect, which
aids in extinguishing the fire.

4.5.9.5 An automatic deluge valve triggered by a separate system of quartzoid bulb detector
heads mounted on a pipe work array charged with water, at HVW spray mains pressure, initiates
the HVW Spray System operation. When a fire causes one or more of the quartzoid bulbs to
operate, pressure in the detector pipe work falls and this allows the deluge valve to open thereby
permitting water to flow to all the projectors in the open pipe array covering the risk.

4.5.9.6 Water Supply to HVW Spray System

(a) Two pumps are provided for HVW Spray System. Of these, one is electric motor driven
and the other diesel engine driven. The capacity and head of the pumps is selected to
protect the biggest risk. It has been experienced that each pump having a capacity of 410
m3/hr is usually adequate for the biggest risk in substations.
(b) These pumps are located in Fire Water Pump House. Suitable connection with the
Hydrant System is provided so as to allow flow of water from Hydrant System to HVW
Spray System but not in the reverse direction.
c) Standby diesel engine driven pump is a common standby facility for HVW spray as well
as Hydrant System,
d) These pumps are automatically started through pressure switches located sequentially in
headers. However, stopping of the pumps is done manually after the fire gets
extinguished.
(e) The values of pressure of running water and discharge density given below are
recommended for HVW Spray System :
(i) Minimum pressure of running = 3.5
Bar at any projector at any instance.
(ii) Maximum pressure of running water = 5.0
Bar at any projector at any instance
(iii) Discharge density on ground surface = 6.1 Ipm/m2
(iv) Discharge density on other surface = Not less than
10.2 Ipm/m2

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 4.5.10 Water Supplies

4.5.10.1 Water for fire fighting purposes should be supplied from the water storage tanks meant
exclusively for the purpose. The aggregate storage capacity of these tanks should be equal to the
sum of the following:

(i) One-hour pumping capacity of Hydrant System or 135 m3 which over is

more.
(ii) Half-an-hour water requirement for single largest risk covered by HVW
Spray System.

The water storage tank made of RCC construction over ground should be in two parts.

4.5.10.2 Fire Water pumps located in the Fire Water Pump House should have pumping head
suitable to cover the facilities for future stages also. The piping system should be designed to
permit extensions without disruption in the existing system. The material of piping is mild steel
as per IS: 1239/IS: 3589 medium grade. The piping laid, underground is coated and wrapped
against corrosion as per IS: 10221 and the piping laid over ground consists of galvanised mild
steel.

4.5.10.3 All equipment and accessories, constituting the HVW Spray System, such as flow
control valve, heat detectors, projector nozzles, piping, valves, fittings, instrumentation etc.,
should be of approved makes acceptable to TAG.

4.5.11 Portable and mobile Fire Extinguishing

Portable and Mobile Fire Extinguishers are provided at suitable locations for indoor/outdoor
applications. These extinguishers are used during early stages of localised fires to prevent them
from spreading. Following types of these extinguishers are usually provided.

(i) Pressurised Water Type in 9.01 kg size

(ii) Carbon Dioxide Type in 4.5 kg size
(iii) Dry Chemical Type in 5.0 kg size
(iv) Halon type in 5.0 kg size
(v) Mechanical foam Type in 50ltrs, 90ltrs.

For the quantities of these types and their applications, the norms given in TAG manual should
be followed.

• The make of these extinguishers should also be acceptable to TAG.

• Halon type fire extinguishers are now getting phased out on account of their negative
effect on the atmosphere.
• The transformers shall be protected by automatic high velocity water spray system or by
carbon dioxide or BCF (Bromochloro-difluromethane) or BTM (Bromotrifluromethane)
fixed installation system or Nitrogen injection and drain method.
• Nitrogen injection fire prevention method is being used by a few utilities at present.

4.5.12 Instrumentation and Control

4.5.12.1 Fire Protection System should include suitable instrumentation and necessary controls to
render the system efficient and reliable. There should be local control panels for each of the
pumps individually as also for the operation of deluge valve of the HVW Spray System. There
should be a common control panel for the Jockey Pump and Air Compressors. Main annunciation

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 panel should be provided in the control room for the facilities provided in the control room and
for repeating some annunciation from pump house.

4.5.12.2 The following Annunciation is usually provided in the Fire Water Pump House :

(i) Electric motor driven HVW spray pump running/fails to start

(ii) Diesel engine driven HVW spray pump running/fails to start
(iii) Hydrant pump running/fails to start
(iv) Jockey pump running/fails to start
(v) Air compressor fails to start
(vi) Hydro-pneumatic tank pressure low
(vii) Hydro-pneumatic tank pressure high
(viii) System header pressure low
(ix) Fire in transformer/reactor
(x) Fire in smoke detection system
(xi) Water storage tank water level low
(xii) High speed diesel oil tank level low

4.5.12.3 The following Annunciations should be available in the control room also:

(i) Fire in transformer/reactor

(ii) Hydrant pump/diesel engine operated HVW spray pump in operation
(iii) Motor operated HVW spray pump in operation
(iv) Fire/Fault in Zone 1
(v) Fire/Fault in Zone 2
(vi) Fire/Fault in Zone 3
(vii) Fire/Fault in Zone 4(depending on the number of zones)

4.5.12.4 All fire protection equipment should be covered by a regular and strict maintenance and
test routine. The hydrant systems should be checked every week which may be possible during
night shifts. Sprinkler systems should be checked at regular intervals. Portable equipment should
be charged at specified intervals and checked regularly for loss of charge, damage, etc. Records
of all tests and checks must be maintained.

4.5.12.5 Provision should be made to switch off the air conditioning equipment in case of
fire.

4.5.12.6 Cable entry openings shall be sealed to prevent the spreading of fire.

4.5.13 Diagram of Fire Fighting System

A flow diagram of a typical HVW Spray and Hydrant System is enclosed as Fig. 4.5

4.5.3 Generators

a) General : Generators with closed air-circulation systems are normally provided with
automatic CO2 extinguishing systems. Up to four generators may be on one system, with
CO2 cylinder storage based on discharge in a single unit (generally above 5 MW
capacity). Standard generator are recommended upto 5 MW and these are open
ventilated and not suitable for carbon dioxide fire protection.

b) System design :

i) General design considerations are as follows :

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 a) CO2 concentration of 30 percent should be maintained within the generator housing for a
minimum period of 20 min without the use of an extended discharge.
ii) CO2 release should be actuated by the following:
a. Generator differential auxiliary relay
b. Thermo-switches in the hot air ducts of each air cooler.
c. Manual operation at the cylinders.
d. Remote manual electrical control.

The CO2 fire extinguishing system normally consist of a sufficient amount of CO2 to maintain an
inert atmosphere during the deceleration of the machine. Two rates of discharge of CO2, are
provided by two groups of CO2 cylinders one group of cylinders, providing the initial discharge,
to ensure a rapid build-up of CO2 concentration, to put out fire and other group of cylinders,
providing the delayed discharge to ensure concentration of CO2 maintained for an extended
period. Capacity of the bank is sized for protection of only one individual generator and CO2
cylinders is arranged for the discharge to any one of the main units. The amount of CO2, for
initial and delayed discharge, should be determined by the manufacturer, taking into account the
volume of the air spaces in the generator enclosure and the deceleration time of the machine. Size
and the number of cylinders required in each bank are accordingly determined. A set of identical
reasons set of cylinders is provided for immediate replacement after use.

iii) Open ventilated generators upto 5 MW capacity may be provided water sprinkler system
or portable system.

4.5.4 Transformers

a) General : Fire protection at a transformer is provided to limit damage to other nearby

transformers, equipment, and structure. It is assumed that a transformer fire will result in
loss of the transformer. Water sprinkler systems are provided for outdoor oil-filled
transformers

b) Outdoor transformers :

1) General : Main power transformers are commonly located outdoors in the

switchyard, on intake or tailrace decks. They are sometimes individually semi-isolated
by walls on three sides. The frequency of transformer fires is extremely low, but the
large quantities of oil involved and absence of other effective fire control measures
normally justify installation of a deluge system where there is a hazard to structures.

2) System design
i) The system Emulsifier Water Sprinkler System. Deluge valves should be
actuated automatically by a thermo-stat, manually by a switch in a
break-glass station located in a safe location near the transformer, or
manually at the valve. Where exposed transformers (without isolating
walls) are located closer together than the greater of 2-1/2 times
transformer height or 9 m, the system should be designed for spraying
the adjoining transformers simultaneously with the transformer-initiating
deluge.

ii) The water sprinkler system system water supply is normally from the
pool or water tank and should be a gravity supply if practicable. A
booster pump should be provided if required. a pumped tailwater source
is an acceptable alternate. Two water intakes are required either of
which can supply the rated delivery of the pump. Consideration must be

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 given to providing a source of power for pumping when the circuit
breakers supplying the transfer are automatically tripped because of a
transformer fault.

c) Indoor transformers: Oil-filled indoor (auxiliary) transformers should be protected by

CO2.
d) Outdoor oil-insulated: Oil-insulated power transformers located outdoors should be
provided with chilling sumps which consist of a catchment basin under the transformer
filled with coarse crushed stone of sufficient capacity to avoid spreading an oil fire in
case of a tank rupture.

4.5.5 Portable Fire Extinguishers

Portable CO2 handheld extinguishers are the first line of fire protection for powerhouse areas and
quipment other than those specifically covered above and should be provided in locations as per
relevant Indian Standard.

4.5.6 Fire Detections

a. Thermal detectors: Thermal detectors are best suited for locations within equipment
such as generators or near flammable fluids.
b. Ionization detectors: Ionization detectors are best suited for gases given off by
overheating, such as electrical cables or a smoldering fire. Location near arc-producing
equipment should be avoided. They are not suited for activating CO2 systems.
c. Photoelectric detectors: Photoelectric detectors are best suited for the particles given off
by an open fire as caused by a short circuit in electrical cables. Their use in staggered
locations with ionization detectors along a cable tray installation would provide earliest
detection. They are not suited for activating CO2 systems.
d. Location: Detectors should be located at or near the probable fire source such as near
cable trays or in the path of heating and ventilating air movement. In areas where
combustible materials are not normally present, such as lower inspection galleries, no
coverage may be appropriate.
e. Reliable detection: The earliest “reliable” detection is required. The detector type or
types, location and adjustment should be carefully considered. The detector sensitivity
adjustment should be adjusted to eliminate all false alarms. A fire detector system
should be provided in the cable gallery and spreading rooms of all powerhouse.
f. Alarm system: The power plant annunciation and, if applicable, the remote alarm system
should be used to monitor the fire detection alarms. An alarm system should be provided
for each area. Properly applied, these systems will provide more reliable and useful
alarm data than the alarm monitor specified in the fire codes.

4.5.7 Isolation and Smoke Control

Smoke and fire isolation is probably the most important fire control item. Smoke inhalation is
one of the major causes for loss of life. The toxic fumes from a minor fire could required total
evacuation of the powerhouse. Many of the existing heating, ventilating, and air conditioning
systems contribute to spreading the smoke as they encompass the entire powerhouse or have a
vertical zone composed of several floors. The fire area should be isolated by shutting down the
ventilating system or exhausting the air to the outside where feasible to prevent the spread of
smoke and to provide visibility for fire fighting reentry to the area. In most cases, the available
oxygen is sufficient to support combustion, and little can be gained by not exhausting the smoke.
Smoke and fire isolation should be provided in areas where isolation can provide a real benefit.
The requirements for fire stops should be considered on a case-by-case basis. Where cable tray

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SHP up to 25 MW
 pass through a floor or wall which could be considered a fire wall, or where cables leave a tray
and enter a switchgear or switchboard through a slot, a fire-stop should be considered. A 12.7
mm asbestos-free fireproof insulation fireboard can provide the basic seal with the voids being
closed by packing with a high-temperature ceramic fiber. Single conduit or single cables which
penetrate a fire wall can be sealed with a special fitting. Thick seals should be avoided as they
could contribute to an excessive cable insulation operating temperature.

4.5.8 Fire protection Scheme Recommended

SHP above 5000 kW and upto 25,000 kW

i) Generator – CO2 protection if CO2 protection is not feasible then water sprinkler system
be provided.
ii) Generator transformer – Provide water sprinkler system protection
iii) Fire detectors, portable fire extinguishers, fire buckets and hydrants as per relevant IS

SHP above 100 KW upto 5000 kW

i) Generator – Water sprinkler system for generator above 1000 kW unit size
ii) Generator Transformer – water sprinkler system above 1000 kW unit size
iii) Fire detectors, portable fire extinguishers, fire buckets and hydrants as per relevant IS

SHP upto 100 KW

Portable fire extinguishers, fire detectors and hydrants as considered figures and as per Indian
standard requirements.
Fire Protection System specification - refer guidelines for procurement of auxiliaries.

4.6 Ventilation and Air Conditioning

4.6.1 General

Power house and ventilation and air conditioning is required to maintain temperature and quality
air conditions suitable for operating requirement, plant personnel and visitors. Ventilation and air
conditioning system for surface hydel power stations should be designed in accordance with IS:
4720 – 1982 entitled code of practice for ventilation of surface hydel power stations as given
below.

4.6.2 Types of Ventilation

The ventilation may be of following types:

a) Natural, that is, by forces set in motion by the heat of sun, namely, winds; and
b) Forced or artificial, that is, by extraction or propulsion.

4.6.3 General Rules For Design

4.6.3.1 Natural Ventilation

i) Thorough ventilation of power house building should be aimed at by the provision of

adequate windows and ventilators.
ii) Provision of Windows and Ventilators - The object of providing windows and ventilators
is two-fold, that is, to get fresh air and light. The minimum area of windows and

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SHP up to 25 MW
 ventilators to be provided in power house building should be one-tenth of the floor area.
However, efforts should be made to increase it to one-fifth of the floor area. Windows
should be well distributed and be located on windward side at low level arid should not,
as far as possible, be obstructed by adjoining structures or partitions. When wind
direction is variable, windows should be provided on all sides, if possible. Effort should
be made to develop cross-ventilation. For protection against fire, it is preferable to
provide steel doors and windows in power house and auxiliary rooms. Reference may be
made to IS :1038-1975 and IS :136l-1978. The ventilators should be fixed as high as
possible for proper expulsion of warm air. Full advantage should be taken of sunshine
which is important in ventilation its availability depends on the orientation of the power
house which in turn may depend on site condition. In providing openings, measures to
guard against entry of birds, moths, etc, should be taken.

4.6.3.2 Forced Ventilation

i) Forced ventilation system is designed keeping the inlet fan capacity 10 percent more than
the exhaust fan capacity.
*Code of practice for industrial ventilation
Steel doors, windows and ventilators (second revision).
Steel windows for industrial buildings (first revision).
ii) Unassigned rooms and storage rooms should be carefully considered, so that sufficient
ventilation may be provided in those which might be used for purpose requiring
additional ventilation in the future.
iii) In portions of the power station building where moisture condensation is anticipated,
dehumidified air should be supplied to prevent condensation, as condensation causes
deterioration of point, corrosion of metal surfaces and breakdown of insulation on
electrical equipment.
iv) The quantity of air required for the power station building should be worked out from the
number of air changes preferred for the various premises of the building as given in
Table 1. In addition to this the points given in 4.6.3.1 to 4.6.3.2 should also be kept in
mind.

TABLE 1 PREFERRED NUMBER OF AIR CHANGES

POWEU HOUSE PREMISES PREFERRED AIR CHANGES

PER Hour
Main generator room, dark room, light and heavy storage 2
rooms, dewatering and drainage sumps, record room
Passage, approach gallery, pipe gallery, ventilation 4
equipment room, governor gallery, cable gallery,
dewatering drainage-pump room or gallery
Oil storage and oil purification rooms, service (pump ) 6
gallery, oil sludge room, compressor room, terminal
board room, machine shop, tool room, pipe shop,
electrical laboratory, fan room, battery room, telephone
and communication equipment room
Offices, reception room, toilets, and control room 8

v) One air change per hour means that the quantity of air equivalent to the total volume of
the room is supplied to and exhausted from the room each hour. This air may be all
outside air or a part of the-circulated air, depending upon the oxygen content.
vi) The proportion of outside air to the circulated air supplied to a room depends upon
temperature conditions, number of occupants and kind of equipment installed in the
room.

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SHP up to 25 MW
 vii) The number of air changes per hour provided for any room is dependent upon the
number ofoccupants. The air should be changed at the rate of l'5ms/min per person and
not less than 0*3ms/niin of this air should come from outside sources.
viii) The number of air changes per hour provided for rooms containing equipment generating
heat should necessarily be increased, depending on the amount of heat to be carried out
by the ventilating system.
ix) For medium climates, the maximum temperature rise of air carrying off heat of
transformers should be limited to 20°G, and for hot climates the temperature rise should
be limited to 16°C ; however, the final temperature of the air exhausted should not
exceed 45°C.
x) Air supplied to rooms containing special mechanical or electrical equipment should be
filtered aridcirculation maintained at a minimum, through diffusers, to prevent the
accumulation of dust on sensitive mechanisms. The relative humidity of air supplied
should not be higher than 65 percent.
xi) Rooms which may contain air contaminated with objectionable or harmful odours,
carbon dioxide gas or smoke, should be exhausted directly to the outside of the building.
xii) When heating or cooling units are provided in the power house, their effect on the
quantity and temperature or air circulating through the building should be considered.
xiii) The spacing of supply and exhaust openings in long rooms or galleries should be such
that sufficient air changes per hour are provided along the full length of the room.

4.6.4 Fans

Forced air ventilation is provided by propeller, axial or centrifugal type fans powered by electric
motors. Propeller fans may be used either to supply or exhaust where no duct system, filters or
other restrictions are in the air passage. When duct system is used, axial or centrifugal fans may
be used for any type of operation involving the movement of air and may be accompanied by
filters, and coolers or heaters where cleaning and tempering of supply air is required. Choice
of a particular type of fan may be made by consulting the fan manufacturers data, which give
full operating characteristics with a preferred range of operation for a particular fan.

4.6.5 Air Intake And Exhaust -Openings

4.6.5.1 Openings are provided for intake and exhaust of air where outside air is required for
ventilation. Where natural ventilation is used, the opening of windows is sometimes
sufficient. For forced ventilation, special openings are required. The number of openings
for intake and exhaust of air depends on the space arrangement in the .building, on the
size of the building and the design of the ventilation system. Small

IS: 4720 - 1982

power plants may have one opening of each type. For larger power plants, separate
outside air intake should be installed for the control, service and main unit bays. Each
intake should be provided with storm louvers, screens, and dampers for controlling the
mixture of outside and circulated air. The obstructive effect of the louvers should be
compensated for by making the gross area of the initial intake twice the area of the
connecting duct. When filters are used, the area should be increased to accommodate the
required filter area.

4.6.5.2 Air opening may be placed any where on the exposed walls or roof of the power plant
building, except that, in order to reduce dust intake, air intake should be at least 1*25 m
above ground or deck level.

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SHP up to 25 MW
 4.6.5.3 Air is exhausted from the building through exhaust openings provided with louvers or by
axial-flow exhaust fans located near the roof in the main generator room. Normally, the
number of exhaust openings may be more than the air inlet openings, since the spaces to
be exhausted are seldom located in the same general area, nor do they have common
requirements. Individual centrifugal fans and connecting ducts are usually installed to
exhaust air from toilets, battery rooms and oil storage rooms.

4.6.5.4 The size of air openings is dependent on noise level, and to a lesser degree, on horse
power requirements, since the smaller the opening the higher will be the noise level and
the resistance. The size of air openings may also be worked out from the air velocity as
recommended in Table 2, which will be found to give satisfactory results in designing
conventional systems.

4.6.6. Air Cleaning

It is desirable to clean the air entering the power plant building in order to remove the air-borne
dust particles which, if allowed to enter the building, may have an abrasive effect on rotating
machinery, interfere with the operation of electric or electronic devices, and may, otherwise
settle on equipment, giving a dirty appearance. The air filters are usually located upstream of the
fan. The size of the air filters may be determined by the recommended velocity of air passing as
given in Table 2. The choice of the air filter may be made by reference to the manufacturer's
catalogues.

4.6.7 Air-Conditioning

4.6.7.1 When the desired temperatures and humidities inside the hydel power station are not
obtainable by ordinary ventilation, air-conditioning may be resorted to bv heating or
cooling the entering air to the desired temperature to maintain comfortable working
conditions in the premises occupied by working personnel. The premises where it will be
desirable to provide air-conditioning are control, room, machine shop, offices, reception
room, first-aid room, dark room, electrical laboratory, switchgear -and terminal board
room and telephone and carrier communication room. For air-conditioning reference
may be made to IS: 659-1964*.

4.6.7.2 In general, all rooms, used by sedentary personnel should be maintained at 22°C with a
relative humidity of about 50 percent, or in special cases local radiant type portable
heaters may be used for the space actually occupied. Operation of the air-conditioning
system should be independent of the main ventilating system and the control of the
system should be automatic by means of thermostatic devices. Heating and cooling load
computations may be based on currently accepted standard practice.

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SHP up to 25 MW
 TABLE 2 RECOMMENDED AND MAXIMUM DUCT VELOCITIES FOR SYSTEMS IN
POWER HOUSE BUILDINGS

Sl DESIGNATION Recommended Maximum Velocities

No. Velocities
i) Outer air intakes 150 370

ii) Filters* 110 110

iii) Heating coils* 180 210
iv) Air washers 150 150
v) Fan outlets 500-730 850
vi) Main ducts 370-550 670
vii) Branch ducts 250-300 550
viii) Branch risers 250 500

*These velocities are for total face area and not the net free area; other velocities in the table are
for net free area. The net free area is the total minimum area of the opening in the face of a coil,
grille, register or louver through which air can pass.

4.6.8 Ducts

4.6.8.1 Where positive ventilation requires ducts for proper air distribution, considerable
advantage may be achieved by incorporating the ducts into the building structure and by
having the interior surfaces carefully finished to render them smooth and air-tight.

4.6.8.2 Where metal duct work is installed, it’ should be fabricated from galvanized steel or
aluminum sheets, and should conform to IS: 655-1963*.

4.6.8.3 The transfer of air by ducts; from source to delivery point, should be as direct as
practicable with the fewest possible bends. Flexible connections should be provided
between fans and ductwork to prevent the noise of fan vibration being transmitted
directly to the sheet-metal ducts.

4.6.8.4 The size of the air ducts should be worked out from the permissible air velocities given
in Table 2.

4.6.8.5 Supply and exhaust ducts of acid battery rooms should be painted with acid resistant
paint both inside and outside.

4.6.8.6 Ducts should be suitably insulated wherever required.

4.6.9 Air Distribution Control

To regulate the flow of air in a ventilating system, control dampers should be provided
throughout. At outside air intakes, multi-louver dampers should be used to control the amount of
air admitted. A similar damper is required on inside air intakes to control the amount of
rectrculated air. These two dampers should be interconnected to permit regulation of the
proportion of outside air to inside air used in the ventilating system. These may be operated
manually or automatically. Back-draft dampers are used where it is desired to prevent a reverse
flow of the air, such as the air supply duct to a battery room. Exhaust ducts from rooms
containing a fire hazard should have dampers which can be automatically and manually closed in
case of fire. Discharge openings, provided with propeller exhaust fans, should be fitted with
motor or mechanically operated type multi-louver dampers, which will open and close
automatically when the fan motor starts and stops.
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SHP up to 25 MW
 4.6.10 Air Conditioning and Ventilation System Recommended

SHP above 100 kW and upto 25,000 kW capacity

Provide air conditioning by individual air conditioning in the required areas.

Provide ventilation system for required no. of air changes by exhaust fans or forced air fans.

SHP Micro Hydel Range

Provide exhaust fans in the generator hall.

Ventilation And Air Conditioning - refer guidelines for procurement of auxiliaries.

4.7 Water Level Sensing

Forebay water level sensing is required for all powerhouses.

Tailrace level sensing is required for all canal fall powerhouses for a optimum power generation
or avoid.

Water Level Sensing specification - refer guidelines for procurement of auxiliaries.

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SHP up to 25 MW
 Version 2

STANDARDS/MANUALS/
GUIDELINES FOR
SMALL HYDRO DEVELOPMENT

Electro-Mechanical Works –
Specifications for Procurement of Auxiliary Equipment for SHP
Stations

Sponsor: Lead Organization:

Ministry of New and Renewable Energy Alternate Hydro Energy Center

Govt. of India Indian Institute of Technology Roorkee

May 2011
 CONTENTS

ITEMS PAGE NO
1. INTRODUCTION 1
1.1 Purpose 1
1.2 Standards and Reference documents 1
1.3 Technical requirements 1
2. SPECIFICATIONS OF MECHANICAL AUXILIARIES 3
2.1 Overhead Traveling Crane 3
2.2 Drainage and Dewatering System 6
2.3 Cooling Water System 8
2.4 High Pressure and Low Pressure Compressed Air System 10
2.5 Water Level Measuring & Transmitting Device 11
2.6 Oil Filteration Unit 12
2.7 Fire Protection Scheme 14
2.8 Ventilation and Air Conditioning 14
3. SPECIFICATIONS OF INDIVIDUAL ELECTRICAL AUXILIARIES 14
3.1 Auxiliary Transformers 14

3.2 Station Batteries and Battery Chargers 16

3.3 L.T. Switchgear (AC & DC) 17

3.4 Power and Control Cables 20

3.5 Lighting System 22

3.6 Cabling, Earthing and Lightning Protection 24

3.7 Internal Communication System 28

3.8 Transformer Oil Purifier 28

3.9 Diesel Generating Set 28

4. TECHNICAL PARAMETERS OF MECHANICAL AUXILIARIES OF 29

POWER HOUSE
5. TECHNICAL PARAMETERS OF ELECTRICAL AUXILIARIES OF 30
POWER HOUSE

 
 SPECIFICATIONS FOR PROCUREMENT OF AUXILIARIES
FOR SMALL HYDRO POWER STATIONS
1. INTRODUCTION
1.1 Purpose
These purchase specifications are produced in the form of recommendations/guide for utilities
and may be used in the form of standard as no National Standard has been issued so far by
BIS for this product. This Guide is intended to assist in the preparation of technical
specifications for the procurement of auxiliary equipment for the power house. The guide
includes, scope, design conditions, performance guarantee, general arrangement and
constructional feature, shop assembly & tests, site installation testing and commissioning of
different type of auxiliaries and commissioning of the same.
The document being only a guide line, AHEC cannot be rendered responsible for any
equipment declared to be in conformity with these guide lines.
1.2 Standards and Reference documents
All equipment shall comply with the latest edition of the relevant Indian Standards
specifications or relevant International Standards. When the equipments do not comply with
the above standards, the salient points of difference between the standards adopted and the
relevant Indian Standards or relevant International Standards shall be clearly brought out.
1. 3 Technical requirements
Following technical requirements should be elaborated in tendering documents :
1.3.1 Scope of work
This sub clause should describe the scope of work and the responsibilities which are to be
conferred upon the Contractor.
The scope of work should begin with a general statement which outlines the various elements
of the work including (where applicable) the design, material selection, manufacture, quality
assurance, quality control, shop assembly and testing, transportation and delivery to site,
insurance, storage ate site, installation, commissioning, field acceptance tests, warrantee and
other services as specified or required. The general statement should be followed by a specific
and detailed list of the major items which the Employer wishes to have as separate payment
items in the tender form.
Detailed list of major items should be given for each equipment.
1.3.2 Limits of the Contract
This sub clause, by making reference to the Employer's drawings and data, should describe in
detail the limits of the Contract considering the following:.
– details of the design and supply limits of the high and low pressure sides of the
equipment;
– details, location and responsibility for field connection to equipment under supply
– details and location of gate(s) or valve(s) on low-pressure side;
– responsibility for supply and installation of bolts, nuts, gaskets at piping termination;
– termination of connecting piping;
1.3.3 Supply by Employer
This sub clause should list the items and services which will be the responsibility of the
Employer. The following items should be considered:
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Hydro Power Stations    
 
 – services during site installation and testing;
– connections to powerhouse air, oil and water piping systems;
– electrical wiring and hardware external to specified termination points;
– electric motor starters and controls;
– lubricants
It should be stated that any materials or services like electricity, water and office/storage
space etc required for installation and commissioning of the equipment is to be provided by
the Contractor under the contract free of charges or with specific costs.
1.3.4 Design Conditions
1.3.4.1 Project arrangement
The Tender documents should contain the Employer's detailed description together with general
arrangement drawings (by the Employer) of the powerhouse, galleries, valves/gates, etc. The
description should be an extension of the applicable data provided in Chapter "Project
information". The data shall be sufficiently clear so that the Contractor can become fully aware
of physical conditions which may influence its detailed design.
1.3.4.2 Project Information
The specifications should state the principal characteristics of individual auxiliary system, for
example :
– capacity,
– power rating of driving electric motors,
– frequency of operations,
– space available for installation
1.3.4.3 Noise Level
Noise level limits may be legislated by national or local statutes. Noise abatement measures
may be the combined responsibility of the Employer and the Contractor. Reference should be
made by the Employer to ISO 3740 together with other standards, statutes and guides to
establish noise measurement and acceptance criteria. The limits and the means by which they
can be achieved should be specified
1.3.4.4 Vibrations
The specifications should specify that the equipment operate without vibrations which would
be detrimental to its service life. Reference should be made to IEC 60994, together with other
suitable standards or guides to establish the acceptable limits of deflections / vibrations, their
measurement and acceptance criteria.
1.3.4.5 Safety requirements
The specifications should state specific safety requirements which shall be met in the design
of the auxiliary equipment.
1.3.4.6 Technical Performance and Other Guarantees
The specifications should establish and specify the parameters on which the performance
guarantees are to be based.
The Employer should select the appropriate level and type of performance guarantees for each
equipment, The Employer should specify measurement methods to be applied and the
relevant standards which explain the measurement error.

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Hydro Power Stations    
 
 1.3.4.7 Mechanical Design Criteria
This sub clause should list the appropriate standards and codes which apply directly to the
mechanical design of the specified equipment.
The specifications should describe clearly the particular criteria and requirements relating to
operation, reliability and maintainability (for erection, dismantling and maintenance of the
main components). Any general statement in this subsection should be expanded as necessary
under the headings of the particular components concerned.
1.3.4.8 Requirements for Contractor's drawings, technical calculations and data
Requirements for the Contractor's drawings, technical calculations and data should be
described so that the Contractor is fully aware of information to be submitted.. The extent of
review intended by the Employer should be defined. The Contractor is normally responsible
for design of the equipment and the Employer's review should only be to the extent that the
product conforms to the requirements of the technical specifications, in particular, and the
contract documents, in general.
1.3.4.9 Contractor's review of Employer's design
A number of items in the design of the auxiliaries have an impact on the design of the
powerhouse. The Employer should outline the requirements for review by the Contractor of
the Employer's design. This could include a review of substructure construction drawings
showing foundation bolt and installation details, and other details which influence layout of
power house.
2. SPECIFICATIONS OF MECHANICALAUXILIARIES
Mechanical Auxiliary Systems for different types of small/medium size hydro power stations
comprise mainly the following auxiliaries :
1. Overhead Traveling Crane
2. Dewatering and drainage system,
3. Cooling Water System with water pipe lines with valves.
4. High Pressure Compressed Air System with air pipe lines and valves,
5. Water level sensing and transmitting device for fore bay and tail race.
6. Centrifuge type Governor/lubricating oil purifier unit
7. Fire Protection System for generators, main transformers and other equipment of
power house
8. Ventilation and Air conditioning
2.1 Overhead Traveling Crane
2.1.1 Scope of Supply
i) Main bridge with trolley, Operator's Cab, Main Hoist, Electrical Controls, safety
devices, fittings & connections and all necessary accessories to handle equipments.
ii) One cradle, slings, etc. for load testing at site.
iii) One set of main run-way rails with base plates, anchor bolts, rail clips, lock nuts end
stops, limit switches, striker plates, etc.
iv) One set of main run-way conductors complete with brackets, fittings, inter connecting
wiring etc.
v) All special tools, devices, spanners etc. for assembly and installation of cranes.
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Hydro Power Stations    
 
 vi) Wire ropes, for main hoists and Auxiliary hoists of cranes.
vii) One set of spares for 5 years of normal operation of cranes.
2.1.2 Standards
Structural design of the crane shall be done in accordance with IS 807 – 1976 or relevant
International Standards. The crane shall be designed as per IS 3177 – 1977 or relevant
International Standards except as otherwise specified in these specifications.
2.1.3 Design Requirements
The crane shall be manual hand operated upto 15 tones capacity and electric operated for
higher capacity. Capacity of the crane must be at least 25% over and above the weight of
heaviest component to be lifted. All parts of the crane and runway rails shall be designed to
sustain the loads and the combination of loads listed below with due allowances for
eccentricity of loading without exceeding safe permissible stresses. Mechanical parts of the
crane including trucks and trolley frames shall be designed for the specific loads using a
factor of safety of 5 (Five) based on the ultimate strength.
a) Loads :
i. Dead load : The weight of all effective parts of the bridge structure, machinery
parts and fixed equipment supported by the structure.
ii. Live load : The weight of trolley and lifted load (rated capacity) considered as
concentrated moving loads at wheels in such positions as to produce the
maximum moment and shear.
iii. Vertical impact load: 15 (Fifteen) per cent of the total live load.
iv. Braking load: The force produced on sudden application of bridge travel brakes
when carrying rated load and traveling at full speed with the power off.
v. Lateral load due to trolley tractive effort: 10 (Ten) per cent of the sum of trolley
weight and the rated crane capacity applied equally on the trolley rails.
vi. Longitudinal load due to bridge tractive effort: 10 (Ten) per cent of the sum of the
weight of crane and its rated capacity with the lifted load located at the extreme
extent of travel of each end of bridge.
vii. Earthquake load: Earthquake force to be taken equivalent to 0.3 g in horizontal
direction and 0.14 g in vertical direction.
viii. Other loads: Such as design floor load, special design load for horizontal frame
design.
b) Combination of loads: Unless otherwise stated, the crane shall be designed to sustain
the combination of loads listed below without exceeding the safe permissible stresses.
i. For crane in static hoisting position with dead load, live load and vertical impact
load.
ii. For crane in motion with dead load, live load, and any one horizontal load listed
under lateral, longitudinal or specific design loads.
iii. For crane in motion with a combination of dead load and braking load.
iv. For crane in static position with dead load plus earthquake load.
v. For crane in motion with dead load, live load and any 2 (two) or more horizontal
loads listed under lateral longitudinal or special design loads with resulting unit
stresses not more than 33-1/2 (Thirty three and one half) per cent in excess of safe
stress.

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Hydro Power Stations    
 
 vi. For crane in static hoisting condition, with a combination of load and forces
produced by the maximum or breakdown torque of the main hoist motor with
resulting stresses not exceeding 90 (Ninety) per cent of the elastic limit of
materials concerned.
2.1.4 Safety Requirements
In the design of crane, all safety regulations as applicable with Factory Acts, Electricity Rules
etc., as prevailing in the Purchaser’s country and at the site of installation shall be taken into
consideration and provided for.
2.1.5 Performance Requirements
The crane shall be capable of raising, lowering, holding and transporting its rated load without
any damage or excessive deflection of any crane component.
The following tolerances shall be maintained in the operation of the crane.
a) Smooth control of vertical movement to within 3 mm with hook carrying rated load
and all hoist brakes properly adjusted at normal operation.
b) Control of bridge and trolley motions to within 6 mm.
c) The motor speed not to exceed 105 (One hundred and five) percent of synchronous
speed while lowering a rated load.
d) The vertical deflection of crane girders caused by the rated load plus all dead loads
not to exceed 1/1000 of the crane span.
2.1.6 Technical Parameters
The following requirements shall be met.
i. Main hoist rated capacity As required and should be approximate 25%
over and above the weight of heaviest part to
be lifted
ii. Auxiliary hoist rated capacity 20% of main hook
iii. Main hoist normal speed 1.5/2.0 m/min
iv. Auxiliary hoist speed 6.0/8.0 m/min
v. Trolley travel speed 8/10 m/min
vi. Bridge travel speed 15/20 m/min
vii. Travel of bridge Maximum possible
viii. Travel of trolley Maximum possible
The above parameters are tentative. The designer may give his own parameters depending upon
the requirement of generating units. The rated load capacity of the main hoist shall be equal to or
greater than the weight of the heaviest assembly as specified but the capacity shall not in any case
be less than the weight of the generator rotor assembly including poles and shaft and turbine
runner. The creep motions of all movements shall be 10% of the main speed.
2.1.7 Electrical Connections and Motors
The main runway conductor system for supplying 415V-3 phase 4 wire 50 Hz power supply for
the cranes shall consist of insulated rigid conductors, accessories and collectors. The conductor
system for transmitting power and control commands to the trolley mounted equipment shall be
of either festooned cable or insulated rigid conductors.
All motors shall be induction type with water tight terminals, antifriction bearings and built in
totally enclosed fan ventilated enclosures. All motors speed shall not exceed 1500 rpm. Creep

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 speed motors shall also be continuously rated. All travels and hoists shall be provided with at
least two sets of brakes working on different principles viz. electro magnetic, thrustor, eddy
current braking system etc.
All motions shall be provided with limit switches at both extreme ends of travel.

2.1.8 Controls
Master controllers shall be located in the operators cabin. Indication and protections shall be
provided on the control panel.
2.1.9 Hoisting Ropes, Hooks, Lifting Beam
Hoisting ropes shall be extra flexible having a breaking strength at least five times that of the
maximum working load.
The crane shall be provided with a main hoist double hook of the ramshorn type and the
auxiliary hoist hooks of the single type with a safety latch. Main hook block shall incorporate a
hole and pin for attaching lifting devices. All the hooks shall be 360 o swivel type rotating on
antifriction bearings.
One lifting beam adequate to lift the heaviest load shall be provided.
2.1.10 Runway Rails
One set of runway rails and associated clamping devices with base plates, splice plates shall be
included in the supply.
2.1.11 Walkways, Platforms & Lighting
Walkways, ladders, inspection platforms for allowing access to all parts of the crane shall be
provided. Interior and exterior lighting inside the operators cabin and on bridge shall be
provided.
2.1.12 Special Tools & Devices
One set of all erection and maintenance tools special erection devices and testing devices shall be
provided.
2.2 Drainage and Dewatering System
2.2.1 Scope of Supply
• Vertical Turbine / Submersible Pumps for dewatering - one or two sets
• Level Controller for dewatering pit. - one set
• Vertical Turbine / Submersible Pumps for Drainage - two sets
• Level controller for drainage pit. - 1 set
• Pipes, valves & fittings. - 1 lot
• Special tools and devices for assembly / dismantling of pumps
NOTE :
i) Dewatering system is not required for surface power houses utilizing Pelton, cross flow,
tubular and small horizontal Francis type of turbines.
ii) Capacity of pumps shall be adequate for the power station.
iii) Submersible type pump-motor sets may be offered as alternative in place of Vertical
Turbine pumps.
2.2.2 Standards and Codes

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 IS : 4721–2000 “Code of Practice for Drainage and Dewatering of Surface/Underground hydro
Electric Power Stations”
2.2.3 General Design & Constructional Requirements
i) Dewatering System
For dewatering the underwater parts, there shall be a sump whose bottom elevation will be
sufficiently lower than the lowest point of the draft tube where the drain box is fitted to permit
flow of water by gravity to the sump by opening a long spindle type gate valve provided at the
sump. The dewatering will be done first by allowing the water in the penstock and spiral casing
to flow into the tailrace through wicket gates till the water in the penstock reaches the tail water
level and then by opening the drain valve in the sump for draft tube dewatering after closing the
draft tube gate. The dewatering sump shall be provided one sealed cover and covered man-hole.
The covers, pump base and level sensor’s base shall be designed to withstand full tail race water
pressure.
Dewatering system shall consist of one vertical turbine pump, one set of level controllers, pipe
lines and valves. The pump should be capable of dewatering the turbine in 4-5 hrs. Level
controllers shall be provided in the dewatering sump to start/stop the pumps automatically &
to give alarm at a preset level. Leakage of water from intake & D.T. gates may be assumed as
0.15% of rated discharge of turbine. The pump shall discharge into tail race above the
maximum tail water level. Suitable wall mounted control panel with starter, etc., shall be
supplied.
ii) Drainage System
A separate drainage sump will be made available so as to permit drainage of water by gravity
into this sump. The water from the drainage sump shall be discharged into the tailrace above the
maximum tailrace water level. The dewatering and drainage sumps shall be inter-connected
through a gate valve and non-return valve to allow rising water in the drainage sump to be
drained into the dewatering sump on failure of both drainage pumps to cope with station drainage
water.
The drainage system (common for Power house) shall consist of two vertical turbine pumps
(one main & one stand by), one set of level controllers, pipe lines and valves. The pumps
shall be of adequate capacity to remove normal seepage & drainage water. The electric motor,
pipes & valves shall be suitable for the pump rating. Automatic control of the pumps shall be
arranged through level electrodes. Provision for manual operation shall be made on the
control panel. Control of the pumps shall be built in Unit Control Panels and their starter
panels will be located near the pumps.
iii) Pump – Motor Sets
The impellors of pumps shall be manufactured from stainless steel and the casing of impellor
from steel casting. The pump casing and impellors shall be provided with removable type of
stainless steel liners. The shaft shall be of alloy steel with stainless steel sleeves where it
passes through bushes. The electric motors shall be squirrel cage induction motors with
hollow shaft and ratchet arrangement to prevent reverse rotation. The enclosure of the motors
shall be drip proof type.
vi) Valves, Pipes and Fittings
All gate valves and non-return valves shall have housing in steel casting and valve seat in
stainless steel. Piping shall be complete with sufficient number of bends, elbows, tees,
clamps, flanges and fasteners.
2,2,4 Shop Tests
The shop tests on drainage / dewatering system shall include:

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 i) Dielectrics and insulation tests on all electric motors,
ii) Routine operational tests including starting current, torque/speed characteristics,
output torque Vs current characteristics, noise, vibrations on electric motors as per
Indian Standard or International standard,
iii) Operational tests and tests for verification of Performance Characteristics offered of
pumps as per Indian Standard/ International standard. Pumps will be tested with
atleast one actual motor tested and supplied for each type of pump motor set
iv) Hydrostatic and leakage tests on all valves at 1.5 times the rated pressure.
v) Operational tests on level controllers
2.2.5 Field Tests
Following testes will be carried out at site after installation:
i) Dielectrics and insulation tests on all electric motors,
ii) Operational tests on Pump Motor sets for determination of pump capacity, power
drawn at full discharge, vibrations and noise,
iii) Operational tests on Pump Motor sets for minimum 8 hrs continuous operation to
establish trouble free operation,
iv) Operational tests on control panels and instruments.
2.2.6 Drawings and Data
Following drawings and data shall be supplied with offer:
i) Schematic drawing,
ii) Typical General Arrangement Drawing of Pump – motor sets,
iii) Catalogues of level controllers,
iv) Electrical Drawing of Control Panel.
Following drawings and data shall be supplied after placement of order:
i) Schematic drawing,
ii) General Arrangement Drawing of Pump – motor sets,
iii) Catalogues of level controllers,
iv) Electrical Drawing of Control Panel,
v) Layout and General Arrangement Drawings of the system showing details of pipes
and fittings and installation details of pump-motor sets.
2.3 Cooling Water System
2.3.1 Scope of Supply
Tapping arrangement from intake - sets
Pump Motor Sets - sets
Motorised self cleaning strainer - sets
Servo operated hydro valve with solenoids - sets
Necessary valves, pipes, supports etc. - lot
2.3.2 General Design & Constructional Requirements

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 2.3.2.1 Cooling water system shall be common for all the units. Cooling water will be tapped
from penstocks of both turbines through embedded pipes and connected to a common header
through isolating valves. Three pump motor sets (two mains, one for each unit and one
standby) shall be used to supply adequate cooling water to generator air coolers and guide
bearings of the units. The system shall provide 100 % redundancy operation of the unit
pumps. Cooling water requirement of one unit shall be met by one pump. The third pump
shall be used as standby pump for both units. Cooling water after passing through strainers
will be fed to a common header and distributed to each unit.
i) The pumps shall be centrifugal type directly driven by 3 phase 415VAC squirrel cage
induction motors. The pump motor shall be mounted on common base plate. The
impeller of pumps will be made in stainless steel, pump casing in steel casting and
shaft in stainless steel. The discharge capacity of each pumps shall meet the total
requirement of cooling water of one unit.
ii) Motorized self cleaning strainer with discharge capacity 1 ½ times the pump
discharge shall be provided after each pump to supply silt free clean water to various
cooling circuits. The strainers shall be cleared off accumulated silt automatically
through a motorised rotating arm mechanism. Cleaning operation will be operable
through pressure differential switch and timers.
iii) Servo operated hydro valve controlled by 48 VDC solenoids or motor operated valve
shall be provided on feeding line of each unit to control cooling water supply during
starting/shut down of units.
iv) Control of the pumps shall be built in Unit Control Panels and their starter panels will
be located near the pumps.
v) Valves, Pipes and Fittings: All gate valves and non-return valves shall have housing
in steel casting and valve seat in stainless steel. Piping shall be complete with
sufficient number of bends, elbows, tees, clamps, flanges and fasteners.
The duplex strainer (2 in nos.) shall be fitted with pressure switches to give alarm in case the
pressure differential across it exceeds a pre-set value. Pressure gauges shall also be provided
to indicate water pressure at its inlet and outlet. Three numbers of pump-motor sets shall be
provided to supply water at desired pressure. The pumps shall be of centrifugal type.
This cooling water supply scheme is of flexible type such that any combination of booster
pump and duplex strainer can be used for any of the unit in operation while the other is in
shutdown and any of the booster pump can be kept as standby while both the units are in
operation. The motors shall be suitable for working on 415 Volts, 3 Phase, and 50 Hz.
2.3.3 Shop Tests
The shop tests on cooling water system shall include :
i) Dielectrics and insulation tests on all electric motors,
ii) Routine operational tests including starting current, torque/speed characteristics,
output torque Vs current characteristics, noise, vibrations on electric motors as per
Indian Standard or International standard,
iii) Operational tests and tests for verification of Performance Characteristics offered of
pumps as per Indian Standard/ International standard. Pumps will be tested with
atleast one actual motor tested and supplied for each type of pump motor set
iv) Hydrostatic and leakage tests on all valves at 1.5 times the rated pressure.
v) Operational tests of self cleaning strainers
2.3.4 Field Tests

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 Following testes will be carried out at site after installation :
i). Dielectrics and insulation tests on all electric motors,
ii). Operational tests on Pump Motor sets for determination of pump capacity, power
drawn at full discharge, vibrations and noise,
iii). Operational tests on Pump Motor sets for minimum 8 hrs continuous operation to
establish trouble free operation,
iv). Operational tests on control panels and instruments,
v). Operational tests on self cleaning strainers.
2.3.5 Drawings and Data
Following drawings and data shall be supplied with offer :
i) Schematic drawing,
ii) Typical General Arrangement Drawing of Pump – motor sets,
iii) Catalogues of self cleaning strainers,
iv) Electrical Drawing of Control Panel.
Following drawings and data shall be supplied after placement of order :
i) Schematic drawing,
ii) General Arrangement Drawing of Pump – motor sets,
iii) General; Arrangement drawing of Strainers,
iv) Electrical Drawing of Control Panel,
v) Layout and General Arrangement Drawings of the system showing details of pipes
and fittings and installation details of pump-motor sets.
2.4 High Pressure and Low Pressure Compressed Air System
2.4.1 Scope of Supply
This system is generally not required mini and micro hydro sets upto approximately 1000 kW
rating. For small and medium size power stations, compressed air system is required for
Governor O.P.U., Generator Braking and service air and consists of :
• 3 Stage Reciprocating Compressors, m3/minute FAD - 2 nos
• Moisture Separators - 2 nos
• 3
High Pressure Air receiver -- m capacity - 1 no
• Low Pressure Air receiver -- m3 (for Generator Brakes) - 1 no.
• Pipes, valves, instruments & fittings. - 1 lot
2.4.2 General Design and Constructional Requirements :
i) Compressed Air System shall be common for both the units. Two reciprocating
multistage compressors driven by electric motors shall be provided to feed
compressed air in the air receiver.. One of the compressors shall work as main and
other as standby. Their operation shall be made automatic with the help of pressure
switches. Compressed air after passing through air dryers shall be fed to one high
pressure air receiver. One low pressure air receiver shall be provided for generator
brakes. Compressed air from high pressure air receiver shall be tapped and fed to low
pressure air receiver through one pressure reducer.

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 ii) Pressure rating of each compressor shall match maximum pressure requirement of oil
pressure unit and generator brakes. The supplier shall check air requirement of the
system and provide higher capacity, if required keeping compressor duty cycle in
view. Design calculation regarding compressor capacity and strength calculation of
air receivers shall be submitted for approval of the Purchaser.
iii) The compressors will be driven by 3 phase, 415 VAC completely enclosed, fan
cooled, squirrel cage induction motors with class F insulation through belt drive.
Compressor and motor shall be mounted on a common base plate which shall be
installed on floor with the help of foundation bolts.
iv) Indian Standard IS 2825 shall be followed for design, manufacture and testing the air
receivers.
v) The motor starter panel housing contactors, switch fuse units and meters etc shall be
mounted on the wall near the compressors and wired complete with leads labeled.
The connections to each motor shall be arranged so that either compressor may be
removed for repair or replacement without interfering with the continuous operation
of the other.
vi) System design shall be subject to approval of the Purchaser.
2.4.3 Shop Tests
The shop tests on compressed air system shall include :
i) Dielectrics and insulation tests on all electric motors,
ii) Routine operational tests including starting current, output torque Vs current
characteristics, noise, vibrations on electric motors as per Indian Standard or
International standard,
iii) Operational tests and tests for verification of Performance Characteristics of
compressors as per Indian Standard/ International standard. Compressors will be tested
with their respective motors.
iv) Hydrostatic pressure tests on air receivers at 1.5 times the rate pressure.
v) Hydrostatic and leakage tests on all valves at 1.5 times the rated pressure.
vi) Operational tests on pressure reducer.
2.4.4 Field Tests
Following testes will be carried out at site after installation :
i) Dielectrics and insulation tests on all electric motors,
ii) Operational tests on compressors for minimum 8 hrs continuous operation to
establish trouble free operation without abnormal vibrations and noise,
iii) Operational tests on control panels and instruments.
2.4.5 Drawings and Data
Following drawings and data shall be supplied with offer :
i) Schematic drawing,
ii) Typical General Arrangement Drawing of compressor set,
iii) Typical General Arrangement Drawing of pressure receivers,
iv) Catalogues of compressor, moisture separator and pressure reducer.
v) Electrical Drawing of Control Panel.

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 Following drawings and data shall be supplied after placement of order :
i) Schematic drawing,
ii) General Layout drawing of compressed air system showing details of pipes and
fittings and installation details of compressors,
iii) General Arrangement Drawing of compressor set,
iv) General Arrangement Drawing of pressure receivers,
v) Catalogues of compressor, moisture separator and pressure reducer
vi) Electrical Drawing of Control Panel,
2.5 Water Level Measuring & Transmitting Device
2.5.1 Scope of Supply
Water level measuring & transmitting device for intake and tail race channel shall comprise of
the following :
• Level transducer with transmitting device for intake with complete mounting
arrangement,
• Level transducer with transmitting device for tail race with complete mounting
arrangement,
• Water level signals receiving and processing device with mounting arrangement,
• Interconnecting cables between sensors, transmitters and control unit.
2.5.2 General Design and Constructional Requirements :
i) For monitoring water level upstream of intake gates, one set of suitable electronic
level sensor (strain gauge or capacitance type) and transmitter unit shall be provided
for transmitting the water level signal to controlling unit mounted in control &
metering panels in control room. One set of identical level sensor and transmitter unit
shall be provided for water level in tail race. The signals from both the units shall be
analogue signals in the form of 4 to 20 mA. These signals shall be processed in
centralized control unit. Necessary power supply to sensors and transmitting units
shall be provided from control unit.
ii) Output signals for fore-bay level, tail race level and their difference shall be provided
from the control unit for further utilization in Governor electronic cubicle and
SCADA. Digital indictors shall be provided in the control unit for indicating fore-bay
level, tail race level and their difference i.e. gross head. The device should be of
reliable make.
iii) The level sensors shall be mounted inside a pipe in such a way that oscillations in
water level are damped out and pipe do not get clogged by floating materials or silt
etc. complete with mounting accessories.
iv) Level sensors should be hermitically sealed and it should be possible to take out and
calibrate them easily.
2.6 Oil Filteration Unit
2.6.1 Scope of Supply
Mobile type Centrifugal Separator for purifying - 1 no.
governor/lubricating oil
ii) Portable Oil Transfer Pump - 1 no.

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 2.6.2 General Requirements
i) Mobile type Centrifugal Separator for purifying governor/lubricating oil of 300 (three
hundred) liters per hour capacity shall be supplied complete with suction filter, positive
displacement motorised pumps, electric heater of minimum 5 kW capacity with thermo-
static control, instruments and control panel etc.. The complete unit shall be mounted on
MS fabricated trolley type base plate with caster wheels and toeing bar. The separator
bowl body, bowl hood and disc stacks shall be made from stainless steel.
ii) The solid particles shall be removed down to Class 18/15 ISO 4406.
iii) Mobile transfer pump of capacity atleast 2000 liters per hour for filling the clean oil in
drums shall be supplied. The pump shall be fitted with filter at the suction and necessary
valves at pump outlet.
2.7 Fire Protection Scheme
2.7.1 General
The arrangements of fire protection in Power House and its 33 kV switchyard has been
divided under the following three groups :
a) Fire protection scheme for Generators.
b) Fire protection for generator transformers located in outdoor switchyard.
c) Fire protection of the area and equipment in power house not covered under above two
groups.
The details of the equipment and method of fire fighting scheme for above referred
equipment/area shall be designed, manufactured, installed and commissioned generally as per
the scheme.
2.7.2 Fire Protection Scheme for Generators
The fire extinguishing equipment for the generators shall be of water sprinkler system. In the
event of fire occurring inside the generator, The water sprinkler system would be
automatically initiated, by one or more of the special detectors provided in the generator air
circuit. The system may also be operated, if required, by manual push button operation to be
located at very conveniently approachable place.
2.7.3 Fire Protection of other Areas
The remaining areas of the power house shall be provided with following fire fighting
arrangements.
i) Fire detectors
The following locations of equipment shall be provided with fire/smoke detectors. These
detectors shall be installed above the equipments.
1. Control room-above control/relay panels, battery chargers etc.
2. Switchgear room-415 volts and 11kV switchgear, generator terminal equipment,
excitation panel etc.
3. Any other location deemed necessary.
The above detectors shall initiate alarm and indication in the fire alarm panel to be installed in
the control room. The indication shall identify the location of smoke/fire for taking corrective
action.
ii) Portable Fire Extinguishers
Various types of fire extinguishers of requisite capacity shall be located at appropriate
locations in the power house as follows.
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 CO2 type fire extinguishers 6 Nos. Control room, switchgear room
Soda Acid type 2 Nos. Offices, if any
Foam type extinguishers 4 Nos. Near OPU, stores etc.
Dry chemical type extinguishers 6 Nos. Switchgear room, control room
Carbon Tetra-Chloride type 10 Nos. General electrical installations,
Extinguishers HT/LT switchgear etc.
iii) Fire Buckets and Hydrants
Fire buckets filled with sand shall be provided on covered steel stand in switchyard,
unloading bay and machine hall. Water pipe line shall be laid in machine hall and fire hydrant
hose pipes shall be provided at two different locations. The specifications IS 1646, IS 3034,
and IS 1948 etc shall be adhered to for these works.

2.8 Ventilation And Air Conditioning

2.8.1 General :
The purpose of providing Ventilation and Air conditioning in power house is to prevent
temperature stratification, to remove contaminated air, to remove heat dissipated from various
equipments/systems, to provide clean air and to provide outside air necessary for human comfort.
The system is required to provide required design condition in the following areas
a) Ventilation System
Location Method
Machine hall, LT room, Battery By mechanical ventilation system
room, Toilet, Kitchen
b) Air Conditioning System
Location Method
Control room and Office By self contained wall split air conditioners
2.8.2 Standards and Codes
IS : 3103-1975 “Code of Practice for Industrial Ventilation”
IS : 4720-82 “ Practice for Ventilation of Surface Hydel Power Stations”
2.8.3 Types of Ventilation
The type of ventilation desired should be specified in the specifications. Ventilation may be of
following types:
a) Natural, that is, by forces set in motion by the heat of sun and winds;
b) Forced or artificial, that is, by extraction or propulsion.

3. SPECIFICATIONS OF INDIVIDUAL ELECTRICAL AUXILIARIES

Electrical auxiliary systems for the powerhouse shall be as under:
Auxiliary Transformers
i). Station Batteries and Battery Chargers
ii). L.T Switchgear (AC and DC)

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 iii). Power and Control Cables
iv). Lighting System
v). Cabling, Earthing and Lightning Protection
vi). Communication System
vii). Transformer Oil Purifier
viii). Personal Computer System
ix). D.G. Set
3.1 Auxiliary Transformers
3.1.1 Scope of Supply
Epoxy cast resin/resin encapsulated air cooled, – Nos..
three phase unit of desired capacity 50 Hz, transformer
3.1.2 Codes and Standards
IEC – 35415
IEC – 185
or relevant Indian or British Standards
3.1.3 General Requirements
i) Type And Rating : Epoxy cast resin/resin encapsulated air cooled type, three phase
unit, 50 Hz, transformer of desired capacity
ii) Reference Drawings to be provided by Employer :
• Single Line Diagram
• Protection and Metering - Single Line Diagram
• Auxiliary Power system – Single Line Diagram
iii) Enclosure : Enclosure of a tested quality sheet steel of minimum thickness 3 mm shall
also accommodate cable terminations. The housing door shall be interlocked such that it
should be possible to open the door only when transformer is off. The enclosure shall be
provided with lifting lugs and other hardware for floor mounting.
iv) Core: High grade non-ageing cold rolled super grain oriented silicon steel laminations.
v) Winding conductor: Electrolytic grade copper. Windings shall be of class F insulation.
vi) Cable box as per relevant ISS.
vii) Bushing CTs : As per IEC 185 of adequate rating for protection, etc.
viii) Fittings of auxiliary indoor transformers: All the required fittings of transformer shall be
provided and will be subject to approved of the purchaser.
ix) Tap changer: Off load tap changer shall be provided on the transformer.
x) Insulation level

• The transformer shall be capable of with standing the specified impulse test
voltage.
• One minute power frequency Test voltage for which the transformer shall be
designed, should be specified

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 3.1.4 Operating Conditions
i) Loading Capability
Continuous operation at rated kVA on any tap with voltage variation of ± 10% corresponding to
the voltage of the tap as well as in accordance with IEC 354.
ii) Flux density
Not to exceed 1.6 Wb/sq.m. at any tap position with +/-10% voltage variation from voltage
corresponding to the tap. Transformer shall also withstand following overfluxing conditions due
combined voltage and frequency fluctuations.
a) 110% for continuous rating.
b) 125% for a least one minute.
c) 140% for a least five seconds.
iii) Noise level : Not to exceed values specified in NEMA TR-1.

3.1.5 Tests
The transformer shall be subjected to all the relevant tests on works and site as per relevant
IS/IEC and copies of the same shall be supplied the purchaser for approval.
3.2 Station Batteries and Battery Chargers
3.2.1 Scope of Supply
The battery system shall meet the complete requirements for control, protection and interlocks,
emergency DC drives, emergency lighting, annunciation and field flashing etc and SCADA
system. The following data should be specified :
• No of Battery sets :
• Type of Battery sets :
• Nos and type of battery Charger :
• Voltage and AH rating of each battery set :
3.2.2 Codes and Standards
IS 13300
3.2.3 Construction Features
The batteries shall be of Nickel-Cadmium and high discharge type. Each battery shall have a
static battery charger, rated to fully recharge the battery from a completely discharged condition
in not more than ten (10) hours in boost charging mode. Each battery charger shall be capable of
float charging the two batteries while supplying the normal voltage regulators and shall have
following facilities as per drawing no. E-257-5.
(a) Manual selection facility for battery charging mode i.e. whether trickle or boost.
(b) Automatic and manual control of output voltage and current. Selector switch shall be
provided for auto/manual selection. Auto to manual changeover shall not result in any
harmful surges.
(c) Effective current limiting feature and filters on both input and output to minimise
harmonics, RFT, EMT etc.
(d) When on automatic control mode during trickle charging, the charger voltage shall
remain within 1% of set value for maximum permissible voltage, frequency and

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 combined voltage and frequency variation on feeding system and dc load variation from
zero to full load.
(e) Degree of protection shall be IP:42. For chargers located in air conditioned areas, same
may be IP:31.
(f) The rectifier shall utilise diode/thyristors and heat sinks rated to carry 200% of the load
current continuously. Temperature of heat sink shall not be permitted to exceed 85 deg.
C duly considering the maximum charger panel inside temperature.
(g) Rectifier fuse and RC surge suppressor.
(h) Ripple content to be limited to 1% peak to peak.
(i) All inter cell connectors and terminals shall be fully insulated/shrouded.
Batteries and chargers shall be connected to dc distribution boards (DCDBs) through single core
cables for each pole. The main HRC fuses on battery and charger output shall have alarm
contacts. The battery fuse shall be located close to battery in the battery room.
The DC systems shall be unearthed, and relays shall be provided for a sensitive earth fault
detection and annunciation. The low/high voltage alarms, instruments for indication of charger
current and voltage, dc voltage, battery current, etc. shall also be provided.
Batteries having complete cell weight of 50 kg or more shall be arranged in single tier. The
batteries which are interconnected to serve as standby to each other shall be located.
One complete set of all accessories and devices required for maintenance and testing of batteries
shall be procured for each battery bank. Each set should include at least the following:
a. Hydrometer -2 nos.
b. Set of hydrometer syringes suitable for the vent holes in -2 nos.
different cells.
c. Thermometer for measuring electrolyte temperature -5 nos.
d. Specific gravity correction chart -2 nos.
e. Wall mounting type holder made of teak wood for hydrometer
thermometer -2 nos.
f. Cell testing voltmeter (3-0-3V) -2 nos.
g. Alkali mixing jar -2 nos.
h. Rubber apron -2 nos.
i. Pair of rubber gloves -2 nos.
j. Set of spanners -2 nos.
k. No smoking notice -2 nos.
l. Goggles (industrial) -2 nos.
m. Instruction card. -10 nos.
n. Minimum and maximum temperature indicator for each
battery room - 1 no.

3.3 L.T. Switchgear (AC & DC)

3.3.1 Scope of Supply

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 • 415 V AC L.T distribution boards along with all ACB, MCCB, CTs, switches, wiring,
instruments and relays etc. in accordance with Employer’s Drawing.
• 24 V DC distribution boards along with all ACB, MCCB, CTs, switches, wiring,
instruments and relays etc. in accordance with Employer’s Drawing.
3.3.2 Codes and Standards
IEC 947,
IS: 13947
3.3.3 Constructional Features
i) All 415 VAC switchgear, motor control centres (MCCs), AC & DC Unit boards, unit
station/distribution boards (DBs), etc. shall be of metal enclosed, indoor, floor mounted and free
standing type. The switchgear/MCCs shall be fully drawout type. However, distribution boards
may be of fixed type construction.
ii) The incomer and bus coupler breakers for switchgear shall be electrically operated with over
current releases or relays. Paralleling of two supplies shall be avoided by interlocking, Auto-
changeover scheme shall be provided for loss of supply to one section of bus. Provision for
manual operation and changeover shall be included. Incomers for MCCs and DBs could be load
break isolators.
iii) For small motors switch-fuse contractor feeders shall be provided. The other outgoing feeders
would be moulded case circuit breakers.
iv) All frames and load bearing members shall be fabricated using mild steel structural sections or
pressed and shaped cold rolled sheet steel of thickness not less than 3 mm. Frame shall be
enclosed in cold rolled sheet steel of thickness not less than 1.6 mm. Doors and covers shall also
be cold rolled sheet steel of thickness not less than 1.6mm. Stiffners shall be provided wherever
necessary. Removable gland plates of thickness 3mm (hot/cold rolled sheet steel) or 4 mm
(non-magnetic material) shall be provided for all panels.
v) All switchboards/panels shall be of dust and vermin proof. All cut outs shall have synthetic
rubber gaskets.
vi) Where breaker/starter module front serves as compartment cover, suitable blanking covers, one
for each size of panel per switchboard shall be supplied for use when carriage is withdrawn.
vii) All switchboards, MCCs and DBs shall have following distinct vertical sections:
a) Completely enclosed bus bar compartment for horizontal and vertical bus bars.
b) Completely enclosed switchgear compartment, one for each breaker, motor starter or
MCCBs.
c) Compartment, alley or cable box for power and control cables. In case of cable box,
they shall be segregated with complete shrouding for individual feeders at the rear
for direct termination of cables. For breaker cable connections, a separately enclosed
cable compartment shall also be acceptable. It should be possible to carryout
maintenance on a feeder with adjacent feeders alive.
d) Compartment for relays and other control devices associated with a circuit breaker,
wherever necessary shall be provided.
viii) MCCs and DBs shall be divided into vertical sections. Each vertical section shall be
provided with adequately sized cable alley covering entire height. In case cable alleys are not
provided for DBs, segregated cable boxes with complete shrouding of individual feeders
shall be provided at the rear for direct termination of cables in each individual feeder.

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 ix) Busbars shall be of high conductivity aluminium alloy. Minimum air clearance in air
between phases and phase-earth shall be 25mm. For all other components, the clearances
shall be at least 10 mm. All connecting strips horizontal and vertical busbars, insulation shall
be provided by sleeving or barriers. In case of dc DBs/fuse boards, the busbar system shall
be insulated or physically segregated with barriers to prevent interpole short circuit.
x) Busbar insulators shall be of track-resistant, high strength, non-hygroscopic, non-
combustible type and suitable to withstand stresses due to over-voltages and short circuit
current. Insulators and barriers of inflammable material such as Hylam shall not be accepted.
xi) Control circuits shall operate at suitable voltage of 24 V DC. Necessary control supply
transformers having primary and secondary fuses shall be provided for each MCC, 2x100%
per section. The auxiliary busbars for control supply shall be segregated from main busbars.
The control supplies shall be monitored.
xii) Contractor shall fully coordinate overload and short circuit tripping of breakers with
upstream and down stream breakers/fuses/MCCBs/motor starters. Various equipment shall
meet requirement of Type-II class coordination as per IEC.
xiii) Suitable trolley arrangement shall be provided for breaker modules. Two trolleys per
switchgear room shall be provided so that top most breaker module of all types, sizes and
rating can be withdrawn on trolley and lowered for maintenance purpose.
xiv) All non-current carrying metal works of boards/panels shall be effectively bonded to earth
bus of galvanised steel extending throughout the switchboard/MCC/DB. Positive earthing
shall be maintained for all positions of chassis and breaker frame.
xv) The circuit breakers shall be air break, three pole, spring charged, horizontal drawout type,
suitable for manual and electrical operation, and shall have inherent fault making and
breaking capacities. They shall have shunt trip coil. In case releases are offered, the same
shall have contact for energisation of lockout relay. It shall have anti-pumping feature. All
breakers shall have built in interlocks for equipment and personnel safety.
xvi) Mechanical tripping shall be through red `Trip' push buttons outside the panel for breakers,
and through switches for other circuits. Clear status indication for each circuit shall be
provided through lamps, switch positions or other mechanical means. Provision of
mechanical closing of breaker only in `Test' and `Withdrawn' position shall be made.
Alternatively, mechanical closing facility should be normally inaccessible, accessibility
rendered only after deliberate removal of shrouds.
xvii) Motor starter contactors shall be of air break, electromagnetic type as per IS:13947 Part-4,
section-1 suitable for DOL starting of motors, and shall be of utilisation AC-3 for ordinary
and AC-4 for reversing starters. DC contactors shall be of DC-3 utilisation category.
xviii) Fuses shall be HRC type with operating indicator. Isolating switches shall be of AC 23A
category when used in motor circuit, and AC 22A category for other applications. Fuse
switch combination shall be provided wherever possible.
xix) Isolating switches and MCCBs shall have door interlocks and padlocking facility. All
switchgear, MCCBs, DBs, panels, modules, local starters and push buttons shall have
prominent engraved identification plates.
xx) Local push button stations shall have metal enclosure of die cast aluminium or rolled sheet of
1.6 mm thickness.
xxi) The temperature rise of the horizontal and vertical busbars and main bus link including all
power drawout contacts when carrying 90% of the rated current along the full run shall in no
case exceed 55 deg.C with silver plated joints and 40 deg.C with all other types of joints over
an ambient of 50 deg.C.
3.3.4 Relays and Protection

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 i) All types of relays and timers shall be subject to Owner's approval. They shall be flush
mounted with connections from inside, and shall have transparent & dust tight cover,
removable from front, drawout construction for easy replacement and testing facility.
The auxiliary relays and timers may be provided in fixe cases. All relays and timers shall
operate on available dc supply and not have any inbuilt batteries. They shall be provided
with hand-reset operation indicators (flags) or LEDs with push buttons for resetting.
ii) All equipments shall have necessary protections. However, following minimum
protections shall be provided.
Motor feeders (motors rated upto 160 kW)
a) Instantaneous short circuit protection on all phases
b) Thermal overload protection
c) Single phasing protection for motors protected by fuses.
iii) All meters/instruments shall be flush mounted on front panel, at least 72/96 sq.mm. size
with 90 degree line scales and accuracy class of 2.0. All motors of 10 kW and above
shall have an Ammeter. Bus-sections have bus VT, voltmeter with selector switch, and
other relays and timers required for protection. Adequate control and selector switches,
push buttons and indicating lamps shall be provided. Thermostatic controlled space
heaters with switches shall be provided to prevent condensation.
iv) Current Transformers of required ratios shall be provided in the panels as per details in
the protection scheme. CT cores; rated and type shall be subject to approval by
Purchaser.
3.4 Power and Control Cables
3.4.1 Scope Of Supply & Design Criteria
These specifications covers the design, manufacture, shop testing before despatch, supply and
delivery F.O.R. project site of power and control cables complete with junction boxes, terminal
connections etc., as specified hereunder. All equipments to be supplied under this head necessary
to fulfil the purpose of the plant and to achieve proper operation of the required design
conditions, even when some of the equipments are not expressively mentioned under the scope
of supply & design criteria of this section.
3.4.2 Standards :
IS:1554,
IS:7098,
IS:502,
IS:6380,
IS:9968
3.4.3 General Requirements
All cables shall be suitable for high ambient, high humid tropical Indian climatic conditions. All
cables shall be Flame Retardant Low Smoke (FRLS) type designed to withstand the mechanical,
electrical and thermal stresses under the foreseen steady state and transient/fault conditions, and
shall be suitable for the proposed method of installation.
For 3.3 kV cables, conductor screen and insulation screen shall both be extruded semi-
conducting compound and shall be applied alongwith XLPE insulation in a single operation by
triple extrusion process. Method of curing for 3.3 kV cables shall be "Dry curing/gas

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 curing/steam curing". 3.3 kV cables shall be provided with copper metallic screen suitable for
carrying earth fault current. For single core armoured cables, the armouring shall constitute the
metallic part of screening. For 3.3 kV insulation shall be XLPE, while for other cables it shall be
PVC.
For cables having more than five (5) cores, each core shall be identified by number marking.
However, for cables upto five (5) cores, the same shall be by colour.
Cables buried direct in ground and cables in switchyard shall be armoured. 3.3 kV cables shall
be unearthed grade. Other parameters of the cables are as follows:
The cable shall withstand all the type tests routine tests and acceptance tests as per the latest
editions of IS 8130 – 1976, 3975 – 1967, 5831 – 1970 mentioned in IS 1554 (part I & II) – 1976.

Particulars Power cables Control cables Trailing cables

XLPE PVC
a) Conductor
i) Material Stranded Aluminium wire complying Stranded plain Tinned copper of
latest edition of I.S. 8130 - 1976 annealed copper class 5 of IS:8130
ii)Size As required Min. 6 sq.mm size As required, but As required, but
min. 1.5 sq.mm. min. 1.5 sq.mm
Iii)Shape Circular/ Sector Circular/Sector Circular Circular
shaped circular only shaped.
for 3.3 kV cables
b) Main
Insulation
i) Material XLPE PVC PVC insulation Heat resistant
shall be type I elastomeric
extended PVC 1.1 compound based
kV grade & free on ethylene
from voids propyline rubber
(EPR)
ii)Continuous 90 70 70 90
withstand
temperature
(deg.C)
iii)Short circuit 250 160 160 250
withstand temp.
(deg.C)
iv)Colour As pre relevant codes and standards
identification
c) Inner sheath All armoured and multicore unarmored cables have distinct extruded inner sheath
i) Material PVC PVC PVC extended Heat resistant
type 6 PVC elastomeric
compound
ii)Colour Black Black Black Black

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 d) Armour
Aluminium wire for single core cable and GS wire/flat as Nylon cord
i)Material GS wire/flat for multicore cables as per per relevant IS. reinforcement
Relevant IS. Minimum Coverage of 90%. Min. coverage of
90%
ii)Breaking load 95% of normal 95% of normal
of joint armour armour
e) Outer sheath
i) Material PVC PVC PVC type 8 PVC Heat & oil
(Polyethylene with flame resistant & flame
based halogen retardant low retardant heavy
free material not smoke properties. duty elastomeric
acceptable) It should not stick compound
to inner sheeth &
consistent in
quality.
ii)Colour Black Black Grey Black
iii)Marking -Cable size & voltage grade (by Grey same as for Black same as for
embossing) power cables power cables
-marking "FRLS" @ 5 m (by embossing)
-Sequential marking @ 1 m
f) FRLS Oxygen Index : Min. 29 (As per ASTMD 2863)
properties on Acid gas generation: Max. 20% (as per IEC 754-I)
outer sheath Smoke density rating : 60% (as per ASTMD 2843)
g)Flammability As per Swedish chimney test F3 as per 8EN 4241475.
lost on all types As per IEC 332 part-3(Category B).
of cables

3.5 Lighting System

3.5.1 Scope
These specification covers design, manufacture, supply, installation, testing and commissioning
of the lighting system at the project. The scope covers lighting arrangement for power house,
switchyard, tail race, forebay and other appurtenant works like bypass approach road and trash
rack etc.
3.5.2 Standards :
IS : 3646 Illumination and glass index
IS : 694 Wires
IS : 732 Wiring installation conditions
IS : 9537
3.5.3 General Requirements
A comprehensive illumination system shall be provided in the entire project i.e. all areas within
the plant boundary. The system shall include lighting fixtures, distribution boards, lighting
panels, junction boxes, lighting poles, receptacles, switchboards, cables and wires, conduits,

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 poles and masts, etc. The system shall cover all interior and exterior lighting such as area
lighting, yard lighting, street lighting, security lighting, etc.
3.5.4 Design Criterion
The illumination system shall be designed on basis of best engineering practice and shall ensure
uniform, reliable, aesthetically pleasing, glare free illumination. The design shall prevent
glare/luminous patch seen on VDU screens, when viewed from an angle.
Power supply shall be fed from 415/240 V normal ac power supply, station service board, and 48
V DC supply for emergency lighting. Lighting panels shall be located at different convenient
locations for feeding various circuits. These panels shall be robut in construction with lockable
arrangements and MCB for deferent circuits.
48 V dc emergency lighting shall be provided in following areas:
a) Generator room -20 lux
b) Operating floors of turbine hall -20 lux
c) Switchgear room -15 lux (min. one lighting fixture
between two rows of switchgear)
d) Control and relay room -100 lux
e) Cable spreader room -at least 10% of illumination (min. one
lighting fixture at convenient location.)
f) Battery room -at least 10% of illumination
g) Exit points and stair cases -One light fixture
h) All other strategic locations for safe personnel movement during any emergency.
DC lighting shall come on automatically on failure of normal ac supply. These shall be switched
off automatically after the normal ac supply is restored and luminaries have attained their full
glow. In off-site areas/buildings dc lighting is to be provided through self contained 4 hour
duration fixtures located strategically. It shall be provided with Ni-Cd battery.
Lighting panels, fixtures, receptacles, poles, masts, distribution boards, switch boxes, conduits,
junction boxes etc. shall be property installed and earthed.
All outdoor fixtures shall be weather proof type. Fluorescent fixtures, installed in other than
control room areas shall have electronic ballasts. For control rooms, the ballasts shall be copper
wound inductive, heavy duty type, filled with thermo-setting insulating moisture repellent
polyester.
All luminaries and their accessories and components shall be of the type readily replaceable by
the available Indian makes. All fixtures and accessories shall be of reputed make and non-
corrosive type. Acrylic covers/louvres shall be of non-yellowing type.
The constructional features of lighting distribution boards shall be similar to AC/Dc distribution
boards described elsewhere. Outgoing circuits in PLS shall be provided with MCBs of adequate
ratings.
Wiring shall be by multi-stranded PVC insulated colour code cable laid in GI conduits. Wiring
for lighting circuits of ac, and dc systems shall be run in separate conduits throughout. Minimum
size of the wire shall not be less than 1.5 sq.mm copper or 4 sq.mm aluminium. Wire shall
conform to IS:694 and wiring installation shall be as per IS:732.
Conduits shall be of heavy duty type, hot dip galvanised steel conforming to IS:9537. In
corrosive areas, conduits shall have additional suitable epoxy coating.

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 At least one 5/15A, 240 V universal socket outlet shall be provided in offices, stores, cabins, etc.
20A 240 V ac industrial type receptacles shall be provided strategically in all other areas. All
these receptacles shall be 3 pin type and controlled with a switch. Suitable numbers of 63 A, 3
phase, 415 V ac industrial type receptacles with control switches shall be provided for the entire
plant for welding purposes, particularly near all major equipment and at an average distance of
50 m. At least one 63 A receptacle shall be provided in each off-site building.
Suitable number of ceiling fans in areas not covered by air-conditioning and ventilation system
shall be provided. Street lighting shall be with swaged/steeped tubular steel poles of swan new
construction. The poles shall be coated with anti-corrosive treatment and paint.
Area lighting shall be with suitable lighting masts. Masts of adequate height shall have lattice
structure with ladder, cage and top platform. Alternatively they shall have lantern carriage of
raise/lower type with electrical winch provided inside the tubular mast.
All outdoor lighting systems shall be automatically controlled by synchronous timer or photocell.
Arrangement shall be provided in the panel to bypass the timer/photocell for manual control.
3.5.5 Illumination Levels and Type of Fixtures and Luminaries

Location Average Type of Fixture

Illumination
level (Lux)
a) Turbine Hall Operating floor 200 HPSV high/medium bay
Industrial trough type
fluorescent
b) Switchgear rooms 200 Mirror optics with anti-
glare feature
c) Control room, computer room 300 Decorative mirror optics
type
d) Offices, conference rooms etc. 300 -Do-

e) Battery rooms 100 Totally enclosed corrosion

resistant / vapour proof.
HPSV flood light, weather
f) Switchyard 10(general) proof
50 (on equip.) HPSV medium
g) Compressor room, pump house, etc. 150 bay/industrial trough type
fluorescent
h) Turbine, auxiliaries like OPU etc. Flame proof fluorescent
150 fixtures suitable for
hazardous area
i) Cable galleries Industrial trough type
50 fluorescent
j) Street lighting roads HPSV street lights
20
k) Outdoor storage handling HPSV flood light, weather
20 proof.
l)Permanent stores Industrial trough type
150 fluorescent
m) Workshop, general work bench Mirror optics fluorescent
150
n) Laboratory - General Corrosion resistant, vapour
-Analysis area 150 proof fluorescent
o) Garage/Car parking 300 Industrial trough type

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 70 fluorescent

3.6 CABLING, EARTHING AND LIGHTNING PROTECTION

3.6.1 Cabling
i) Scope

The specification covers design, supply, insulation, testing and commissioning of cabling,
earthing and lightning protection at the powerhouse
The complete cable support system shall be supplied and installed for the entire project. The
system shall enable proper laying of all power, control, instrumentation and telephone cables, and
shall provide necessary mechanical protection, ventilation and segregation for them. All
hardware and anchoring arrangement shall be included. All steel members shall be hot dip
galvanised.
ii) Design
The contractor shall furnish detailed design and calculation for owner’s approval.
iii) General requirements
No sub zero level cable vault/trenches shall be provided below control building/switchgear
rooms in main plant and switchyard areas.
Interplant cabling for main routes shall be laid along overhead trestles/duct banks/directly buried.
However, from tap-offs, same can be through shallow trenches with approval of Owner. Directly
buried cable, if essential, shall not have concentration of more than four (4) cables. However,
cables in switchyard area shall not be buried. Cables from main plant to switchyard control room
shall be laid in duct bank/cable trenches.
In switchyard area, cables shall be laid in RCC concrete trenches. Wherever false floors are
envisaged for cabling, the cables can be directly laid on ground, neatly routed along grid spacing.
The false floor shall be atleast 1000 mm deep. False floor requirement shall be subject to Owner's
approval.
Cable entry from outdoor underground/cable routes to the buildings, if any shall be above the
finished floor level inside the building.
PCC flooring of built up trenches shall be sloped for effective drainage with sump pits and sump
pumps.
Cable trays, support system and pipes.

a) support system for cable Prefabricated out of sheet steel and fully galvanised flexible type
trays consisting of channels, cantilever arms and associated brackets &
hardware, installed at site by bolting or clamping. These shall be
rigid enough to withstand max. possible loads during and after
installation.
b) Type of cable trays Ladder for power cables and perforated for control instrumentation
cables, complete with all accessories, fittings and hardware.
c) Material of cable trays Rolled mild steel, min. 2 mm thick for trays and 3 mm thick for
coupler plate .
d) Finish of cable trays Hot tip galvanised.

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 e) Duct banks (if provided) Heavy duty GI pipes/heavy duty PE pipes (10% spare of each size,
subject to min 1) with suitable water-proof manholes. For corrosive
areas, pipes shall have anti-corrosion coating both inside & outside.
f) Pipe size Suitable with 40% fill criteria
Junction and Pull boxes Hot dip galvanised sheet steel of 2 mm thickness.
Cable glands Nickelchromium plated brass, heavy duty, single compression type
for unarmored, and double compression type for armoured cables
conforming to BS: 6121.
Cable lugs Solderless tinned copper crimping type. For HT cables, lugs shall
be as per DIN 46329. For rest, it shall be as per relevant IS.
HT cable terminations and Proven design and type tested as per VDE 0278. Elastimold or
joints equivalent fully insulated moulded terminations shall be preferred.
Cable Laying
a) Identification tags for To be provided at all terminations, on both sides of wall or floor
cables crossing, on each conduit/duct/pipe entry/exit, and at every 20 m in
cable trench/tray or buried run.
b) Cable tray numbering To be provided at every 10 m and at each end of cable way &
branch connection.
c) Joints Joints for less than 250 m run of cable shall not be permitted.
d) Buried cable protection With concrete slabs; Route markers at every 20 m along the route
& at every bend.
e) Road crossings Cables to pass through buried RCC hume pipes.
f) Transformer yard Handling RCC trenches to be filled with sand after cable laying.
area
g) Separation At least 300 mm between HT power & LT power cables, LT
power & LT control/instrumentation cables.
h) Segregation All cables associated with the unit shall be segregated from cables
of other units. Interplant cables of station auxiliaries and unit
critical drives shall be segregated in such a way that not more than
half of the drives are lost in case of single incident of fire. Power
and control cables for ac drives and corresponding emergency ac or
dc drives shall laid in segregated routes. Cable routes for one set of
auxiliaries of same unit shall be segregated from the other set.
Segregation means physical isolation to prevent fire jumping or
minimum one hour fire rating.
In switchyard, control cables of each bay shall be laid on separate
racks/trays.
i) Cable clamping To be suitably clamped/tied to the tray; For cables in trefoil
formation, trefoil clamps as required.
j) Fire protection Fire proof cable penetration seals rated for one hour when cable
passes through walls and/or floors. This shall be by suitable block
system using individual blocks with suitable framework or by
silicon RTV foaming system. In case foaming system is offered,

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 damming board, if used, shall not be considered for fire rating
criteria. Any of the system offered shall be of proven type as per
BS:476 (Part-8) or equivalent standard.

3.6.2 Earthing/Grounding
Earthing system shall be designed as per IS: 3043 and IEEE: 80. The earth resistance of the earth
mats for the P.H. and switchyard will be of the order of 0.5 ohms and 1 ohm respectively. The
two mats will be joined together through 3 parallel conductors of the same cross section as those
of conductors used in the mats.

Earthing system network/earthmat shall be interconnected mesh of mild steel rods buried in
ground in the plant. All off-site areas shall be interconnected together by minimum two parallel
conductors. The contractor shall furnish the detailed design and calculations for Owner's
approval. Contractor shall obtain all necessary statutory approvals for the system.
Enclosures of all electrical equipment as well as all cabinets/boxes/panels/etc. shall be earthed by
two separate and distinct earth connections. Metallic pipes, conduits, cable tray section, etc. shall
be bonded to ensure electrical continuity and earthed at regular intervals as well as at both ends.
Metallic conduits, pipes, etc. shall not be used as earth continuity conductor. All hinged doors
shall be earthed by flexible braids of adequate size.
All steel structures shall be duly earthed. Metallic sheaths and armour of all multicore cables
shall also be earthed at both equipment and switchgear end. Earthing conductor shall be buried at
least 2000 mm outside the fence of electrical installations. Every alternate post of the fences and
all gates shall be connected to earthing grid by one lead. Earthing conductor embedded in the
concrete floor shall have at least 50 mm concrete cover.
Earthing connections with equipment earthing pads shall be bolted type with at least two bolts,
and joint surfaces shall be galvanised. The connections shall be painted with anti-corrosive paint
after testing and checking.
Neutral of power transformers shall be directly connected to two rod electrodes in treated earth
pits, which in turn shall be connected to station earthling grid.
The earthing terminal of surge arresters and voltage transformers, and lightning protection down
conductors shall also be connected to station earthing grid through separate rod electrode.
3.6.3 Lightning Protection
The lightning protection system shall be designed as per IS: 2309. It shall cover all buildings and
structures in the plant, and switchyard areas. It shall comprise horizontal/vertical air terminations,
down conductors, test links and earth connections to the station earthing grid. All conductors
shall be of minimum 25x6 mm size and shall be of galvanised steel only.
The down conductors of lightning protection system shall have a test joint at about 1500 mm
above ground level. Each down conductor shall be connected to a 40 mm dia, 3 m long mild steel
earth electrode as well as station earthing grid.
The lightning protection system shall not be in direct contact with under ground metallic service
ducts and cables, and shall not be connected above ground level to other earthing conductors. All
joints in the down conductors shall be of welded type. Pulser system for lightning shall not be
accepted.
Hazardous areas handling inflammable/explosive materials and associated storage areas shall be
protected by a system of aerial earths as per IEEE: 142. Other requirements for Earthing system
a. Standard/Code EE-80, IS: 2309
b. Earthing system life expectancy 40 years

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 c. System fault level 40 kA for one second
d. Soil resistivity Contractor to measure at site at min. 20 locations
approved by Owner.
e. Min. steel corrosion rate 0.25 mm per year.
f. Depth of burial of main earth 600 mm below grade level; where it crosses renches,
conductor pipes, ducts tunnels, rail tracks, etc., it shall be at least
300 mm below them.
g. Conductor joints By electric arc welding, with resistance of joint not
less than that of the conductor. Welds to be treated
with red lead for rust protection and then coated with
bitumen compound for corrosion protection.
The minimum conductor size for earthing system shall be as follows:

Equipment Buried Conductor above ground & in trenches

conductor
Main station grid 40 mm dia MS 65x8 mm GS flat
rod
Switchgear/MCC -- 65x8 mm GS flat
415 V distribution boards -- 50x6 mm GS flat
HT motors -- 50x6 mm GS flat
LT motors above 125 kW -- 50x6 mm GS flat
LT motors - 25 to 125 kW -- 25x6 mm GS flat
LT motors - 1 to 25 kW -- 25x3 mm GS flat
Fractional HP LT motors -- 8 SWG GS wire
Control panel & control desk -- 25x3 mm GS flat
Push button stn. & Junction box -- 8 SWG GS wire
Cable trays, cols. & structures -- 50x6 mm GS flat
Busduct enclosures -- 50x6 mm GS flat
Rails & other metal parts -- 25x6 mm GS flat
Eqpt. earthing for switchyard -- 75x12 mm GS flat and 50x6 mm GS flat

3.7 Internal Communication System

3.7.1 Scope
An electronic telephone exchange suitable for 10 subscribers shall be provided, installed and
commissioned in the powerhouse. The subscribers shall be located at various vulnerable
positions to facilitate the communication. Standard PVC cables shall be laid for these
subscribers. Some of the important locations for subscribers may be as follows.
i) Control room
ii) Switchgear room

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 iii) Machine hall
iv) Unloading/erection bay
v) Drainage/dewatering motor starter panel
vi) Switchyard
vii) Fore Bay
viii) Pump house
ix) Security gates
x) Offices
3.8 TRANSFORMER OIL PURIFIER
One No oil purifier complete in all respect for centrifuging transformer oil shall be supplied
and commissioned for successful performance. The purifier shall be mounted on rubber pad
wheels trolley and shall comprise of compressor systems, heater system, filter packs etc
including all electrical switches, fuses, temperature controllers, indicating instruments and
operating valves. This machine should be able to centrifuge the transformer oil as per relevant
Indian standards.
3.9 Diesel Generating Set
One no. Diesel Generating Set of specified capacity shall be provided for meeting the power
requirement during isolation of the power station from the grid. The D.G. set shall be as per
the relevant standards.

4. TECHNICAL PARAMETERS OF MECHANICAL AUXILIARIES OF POWER

HOUSE

S.No Description Value (to be filled by

bidder)
1. 1 Dewatering System:
a) No. of pumps
b) Type & make of pumps
c) Rating of each pumps (discharge, speed, head)
d) Diameter of impellor
e) Material of casing, shaft & impellor
f) Type, rating, speed and insulation type of motors
g) Type and make of level controllers
2. Drainage System
h) No. of pumps
i) Type & make of pumps
j) Rating of each pumps (discharge, speed, head)
k) Diameter of impellor
l) Material of casing, shaft & impellor
m) Type, rating, speed and insulation type of motors
n) Type and make of level controllers
o) Pressure rating of valves used

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2. Cooling Water System:
a) Source of cooling water (Intake / tail race )
b) No. of pumps
c) Rating of each pumps ( discharge, speed, head)
d) Diameter of impellor
e) Material of casing & impellor
f) Motor type, rating, speed & insulation
g) Type of starter for motors
h) Capacity & make of self cleaning strainers
i) Material and size of strainer element
j) Capacity & make of actuator for strainer
k) Pressure rating of valves
l) Materials of casing, valve seat & stem of valves
3. Compressed Air System
a) No. and capacity of compressors
b) Type & make of compressors
c) Rating of motor, speed & type of insulation
d) Working pressure
e) Volume of high pressure air receiver
f) Volume of low pressure air receiver
g) Test pressure for air receivers
h) Nos., type & make of pressure switches
i) Type & make of pressure reducer
4. Fore bay & tail race water level measuring device
1. Type / basic principle of head sensors
2. Output signals from sensors
3. Make
5. E.O.T. Crane
a) Span
b) Longitudinal Travel
c) Capacity of Main Hook
d) Capacity of Auxiliary Hook
e) Min. clearance of main hook from wall
f) Operating speed of :
i) main Hook
ii) auxiliary hook
iii) bridge travel
iv) trolley travel
g) Rating of main hoisting motor
h) Rating of bridge travel motor
i) Rating of trolley travel motor
j) Height of Girder
k) Min. clearance of roof required above girder
rail level
l) Cross Section of rails
m) Maximum lift of heaviest part possible
n) Total weight of crane

6. Fire Extinguishing System

7. Largest Package for shipment
a) Name
b) Weight
c) Dimension (LxWxH)
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Hydro Power Stations    
 
8. Heaviest Package for shipment:
1. Name
2. Weight
3. Dimension (LxWxH)

5. TECHNICAL PARAMETERS OF ELECTRICAL AUXILIARIES OF POWER

HOUSE
S.No Description Value (to be filled by
bidder)
1 Auxiliary Transformers

(a) No. of transformer

(b) Type and make
(c) Continuous maximum rating
(d) No. of phases
(e) No. of windings
(f) Normal ratio of transformation

(g) Corresponding highest system

voltage -------------------kV

(h) Minimum withstand voltages :

full wave impulse ----------------kV
induced voltage ----------------kV
applied voltage ----------------kV
(i) Type of cooling
(j) Maximum hotspot temp at CMR ----------------xC
(k) Maximum temperature
(Ambient air temperature 450C) ------------------------0
C
(l) Phase connections:
11 kV windings
415 kV windings
m) Vector group
n) Short circuit MVA available
11 kV terminals ----------------MVA
415 kV terminals -----------------MVA
o) Impedance voltage at 750C and at
CMR ( % on HV base) :
Maximum at normal ratio ----------------%

p) Voltage control
Total range of variation
Ratio plus -----------------%
Ratio minus ------------------%
Number and size of steps -------------------%

q) General
Maximum flux density in iron at
normal voltage and frequency and
at normal ratio.
i. Cores Tesla
ii Yokes Tesla
magnetising current --------------------%

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 (approx)

r) Guaranteed total losses at normal ratio, ------------------kW

rated output, rated voltage, rated frequency
and 750C average winding temperature
s) Effieciency at normal ratio, rated voltage,
Rated frequency 0.9 p.f. and 750C average
Winding temperature for the output of;
Full load ------------------%
3/4 full load -----------------%
1/2 full load ------------------%
1/4 full load ------------------%
t) Resistance per phase of ;
H.V. winding Ohms
L.V. winding Ohms
u) Reactance per phase of ;
H.V. winding Ohms
L.V. winding Ohms
v) Regulation at 750C and normal ratio ;
At unity power factor -------------------%
At 0.9 lagging power factor ----------------------%
w) Details of construction
i) Types of winding
HV
LV
ii) Type of insulation
HV windings
LV winding
iii) Type of insulation
Tappings
Tapping connection
iv) Details of Bushing
2 D.C. Station Batteries
(a) Manufacture
(b) Type
(a) Capacity
110 volts
48 volts
24 volts
(b) No of Batteries
110 volts
48 volts
24 volts
(c) Battery Charger
Make
Type

3. L.T. Switchgear (A.C. and D.C.)

(a) A.C distribution Board

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 (i) Manufacture
(ii) Type
(iii) Rated Bus bar current
(iv) Circuit Breaker Manufacture and type
(v) Isolator manufacturer and types
(vi) Details of relays
(vii) Make
(viii) Type
(ix) Details and make of CTs:

(b) D.C. switchgear

(i) Manufacturer
(ii) Type
(iii) Rated breaker current
(iv) Circuit breaker manufacturer and type
(v) Isolator manufacturer and type

4. Power and control cables

Use duplicates of this page as necessary to detail each

type of cable used.

(i) Manufacturer
(ii) Continuous Current Rating -------------------A
(iii) Rated voltage -------------------V
(iv) Cable Type (PVC/SWA/PVC MIAC,XLPE,etc)
(v) Number of Cores
(vi) Cross Section sectional area -------------------mm2
(vii) Core Material
(viii) No. of strands/core
(ix) Nominal strand diameter -------------------mm
(x) Conductor Insulation
-Material
-Thickness -------------------mm
(xi) Aromour /material
(xii) Armour wires diameter -------------------mm
(xiii) Sheathing Material
(xiv) Sheath thickness -------------------mm
(xv) Completed cable
- Diameter -------------------mm
- Weight per meter -------------------kg
- Max. drum length -------------------m
(xvi) Application (connected plant )

5. Lighting system

(i) Lighting fitting

(ii) Manufacturer and Types
(iii) Power Point / Switch fitting manufacturer

6. Cabling Earthing and lightning protection

(i) Make and type of cable supports

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Hydro Power Stations    
 
 (ii) Make and types of cable trays
(iii) Earthing material
(iv) Lightning protection

7. Communication system
Internal Communication System
(i) Make
(ii) Type
(iii) No. of subscriber

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Hydro Power Stations