Kangan Report

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An Internship Report

On

MAINTENANCE AND OPERATION OF HYDROELECTRIC POWER PLANT

At

JAMMU AND KASHMIR POWER DEVELOPMENT CORPORATION


(KANGAN POWER PLANT)

SUBMITTED BY:

SUHAIL YOUSUF (17206145005)


MOIEN MUZAFFAR BHAT (17206145036)
ASHIQ HUSSAIN TEELI (17206145039)
KHURAM MAJEED BHAT (17206145059)
OWAIS GULZAR (17206145051)
AAQIB GULL (17206145014)
SHABIR AHMAD BUJAL (17206145060)

In conformity with the requirements for the degree of

BACHELOR OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING


INSTITUTE OF TECHNOLOGY, ZAKURA CAMPUS
UNIVERSITY OF KASHMIR, SRINAGAR
ACKNOWLEDGEMENT
The success and final outcome of this training required a lot of guidance and assistance and
we are extremely privileged to have got this all along the completion of the training. All that
we have done is only due to such supervision and assistance and we would not forget to be
thankful.
We owe our deep gratitude to our training guides especially Ashraf sir (AEE).We are
extremely thankful to them for providing such a nice support and guidance and provided
us with all the necessary information for developing a good system.

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Table of Contents
ACKNOWLEDGEMENT ....................................................................................................................i
1. INTRODUCTION ........................................................................................................................... 1
1.1 Hydropower: Global status ........................................................................................................ 1
1.2 Installed utility capacity of India ............................................................................................... 1
1.3 Hydropower utility capacity in J&K ......................................................................................... 1
1.4 3*35 MW UPPER SINDH HYDROELECTRIC POWER PROJECT STAGE 2, KANGAN. 1
2. OVERVIEW .................................................................................................................................... 3
2.1 HYDRO SYSTEM OVERVIEW .............................................................................................. 3
3. COMPONENTS AND OPERATION ............................................................................................. 6
3.1 TURBINES ................................................................................................................................ 6
3.2 SYNCHRONOUS GENERATOR .......................................................................................... 10
3.3 DEWATERING UNIT ............................................................................................................ 12
3.4 HIGH/LOW PRESSURE COMPRESSOR UNITS ................................................................ 13
3.5 TAIL POOL ............................................................................................................................. 13
3.6 TAIL RACE ............................................................................................................................ 14
4. MAINTANANCE OF HYDRO TURBINES................................................................................ 15
4.1 PREVENTIVE MAINTENANCE .......................................................................................... 15
4.2 LOAD MANAGEMENT SYSTEM ........................................................................................... 15
4.3 EMERGENCY SYSTEM SHUTDOWN ................................................................................ 15

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LIST OF FIGURES
Figure 1: Wangath balancing reservoir........................................................................................... 3
Figure 2: Forebay. ............................................................................................................................. 4
Figure 3: Diversion Anchor Block For 1, 2, 3 Unit. ........................................................................ 4
Figure 4: Penstock line 1: 3M diameter (unit 1&2), line 2: 2.25 M diameter (unit 3). ............... 5
Figure 5: Operation of a hydroelectric power plant. ..................................................................... 7
Figure 6: Impulse and reaction turbine ........................................................................................... 8
Figure 7: Parts of Francis turbine.................................................................................................... 9
Figure 8: Generator. ........................................................................................................................ 10
Figure 9: A three-phase synchronous generator. ......................................................................... 11
Figure 10: Control and relay panels. ............................................................................................. 11
Figure 11: Control system. .............................................................................................................. 12
Figure 12: Dewatering pumps ........................................................................................................ 12
Figure 13: Compressor units .......................................................................................................... 13
Figure 14: Tail pool ......................................................................................................................... 13
Figure 15: Tail race ......................................................................................................................... 14

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1. INTRODUCTION
1.1 Hydropower: Global status
Hydropower is the leading renewable source for electricity generation globally, supplying 71% of
all renewable electricity. Reaching 1,064 GW of installed capacity in 2016, it generated 16.5% of
of world’s electricity from all sources.

1.2 Installed utility capacity of India

India is the 7th largest producer of hydroelectric power in the world. As of 30th April, India’s installed
utility scale hydroelectric capacity was 44,594 MW, or 13.5% of its total utility power capacity.
Additional small hydroelectric power units with a total capacity of 4,380 MW (1.3% of its total utility
power generation capacity) have been installed. India’s hydroelectric power potential is estimated at
84,000 MW at 60% load factor. In the fiscal year, 2016-2017, the total hydroelectric power generated in
India was 122.31 TWH (excluding small hydro) with an average capacity factor of 33%.

1.3 Hydropower utility capacity in J&K


“Presently, J&K is the only state where development of hydropower is a priority. Elsewhere in India, the
focus is on solar power”. The installed capacity of power stands just at 504.44 MWs in the state of which
308.70 MWs are Hydel and rest thermal. From a negligible base of 3-4 MWs in 1950-51, the installed
capacity of power has risen to 504.44 MWs. Most important hydro projects are: lower Jhelum with 105
MWs, Upper Sindh Hydro Kangan with 105 MWs, Upper Sindh Sumbal with 22.60 MWs, etc.

1.4 3*35 MW UPPER SINDH HYDROELECTRIC


POWER PROJECT STAGE 2, KANGAN.

1.4.1 HISTORY

Jammu & Kashmir State Power Development Cooperation Limited developed Upper Sindh Hydel Power
Project Stage 2 in Ganderbal district of J&K. Upper Sindh 2 dam has been constructed on Sindh Nallah

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and Wangath Nallah tributaries of Jhelum River. It is located 40 km from Srinagar. The catchment area of
the dam is 927sq. km out of which 697sq. km lies in Sindh basin and the rest 230sq. km in Wangath
basin. The tail waters of Upper Sindh 1 are diverted into Upper Sindh 2 for power generation in the
project. This project utilizes the head of about 220m between Sumbal and Wangath.

Upper Sindh 2 power house has 3 units of 35 MW each. JKPDC commissioned the project in 2000-2002.
The plant is operational since June 2002.

➢ LOCATION: NE of Srinagar
➢ CAPACITY: 105MW
➢ GENERATING CAPACITY: 90-100MW (during peak season), 3-5MW (during off season)

1.4.2 SALIENT FEATURES:

➢ COST OF THE PROJECT: Rs. 42,500 LACS


➢ NET HEAD: 231.4(759 ft)
➢ PEAK GENERATION: 105 mw
➢ UNIT SIZE: 3*35 MWs
➢ TOTAL UNITS TO BE GENERATED ANUALLY: 448 million units

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2. OVERVIEW
2.1 HYDRO SYSTEM OVERVIEW

Major components of a hydro system:

A hydro system is a series of inter connected components: water flows in one end, and electricity
comes out the other.

• BALANCING RESERVOIR: A balancing reservoir is one from which water is not abstracted for
household chores or drinking rather it is used in conjunction with other reservoirs upstream in
order to ensure that whatever happens to water supply and demand upstream, an acceptable
water level is maintained in the river downstream of the reservoir chain.

Figure 1: Wangath balancing reservoir.

• FOREBAY: A reservoir or canal from which water is taken to run a waterwheel or turbine.
The channel conducts the water from the intake to the forebay tank. It forms the connection
between channel and penstock. The main purpose is to allow the particles to settle down
before the water enters the penstock.

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Figure 2: Forebay.

• WATER DIVERSION (INTAKE): A water diversion system serves two primary purposes.
The first is to provide deep enough pool of water to create a smooth, air free inlet to the pipeline.
The second is to remove dirt and debris.

Figure 3: Diversion Anchor Block For 1, 2, 3 Unit.

• PIPELINE (PENSTOCK): The pipeline is responsible for not only moving water to the
turbine, but is also the enclosure that creates head pressure with increasing vertical drop. In
effect the pipeline focuses all water power at the bottom of the pipe where the turbine will
connect. In contrast, an open stream dissipates the energy as it travels down the hill.

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Figure 4: Penstock line 1: 3M diameter (unit 1&2), line 2: 2.25 M diameter (unit 3).

• POWERHOUSE: The powerhouse is simply a building that houses the turbine, generator and
controls. Proper design significantly affects systems efficiency, however, especially with regard
to how the water enters and exits the turbine.

• TURBINES: It is the heart of the hydro system, where water power is converted into the
rotational force that drives the generator. It is arguably the most important component of the
system, because it’s efficiently determines how much electricity is generated. The turbines
used in this power house are of Francis type. The selection of turbines depends on their
operating heads and flow rate. The head and flow rate of Francis Turbines are:

Head: 45 – 400 meter

Flow Rate: 10-700 cubic meter per second

There are 24 guide vanes outside the runner of the Turbine which controls the flow rate of water.
The opening and closing of guide vanes is done by using servo motors, automatically as well as
manually.

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3. COMPONENTS AND OPERATION
3.1 TURBINES
A turbine is a rotator mechanical device that extracts energy from a fluid flow and converts it into useful
work. The work produced by the turbine can be used in generating electrical power when combined
with a generator or producing thrust. A turbine is a turbo-machine with at least one moving part called a
rotor assembly, which is a shaft or drum with blades attached. Moving fluid acts on the blades so that
they move and impart rotational energy to the rotor.

WATER TURBINE: A water turbine is a rotator machine that converts kinetic energy and potential energy
of water into mechanical work. Water turbines were developed in the 19th century and were widely used
for industrial power prior to electrical grids. Now they are mostly used for electrical power generation.
Water turbines are mostly found in dams to generate electric power from water kinetic energy.

THEORY OF OPERATION
Flowing water is directed on the blades of a turbine runner, creating a force acts through a distance. The
water flowing in the river possesses two types of energy; The Kinetic energy due to the flow of
water and potential energy due to the height of water. In hydroelectric power plant, the potential
energy of water is utilized to generate electricity.
The formula for total power that can be generated from water in hvdro electrical power plant due to
its height is given:
P = rgh

Where, p is the power produced in watt and r is the rate of flow of water which cubic meter/
second, 'h' = height of water which is measured in meter its also head water. The difference between
source of water (from where water is taken) and water out flow (where the water is used to generate
electricity, it is the place near the turbines). g is the gravity, constant 9.8 m/s square.

The formula clearly shows that the total power that can be generated from the hydro Electrical power
plants depends on two major factors: the flow rate of water, and volume of flow of water and height

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or head of water. More the volume of water and more the head of water more is the power produced
in the hydro electrical power plant.

Figure 5: Operation of a hydroelectric power plant.

Water turbines are divided into two groups; reaction turbines and impulse turbines.

Impulse turbines change the direction of flow of a high velocity fluid or gas jet. The resulting
impulse spins the turbine and leaves the fluid with diminished kinetic energy. There is no
pressure change of the fluid or gas in the turbine blades. Before reaching the turbine, the fluid’s
pressure head is changed to velocity head by accelerating the fluid by a nozzle. Impulse turbines
do not require pressure casement around the rotor since the fluid jet is created by the nozzle
prior to reaching the blades of the rotor. Newton’s second law describes the transfer of energy
for impulse turbines. These turbines are most efficient for use in cases where the flow is low and
inlet pressure is high.
Reaction turbines develop torque by reacting to the gas or fluid’s pressure or mass. The pressure of
the gas or fluid changes as it passes through the turbine rotor blades. A pressure casement is
needed to contain the working fluid as it acts on the turbine stages or the turbine must be fully
immersed in the fluid flow. The casing contains and directs the working fluid and, for water
turbines, maintains the suction imparted by the draft tube. Francis turbines and most steam
turbines use this concept. For compressible working fluids, multiple turbine stages are
usually used to harness the expanding gas efficiently. Newton’s third law describes the
transfer of energy for reaction turbines.

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Figure 6: Impulse and reaction turbine

Francis turbines: it is a type of water turbine developed by James B. Francis in Lowell. It is an inward
flow reaction turbine that combines radial and axial flow concepts.

Components: A Francis turbine consists of following main parts:


• Spiral casing: The spiral casing around the runner of the turbine is known as volute
casing or scroll casing. Throughout its length it has numerous openings at regular
intervals to allow the working fluid to impinge on the blades of the runner. These
openings convert the pressure energy of the fluid into momentum energy just before
the fluid impinges on the blade. This maintains a constant flow rate despite the fact that
numerous openings have been provided for the fluid to enter the blades, as the cross-
sectional area of this casing decreases uniformly along the circumferences.
• Guide or stay vanes: The main function of the guide or stay vanes is to convert the
pressure energy of the fluid into the momentum energy. It also serves to direct the flow
at design angles to the runner blades.
• Runner blades: These are the centers where fluid strikes and the tangential force of the
impact cause the shaft of the turbine to rotate, producing torque. Close attention in
design of blade angles at inlet and outlet is necessary, as these are major parameters

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affecting power production.

• Draft tube: The draft tube is a conduit that connects the runner exit to the tail race
where the water is discharged from the turbine. Its primary function is to reduce the
velocity of discharged water to minimize loss of kinetic energy at the outlet. This permits
the turbine to be set above the tail water without appreciable drop of available head.

Figure 7: Parts of Francis turbine.

• DRIVE SYSTEM: The drive system couples the turbine to the generator. At one end
it allows the turbine to spin at its optimum rpm. At the other, it driver the generator
at the rpm that produces correct voltage and frequency.
• GENERATOR: The generator converts the rotational power from the turbine shaft into
electrical power.

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Figure 8: Generator.

3.2 SYNCHRONOUS GENERATOR


A synchronous generator is a machine for converting mechanical power from a prime mover to A.C
electric power at a specific voltage and frequency. A synchronous machine moves at a constant speed
known as synchronous speed. These are the majority source of commercial electrical energy. In a
synchronous generator, a rotor magnetic field is produced either by designing the rotor as a permanent
magnet or by applying dc to a rotor winding to create an electromagnet. The rotor of the generator is
then turned by a prime mover, producing a rotating magnetic field within the machine. This magnetic
field induces three-phase set of voltages within the stator windings of the generator.

Large synchronous generators are used to generate bulk power at thermal, hydro and nuclear power
stations. Synchronous generators with power ratings of several hundred MVA used in super-power are
used in generating stations. Synchronous generators are the primary source of the world’s electric
power systems today. For bulk power generation, stator windings of synchronous generators are
designed for voltages ranging from 6.6KV to 33KV.

1. Active power =35000 KW


2. Apparent Power = 38888 KVA
3. Power Factor (cosØ) =0.8 Lag
4. Synchronous Speed = 120×f ÷ p = 120 × 50 ÷ 10 = 600 rpm.
5. Stator V= 11000 V and I = 2041 A

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6. Rotor V = 159V & I =810 A

Figure 9: A three-phase synchronous generator.

• GOVERNORS AND CONTROLS: Governors and other controls help ensure that the generator
constantly spins at its correct speed. With no load whatsoever, the generator would ‘freewheel’,
and run at a very high rpm probably causing damage. But by adding progressively higher loads,
the generator will slow down until it reaches the exact rpm for proper voltage and frequency.
As long as the load “design load” is maintained, power output will be correct.

Figure 10: Control and relay panels.

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Figure 11: Control system.

3.3 DEWATERING UNIT


The water leakage from turbines and other allied pipes in a power house can be removed from it with
the help of dewatering motor pumps, as shown:

Figure 12: Dewatering pumps

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3.4 HIGH/LOW PRESSURE COMPRESSOR UNITS
The compressor units are installed in the power house in order to regulate the pressure and maintain
it upto desire level for oil lubrication & cooling of different equipments in the power house.

Figure 13: Compressor units

3.5 TAIL POOL


When water leaves the turbine after imparting energy to the turbine, it finally goes to tail
pool through draft tube. The water level of tail pool is higher than turbine level, so that maximum
energy is utilized from pressure energy of water.

Figure 14: Tail pool


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3.6 TAIL RACE
The water after having done its useful work in the turbine is discharged to the tail race which may
lead it to the same or to any other.

The tale pool water goes ahead to meet with other river through tail race. The breadth of tale race is
smaller than tale pool so that the water gets quickly off from tail pool.

Figure 15: Tail race

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4. MAINTANANCE OF HYDRO TURBINES

4.1 PREVENTIVE MAINTENANCE


In order to achieve the objective of maintenance, time has to be allotted every year for each machine.
Normally the periodicity and procedure for maintenance is recommended by the manufacturer of the
equipment.
After successful running of the plant for about one year, a few weeks are required to inspect the rotating
parts, control equipment and measuring instruments and to analyze the cause of changes in performance
characteristics, if any.
The checks for annual maintenance include the foundation parts, runner, guide apparatus, guide
bearing, centralized grease lubricating system, oil pressure unit, oil header, oil leakage unit, oil cooling
unit, governor mechanical unit.

4.2 LOAD MANAGEMENT SYSTEM


A load management system is an enhanced version of the electronic load governor, offering not only
the ability to regulate power usage but also the option to choose and prioritize how power is used. In
addition to ballast loads, it can directly control a wide variety of devices via relays.
Small load adjustments work just like electronic governor; the variable electronic switch regulates power
to the ballast loads. When there is enough excess power, however the load management system will
control other devices in certain priority.
Load management systems have six or more loads that can be prioritized and switched using relays, and
their seamless operation help them facilitate normal household activities even with relatively small
hydro systems.

4.3 EMERGENCY SYSTEM SHUTDOWN


An emergency shutdown system is an option that protects the system from over speed, which may damage
the generator dead short (an extremely high load), open line (zero load), generator runaway (a dead short can
also cause runaway if it trips a breaker). Any of these conditions are both dangerous and expensive.
Emergency shutdown usually means removing all water power from turbine. It is important to
recognize, however, that an abrupt halt to water flow could damage the pipeline.
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