CHASHMA HYDEL

POWER STATION

By

Muhammad Shakeel
[email protected]
+92-333-4962507
https://www.facebook.com/EngnrShakeel

From
Army Public College of Management and Sciences,

RAWALPINDI
(Affiliated to U.E.T TAXILA)

“Verily never will ALLAH PAK change the condition of a nation until they
change it themselves (with their efforts)”

“HOLY QURAN”

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 Chashma Hydel Power Station, Chashma (Mianwali)

TABLE OF CONTENTS

Acknowledgement…………………………………………… 4

Chapter no 1: Introduction to Hydro-Electricity…………… 5

1.1 What is Hydro-electricity?
1.2 Generation of Hydropower in World
1.3 Generation of Hydropower in Pakistan
1.4 Why Hydro Power is Important for Pakistan

Chapter no 2: Chashma Hydropower Station ……………… 15

2.1 Introduction
2.2 Salient Features of Chashma Hydropower Station

Chapter no 3: Operation Section …………………………… 18

3.1 Kaplan Type Turbine
3.2 Main Parts of TURBINE
3.3 Systematic Diagram of Excitation mechanism

Chapter no 4: Electrical Section ……………………………. 23

4.1 Electrical Generator
4.2 Synchronous Generator
4.3 Advantages of Synchronous Generator
4.4 Transformer

Chapter no 5: Mechanical Section ………………………….. 29

5.1 Governor and Its Operation
5.2 Governor Parts
5.3 Types of Faults In Governor
5.4 Bearings used on main shaft

Chapter no 6: Lubrication Oil System ………………………. 32

6.1 Composition of lubrication oil system
6.2 Block Diagram For Turbine’s Oil Lubrication System

Chapter no 7: Protection and Instrumentation Section ………35

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 7.1 Transformer
7.2 Automatic Voltage Regulator (AVR)
7.3 Relays
7.4 Transducers
7.5 Circuit Breakers

ACKNOWLEDGEMENT

All praise to Almighty Allah, the most Gracious and compassionate. Who
created the universe and bestowed mankind with the knowledge and blessings of Allah be
upon the Holy Prophet Muhammad (S.A.W.) who guided mankind with the Holy Quran and
Sunnah, the everlasting source of guidance and knowledge for humanity.

I has taken efforts in this project. However, it would not have been possible
without the kind support and help of many individuals and organizations. We would like to
extend my sincere thanks to all of them.

I am highly indebted to Chashma Hydropower Station for their guidance and

constant supervision as well as for providing necessary information regarding the project &
also for their support in completing the project.

I would like to express our gratitude towards our parents & member of CHP
for their kind co-operation and encouragement which help us in completion of this project.

I would like to express my special gratitude and thanks to

 Mr. Ghulam Hussain (Resident Engineer)

 Mr. Mehmood Khan (Senior Engineer) for giving us such attention and time.

My special thanks to,

 Mr. Arif
 Mr. Shafique
 Mr. Shakoor
 Mr. Abdul Rehman

My thanks and appreciations also go to our university in developing the

project and people who helped me with their abilities.

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 Chapter No
1

Introduction To Hydro-
Electricity

1.1 What is Hydro-electricity?

Hydro-Electricity is the production of electric power through the use of the
gravitational force of falling and flowing of water. It is form of renewable energy. Most
hydroelectric power comes from the potential energy of dammed water driving a water
turbine and generator. In this case the energy extracted from the water depends on the
volume and on the difference in
height between the source and
water‘s outflow. This height
difference is called head. The
amount of potential energy in water
is proportional to the head. Water to
the turbine is delivered through the
large pipe called penstock. This
water due to its potential energy
rotates the turbine blades which In
turn rotate the turbine generator
shaft. The rotation of the shaft makes
the generator produce electricity

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which is then supplied to the power lines and hence the consumer through a distribution
system.
A generating station which utilizes the potential of energy of water at a high
level for the generation of electrical; energy is known as hydroelectric station. A cross
sectional view of power station is as shown n figure.

1.2 Generation of Hydropower in World

World wide, hydro-electric power plants produce about 24 percent of world’s

electricity and supply more than 1 billion people with power. The world’s hydropower plants
output a combine total of 675,000 MW.

Some of the major hydro plants across the world are as shown in table.

List of largest hydroelectric power stations around the worlds

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Advantages:
 Modern hydro turbines can convert as much as 90% of the available energy into electricity

 Hydropower leaves behind no waste. Hydropower does not produce greenhouse gasses or
other air pollution.

1.3 Generation of Hydropower in Pakistan

Pakistan has very good potential in electric generation through water.
Pakistan has a potential of 40,000MW hydropower, out of which the economic Hydropower
Potential is around 20,000 MW. Whereas total capacity of 13 existing hydel stations as
today 6444 MW which is 35.88 % of total installed generation capacity of WAPDA (Water
and Power Development Authority). Hydroelectric power represents a third of Pakistan’s
power source, however, periodic droughts affect the availability of hydropower production.
WAPDA controls the country’s major hydroelectric plants as shown in table below.

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Electricity in Pakistan generated, transmitted, distributed and retail by two vertically
integrated public sector utilities. WAPDA deals for all of Pakistan except Karachi. The
Karachi Electric Supply Corporation (KESC) for the city of Karachi and its surrounding
areas. There are around 16 independent power producers (IPPs).

Electricity production:
Total Electricity – production in Pakistan in last year is 98.632 TWh (2012

Total electricity generation has virtually remained flat since 2008 despite an increase of
7,827 GwH produced by the IPPs since the generation by old public sector power plants
(otherwise known as GENCOs) decreased by 7,647 GwH as shown in the table.

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 Table: Share of Electricity Generation of all power generators in Pakistan

1.4 Why Hydro Power is Important for

Pakistan
The present crisis started around 2006-2007 as a gradual increase in demand outstripped
power generation. The installed generation capacity is 23,500 megawatts (MW) but any
given time, the actual available capacity has remained below 14,000 MW because the
independent power plants (IPPs) have not been able to buy the fuel oil and production of
old plants in the public sector has dropped causing shortfall of 4,000 to 7,000 MW. While it
is true that the IPPs are not producing enough power to meet the shortfall, it is only part of
the problem.

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Pakistan’s unfavorable high cost energy mix, in contrast to international and Asian norms,
lies at the core of the energy crisis. While the IPPs provided much-needed new power
generation capacity at the time, the country’s generation mix shifted heavily towards Fuel
Oil/Furnace Oil (FO). The policy to divert gas to other sectors of the economy, such as
domestic consumers, fertilizer producers, and to encourage use of compressed natural gas
(CNG) for private vehicles further limited gas supply to the power sector, forcing thermal
generators to depend on more expensive fuels. The share of hydel power that accounted
for 60% of the power generation during the 1960s through the 1980s fell to around 30% by
2005. But even in 2005, gas-based (whose costs are lower compared to plants using oil)
plants accounted for 52% the power generation. Today, the plants using imported oil
represent the single largest source of electricity generation as shown in the figure 1.

Since 1994, the

international price of oil
increased five-fold as
depicted in figure 2, inflating
the cost of generation. The
problem of rising oil prices
was compounded by the
depreciating Pakistani
currency. As international oil
prices are denominated in
US dollars, the cost of
imported FO increases as
the Pakistani rupee
devalues against the dollar.
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From 2005 to 2011, the cost of FO increased in real terms from $236 per ton to $639 per
ton. At the same time, the Pakistani rupee depreciated against the dollar such that the cost
of imported Furnace Oil rose from Rs21,087 per ton to over Rs70,930 per ton. As a result,
the cost of power generated from Furnace Oil grew 236% in just six years.`

As shown in figure 3, the

average cost of Furnace Oil-
based electricity delivered to
the power distribution
companies (DISCOs) was
Rs15.94/kWh in 2011-12
compared to Rs4.24/kWh for
electricity using gas,
Rs1.13/kWh using nuclear
power, and Rs0.16/kWh using
hydel power.

The widening gap between

the high cost of thermal power
and the regulated electricity
prices is the primary reason
for the debt crisis. That’s why
hydel power is necessary for
such a developing country like
Pakistan.

The widening gap between the high cost of thermal power and the regulated electricity
prices is the primary reason for the debt crisis.

It was in 2005 that the circular debt problem emerged as a significant issue. At the end of
2005, the circular debt (or rather the inter-enterprise and corporate debt) stood around
Rs84 billion because the government kept electricity tariffs far below cost-recovery level.
General Musharraf’s government did not allow the rise in electricity prices in line with the
steep rise in the international oil prices for obvious political reasons and tariffs were frozen
between 2003 and 2007 at a very low level.

While the Pakistan Peoples Party government increased electricity prices by 34% to 74%
during 2008-2011 (based on usage), the tariff hikes were still not enough to compensate for
the rise in the energy costs. The gap between the timing of increase in costs and
implementing of higher tariffs compounded the crisis. Apparently, higher prices also led to
collection problems. Out of the Rs872 billion in energy-related debt, Rs197 billion (or 22%)

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is on account of non-payment of bills by the consumers. The federal and provincial
governments also ran up unpaid bills to the tune of Rs133 billion reflecting the poor state of
fiscal governance.

During the period 2006-2012, the circular debt grew by a staggering Rs788 billion to Rs872
billion (nearly 4% of the GDP) at June 2012 according to recent study published by the
Planning Commission of Pakistan. Notwithstanding the non-collection problems, about 62%
of the cumulative increase in the debt has been attributed to the pricing and subsidy issues
as shown in figure 4.

The recent tariff determinations given by the National Electric Power Regulatory Authority
(Nepra) indicate an increase in the financing gap to Rs550 billion per annum from Rs350
billion due to the widening gap between the applicable electricity tariff and the tariff
approved by the Nepra. In other words, users would have to pay an aggregate of Rs550
billion (or about 2.5% of the GDP) to prevent further accumulation of circular debt or the
situation will continue to deteriorate. Even if half of this burden is transferred to the users
through tariff hikes, it would still represent a substantial burden and would probably result in
more unpaid bills and energy theft. The energy crisis has already slowed growth by an
estimated 2% per annum in the last five years. Another price shock is bound to adversely
affect the growth. In the next 6-12 months, government may end up increasing the
electricity tariffs. It may however try to minimize such an increase by borrowing from
external sources (e.g. Saudi Arabia) to buy some time.

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But is it fair to ask the public to bear the entire cost of what is arguably the strategic blunder
of the state compounded by bad governance? It must be pointed out that as a country; the
most rational and optimal choice would be to import electricity till such time generation
capacity of non-thermal sources is increased because the domestic cost of thermal power
is prohibitively higher. Advocates of free markets and trade should support this argument
rather than make a case for financing the white elephants called the oil-based power plants.
This is inherently an unsustainable proposition.

A three-pronged strategy

While the government is reportedly considering borrowing from Saudi Arabia, the borrowing
should be used only as a short term measure and must be accompanied by a
comprehensive three-pronged strategy around:

A. Restructuring and rationalization of generation sector

B. Consolidation of distribution channels

C. Investments in hydel, coal and nuclear energy

The most important part of this strategy would be a restructuring and rationalization plan for
the generation sector. This should include the following steps:

The government should attach the highest priority to importing electricity from the
neighbouring countries as a temporary measure to minimize the adverse impact of high
cost energy mix. Around 1500MW or even higher could be available from India & Iran and
has the potential of reducing the 4000-7000MW shortfall by 30-50%.

The government should aim to convert another 2500-3000MW idle capacity in the
thermal sector into coal-based plants to bring down national average cost. Last year,
Ukraine completed conversion of six thermal power plants to allow them to use coal instead
of natural gas to reduce its dependency on gas imports from Russia. To achieve this, the
IPPs owned by the domestic companies should be bought by the federal government to
because they are not economically viable. A one-time cost restructuring cost would be a
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better option compared to throwing money into what seems to have become a bottom less
pit. Some of the larger public sector oil-based plants should also be converted into coal-
based operations to the maximum possible extent.

The residual financing gap should be financed through tariff hikes and additional direct
income and property taxes with the target of raising an amount equivalent to at least 0.5%
of the GDP. For this purpose, a financial emergency may be declared in accordance with
article 235 (1) of the constitution and the federal government should help the provincial
governments to raise more revenues as they currently lack the capacity to do so.

The level of transmission and distribution (T&D) losses which have ranged around 22% is
another critical aspect. The public ultimately pays for these losses through higher prices
and power outages. In comparison to other Asian countries, these losses are extremely
high. For example, T& D losses are only 3.6% in South Korea; 8% in China; and just 7% in
OECD countries.

Ironically, the privatised KESC has experienced much higher level of T&D losses (around
little more than 30%) compared to the public sector distribution companies. These losses
are due to a host of factors including old-age generation plants, low-voltage transmission
and distribution lines, weak grid infrastructure, inaccurate metering and billing, and outright
theft. It is obvious that the experiment to improve distribution through setting up different
regional companies also failed.

Consolidation of distribution companies at the provincial level via four companies (other
than the KESC) and making the provincial governments a major stakeholder should be
considered provided the companies are run by autonomous boards consisting of
professionals from the private sector. The distribution network requires political and
administrative support of provincial governments, professional management as well as
huge capital investments. Privatization is high unlikely to be a successful policy to meet the
challenges in the electricity distribution in the medium term. Moreover, large companies
backed by the provincial governments would have a better chance of attracting capital and
support from foreign governments.

While some make a case for the so-called intermittent or alternative energy sources like
solar and wind power, the supply from these sources is highly variable and can only
supplement the three main sources of energy (fossil fuels, hydro, and nuclear). Therefore,
in the long term, the government must not allow any more oil-based power plants and
should focus on hydel (specially through smaller dams), coal, and nuclear energy because
only a radical shift in the current energy mix can provide a lasting solution to Pakistan’s
crippling energy crisis.

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Chapter no
2

Page 15 of 41
 Chashma Hydropower
Station

2.1 Introduction
Chashma Hydropower Project is located on the right abutment of Chashma
Barrage. The barrage is located on the Indus River near the village Chashma in Mianwali
District about 304 k.m North West of Lahore. The project has been estimated at Rs17,
821.77 million including foreign exchange component of Rs 9264.25 million.

The installed capacity of power Station is 184 MW comprising of 8 bulb type turbine units
each of 23 MW capacities. The bulb turbines have been installed for the first time in
Pakistan. The first unit was commissioned in January 2001, while final commissioning of all
units was completed in July 2001.

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Salient Features of Chashma Hydropower Station:
Maximum Pound Level: 197.8 m (649 ft)
Normal pound level: 195.7 m (642 ft)
Minimum pound level: 194.2 m (637 ft)

Power House Turbine:

Mad By: Fuji, Japan
Type: Kaplan type
Total Turbines: 8

Generators:
Made By: Fuji, Japan
Type: Synchronous generator
Total Installed: 8
Output: 23 MW each

Step-up Transformers:
Made by: GEC, ALTSOM France
Rated Capacity: 26 MVA
Rated Voltage: 11/ 132 KV
Rated Current: 113.2 A

Output Distribution:
The power generated in this plant is supplied to four Grid Stations through 132 KV
transmission lines which are as:
1. D.I Khan
2. Chashma Left Bank
3. Wanbachran circuit 1
4. Wanbachran circuit 2

Turbines Characteristics:
Type: Kaplan type with movable blades
No. of Blades: 4
Wicket Gates: 16
Rated Net Head: 8.4
Rated Speed: 85.7 rpm
Run Away Speed: 300 rpm
Tripping over speed: 136 rpm

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Arial View of Chashma Hydropower Station:

Chapter no
3
Page 18 of 41
 OPERATION
SECTION

Introduction
CHP is a low head power station utilizing a head of 4 to 13 m.

In low head, Kaplan type turbines are used. Here in CHP; bulb type Kaplan turbines are
used which are very effective in low head.

3.1 Kaplan Type Turbines:

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The Kaplan turbine is a propeller-type water turbine which has adjustable blades. It was
developed in 1913 by the Austrian professor Viktor Kaplan. This turbine is an inward flow
reaction turbine, which means that the working fluid changes pressure as it moves through
the turbine and gives up its energy. Te design combines redial and axial features. The inlet
is a scroll-shaped tube that wraps around the
turbine’s wicket gate. Water is directed
tangentially through the wicket gate and
spirals on to a propeller shaped runner,
causing it to spin. The outlet is a specially
shaped draft tube that helps decelerate the
water and recover kinetic energy.

Bulb Type Kaplan Turbine:

Bulb type Kaplan is a hydro turbine in which
the entire generator is mounted inside the
water passageway as an integral unit with the turbine. These installations can offer
significant reductions in the size of the powerhouse.

3.2 Main Parts of Turbine

RUNNER:
 Inlet Diameter is 6300mm
 Four adjustable blades
 Material is 13% Cr 4Ni stainless steel

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  Runner Hub is made of cast steel
 In hub and runner cone hydraulic servomotor blades are accommodated

MAIN SHAFT:
 Shaft diameter is 900mm
 Material of main shaft is forged carbon steel,
 Have two integrally forged coupling flanges.
 Carries two concentric pipes:
 For carrying pressure oil for closing and opening operation of runner blades,
Servomotor.
 Restoring pipe for carrying lubricating oil from oil gravity tank to runner hub.
It forms two journals which are supported by turbine and generator guide bearings.

Main shaft is directly coupled to generator center at one end, and to runner at the other end.

TURBINE GUIDE BEARING:

Turbine guide bearing is of forced oil circulating type and is a half bearing with its lower half
only being lined by Babbitt metal. The upper half of the bearing is lined at only it’s both ends.
After lubricating the bearing the lubricating oil passes to shaft cover mounted on the turbine
guide bearing, Then it returns to the lubricating oil tank. The bearing shell is split in two parts
in order to facilitate assembling and disassembling. An oil deflector which will through off oil to
bearing cover and prevent from leakage out of oil is fitted on the main shaft near the outlet end
of the bearing. The turbine guide bearing is equipped with three thermometer elements, used
for temperature relay for shutdown and resistance type thermometer recording and indication.

PRESSURE OIL DISTRIBUTING HEAD:

The distributing head shall be mounted on the upstream end of generator. Pressure oil
through distributing valve from governor for controlling the runner servomotor shall be
distributed through concentric pipes used for leading the closing directing oil and opening
directing oil respectively. At the upstream side of the distributing head, feedback device of
runner blade opening is mounted. An oil deflector which will through off oil to cover that is
mounted at downstream side the distributing head and prevents from leakage out of oil.

WICKET GATES:
Wicket gates are made of 13% Cr-4% Ni stainless steel casting and have simple rigidity to
minimize the clearance between adjacent gates in closed position. The side clearances of
wicket gates can be adjusted with adjusting liner. The outer and inner ends of wicket gates are
machined to spherical shape to match the gate ring and minimize leakage. The wicket gate
stem is detachable from inside of the inner gate so as to wicket gates together with outer gate
ring can be removed for over hauling.

WICKET GATES OPERATING MECHANISM:

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 16 wicket gates are located between outer gate ring and inner gate ring. The wicket gate is
supported at its stem by outer and inner bearings. These bearings are non grease lubricating
type and provide spherical sliding so as to allow inclination of wicket gate due to deformation
and displacement of bulb which may occur at the load rejection of turbine. The wicket gates
are of movable type connected to wicket gate operating mechanism and designed to adjust
the discharge, and water flow angle according to the turbine load. The movement of wicket
gates servomotor is converted to rotating motion by the wicket operating ring, and transmitted
to outer wicket gate stems through links.

DISCHARGE RING:
The discharge ring is fabricated from 13% Cr-4% Ni stainless steel plate is split horizontally.
Lower half of discharge ring has man hole. Before man whole is opened, the water must be
checked with test cocks provided near man whole. At downstream end ring, the loose point to
connected to draft tube liner is provided.

DRAFT TUBE LINER:

The draft tube consists of steel lined parts i-e draft tube liner concreted parts, and its profile is
designed to gain maximum turbine efficiency. Draft tube liner is of conical shape extending
from Ф 6625mm to Ф 8200mm measured from upstream side and is fabricated from steel
plates and is of welded construction. The outer surface of draft tube liner is provided with
sufficient ribs and anchors for reinforcement to establish firm grip with surrounding concrete.

OVER SPEED SHUTDOWN DEVICE:

It consists of Fly Weight Assembly which rotates with the main shaft and Control Valve
Assembly. Fly Weight Assembly which attached to main shaft consist of fly weight, he strike
rod and the spring. The strike rod is connected to the fly weight, and protrude out to outside
according to increase the rotational speed. When the rotational speed reaches the setting
speed i-e 140 rpm, the strike rod hit the strike lever of Control Valve Assembly and operate the
control valve to trip the water turbine. The rotational speed for turbine trip can be adjusted
clearance between strike rod strike levers.

3.3 Systematic Diagram of Excitation

mechanism

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Operation involves:
1) First of all when wicket gates of turbine opens, water applies a force on runner blades
through which shaft rotates, which is connected to generator’s rotor.

2) Generator rotor is excited by 110 V of DC supply, generator produces a three phase AC

3) AVR ( automatic voltage regulator) converts AC into DC with help of thyristors, and this DC
supply is fed to the armature to excite it

4) (Excited Generator )Excited armature induced e.m.f in stator and excites it.

5) Main generator produces 11 KV Three Phase AC, which comes to the tap off transformer

6) Tap off transformer gives two paths to 11 KV

i. For auxiliaries

ii. For step-up transformer

7) Step-up transformer step-ups 11 KV to 132 KV and fed it to transmission lines.

All 8 generators are connected to two bus bars. One bus bar is excited at one time
and second bus bar is as a stand-by bus bar; works in the situation when 1st bus bar is not
connected.

Safe Operation of Turbine:

Permissible range of head race and tail race for safe operation of turbine are as follows:
1. Head race level EL 197.8m ~ EL 194.5m.
2. Tail water level EL 192.7m ~EL 184.0m.

Chapter no
4

Electrical Section
Page 23 of 41
4.1 Electrical Generator
Electrical section covers electrical generator and transformer. In
electricity generation, an electric generator is a device that converts mechanical energy to
electrical energy, works on the phenomena of electromagnetic induction. A generator forces
electric charges to move through an external electrical circuit. But here it does not create
electricity or charge, because we are not using permanent magnets in its construction. Here
excitation is needed for creating a magnetic induction. It is analogous to a water pump,
which creates a flow of water but does not create the water inside. The source of
mechanical energy may be reciprocating or turbine steam engine water falling through a
turbine or waterwheel, an internal combustion engine, a wind turbine, a hand crank,
compressed air or any other source of mechanical energy.

The main parts of a generator or motor can describe in either mechanical or electrical
terms.

Main Parts Of Generator In Mechanical Terms:

Rotor: The rotating part of alternator, generator, dynamo or motor.

Stator: The stationary part of alternator, generator, dynamo or motor.

Main Parts Of Generator In Electrical Terms:

Armature: The power-producing component of generator. The armature windings

generate
Electrical current. The armature can be a stator or the rotor.

Field: The magnetic field component of a generator. The magnetic field can be
provided by either electromagnetic or permanent
magnets mounted on either rotor or the stator. Because power transferred into
the field circuit is much less tan in armature circuits.

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 AC generator nearly always has the field winding on the rotor and the stator as the
armature winding. Only a small amount of field current must be transferred to the moving
rotor, using slip rings. Direct current machines necessarily have the commutator on the
rotating shaft, so the armature winding in on rotor of the machine.

4.2 Synchronous Generator

Synchronous Generators are the primary source of all electrical energy and
commonly used to convert the mechanical power output of steam turbines, gas turbines,
reciprocating engines, hydro turbines and wind turbines into electrical power for the grid.
They are known as synchronous generators because they operate at synchronous speed,
which is the same principle of operation as a synchronous motor. The speed of the rotor
with a constant magnetic field always matches supply frequency of the stationary winding.
The constant magnetic field of the rotor is produced by the persistent magnetic field of a
rotor permanent magnet assembly or by controlling direct current to a rotor field winding
(i.e., electromagnet) fed through a slip-ring assembly or a brushless means.

Rating of installed synchronous generator:

Output 26000 KVA
Voltage 11000 V
Current 1365 A
Ex Voltage 275 V
Ex Current 688 A
Phases 3
Frequency 50 Hz
Power Factor 0.9
Rating Continuous
Poles 70
Speed 85.7 RPM
Max Temp of Stator 120o
Max Temp of Rotor 130o

Synchronous speed:
The "synchronous speed" of a synchronous generator is determined by the
following formula:
S = 120 f / p

Where s is the speed of the rotor (in rpm)

f is the frequency of AC (in Hz) and
p is the number of magnetic poles.
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Different from all other synchronous motors, the synchronous brushless wound-rotor
doubly-fed-electric machine operates from sub-synchronous to super-synchronous speeds
or twice synchronous speed.

Conditions of Synchronization:
The following three conditions are considered for synchronization.

1. The alternator must have equal line voltage to the bus voltage.
2. The alternator must have equal frequency to the bus frequency.
3. The alternator must have equal phase sequence to the bus phase sequence.

4.3 Advantages of Synchronous Generator

 There generator can be made to operate at a leading power factor and thereby
improve the power factor of an industrial plant from lagged to one that is close to
unity.
 It gives constant speed from no load to full load.
 Electro-magnetic power varies linearly with voltage.
 These motors can be constructed with wider air gaps than induction motors,
which make them better mechanically.
 These motors operate at higher efficiency, especially in the low speed unity
power factor range.

There are usually use two types of generators are used and they are salient
pole and non salient poles generators.

Salient Pole Generator:

Salient pole generators are those generators in which no. of poles are high and the speed are
very low.

Non Salient Pole Generator:

Non salient pole generators are those generators in which no. of poles are low and the speed
is very high.

Non salient pole generator is also called cylindrical pole generator.

4.4 Transformer
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 A transformer is an electrical
device that transfers energy from one circuit
to another purely by magnetic coupling.
Relative motion of the parts of the
transformer is not required for transfer of
energy. Transformers are often used to
convert between high and low voltages, to
change impedance, and to provide electrical
isolation between circuits.

Basic Principles:
In its most basic form a transformer consists
of:

 A primary coil or winding.

 A secondary coil or winding.
 A core that supports the coils or windings.

The primary winding is

connected to a 60 hertz ac voltage
source. The magnetic field (flux) builds
up (expands) and collapses (contracts)
about the primary winding. The
expanding and contracting magnetic field
around the primary winding cuts the
secondary winding and induces an
alternating voltage into the winding. This
voltage causes alternating current to flow
through the load. The voltage may be
stepped up or down depending on the
design of the primary and secondary
windings.

Conservative Tank:
Conservative tank is play a vital role because we know that oil is present in
transformer. So when it become hot then oil expand so it take space so the expand oil is
come in conservative tank.

Serge Erester:
Serge Erester play the most important role for the protection of the transformer. It is
present between the outputs of the step up transformer. When the voltage is increased with

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the specific value then the serge Erester becomes short to protect the any damage of the
transformer. When serge Erester is short then its further connection will be ground so from
this we protect the transformer.

Tap Changer:
Tap changer is used to change the output voltages by rotating his switch. It has total
seven levels of different voltages. When we increase level by moving its handle the output
voltages will be decreased.

Transformer Cooling System:

In transformer cooling system hot oil come from transformer to
heat exchanger by pipe line. Heat exchanger consists tubes for oil, cooling water circulate
around these tubes to decrease temperature of oil, water circulate by Transformer cooling
water pumps (placed in H cover) these pumps collects water from water cooling surface
bucket. One pump is in operation while other pump on standby .after that hot water from
heat exchanger sends back to cooling water surface. When the oil become hot it also
expand so its will go to the conservative tank.

Expansion replacing Tank:

A tank is placed on E.L 196.80 m for water; in normal
conditions its level remains constant. It is divided in three portions,

 air cooling of generator

 Bearing cooling water

 Transformer cooling water

From expansion replacing tank water flows by gravitational force to maintain volume of
water (in cooling water surface) constant. Expansion replacing tank filled if low water level
found.

Specifications of Power Transformer:

High Voltage Low Voltage
Rated power 27.5 MVA 27.5 MVA
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 Rated voltage 140 ±10 %-5 % KV 11 KV
Rated current 113.2 A 1443.4 A
Highest voltage for 145 V 17.5 V
equipment
Connection WYE ¥ DELTA ∆
Type of cooling ODWF

Chapter no
5

Mechanical
Section

Page 29 of 41
5.1 Governor and Its Operation:

The turbine governor is a system that regulates the inlet of water into a
turbine, which in turn rotates the generator to produce electricity. In order to maintain the
required generated frequency of 50 Hz, the speed of the rotation must be kept constant.
Here in Chashma Hydropower Project plant, this speed is always maintained at 85.7 rpm.
The governor receives the information about the current speed of the turbine from a system
of speed sensors on the turbine shaft and adjusts the water flow by opening and closing of
wicket gates to maintain the required speed of the turbine.

Response to Speed Sensors:

The is a servo motor linked to the throttle and controlled by an electronic
module that senses turbine speed by counting electrical pulses emitted by the switches
connected to turbine shaft through gears or magnetic pickup. Frequency of these pulses is
directly proportional to the shaft speed allows the control electronic module to apply a
proportional voltage to the servo motors to regulate the engine speed. Due to their rapid
response to the speed changes, electronic governors are often fitted to engine-driven
generators, as the generator’s output frequency must be held within narrow range to avoid
malfunction.

Operating Form:
The normal operating form is remote surveillance control, while it is controlled
locally at the unit control cubicle located in the power plant if necessary. In other words the
operator (s) can perform start and stop operation of the generating unit by master control
switch. While watching the indicators in the unit control cubicle. When equipment related to
the generating unit is faulted, the corresponding protection relay is operated and gives
alarm.

5.2 Governor Parts:

 GDA (Gate Driver Amplifier) Interfacing card
This electronic card is used to control the position

 BDA (Blade Driver Amplifier) Interfacing Card

This electronic card is used to control the position of wicket gates
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  ZVPU (Zero Velocity Pick Up) Interfacing Card
This electronic card is used to sense the speed of turbine through the speed sensors at
generator’s turbine shaft

 MPU (Magnetic Pick Up) Interfacing Card

This card is used to sense the generator’s frequency through sensing the rotation of the
shaft on account of the 7 sensors connected in series and feedback. The resistance of
each is collected by DCS (Digital control system) of the governor.

5.3 Types of Faults In Governor:

There are 3 critical faults for the governor to shutdown itself

1. Runner Blade Fault

2. Wicket Gate Fault
3. Speed sensor Fault

5.4 Bearings used on main shaft:

The bearings used on the main turbine shaft are as follows:

1. Guide bearing for Turbine

Used to absorb vertical deflection of shaft on turbine side

2. Guide bearing for Generator

Used to absorb vertical deflection of shaft on generator side

3. Reverse thrust bearing

Used to withstand thrust produced in reverse direction in shaft

4. Normal thrust bearing

Used to withstand normal thrust in shaft

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 Chapter no
6

Lubrication Oil
System

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

Lubricating Oil Pump:

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

Lubricating Oil Sump tank:

The lubricating oil sump tank is oil reservoir for the lubricating oil system and
at the same time used as amounting bed for oil pump units. The volumetric capacity is
sufficient to contain 110% of total necessary lubricating oil quantity. This sump tank is
provided with a float type level indicator with level switches (33QBh, 33QB 11, 33 QB 12).
These are micro switches and operated through cams.

Elevated oil tank:

The elevated oil tank is used to feed lubricating oil gravity to the bearings.
Also used when the lubricating oil pumps are in trouble or AC power is lost. In this case, the
stored lubricating oil permits to supply oil to the bearing for the time required stopping the
turbine safely.

Solenoid valve and pilot check valve:

Page 33 of 41
 The pilot check valve controlled by the solenoid valve (20QBS) is used to
prevent the oil in elevated tank from flowing into the oil sump tank through the bearing while
the turbine is not operated. When the turbine is not to be operated for a month or more, the
solenoid valve should be periodically opened by hand to lubricate the bearing with oil.

High pressure oil pump:

High pressure oil pump are used to do lift of turbine/generator shaft when
units stops and starts. Two units of horizontal gear type pumps, each directly coupled with
an electric motor and installed near side of lubricating sump tank. One unit being used as
normal lubrication oil pump and the other as standby
Normal high pressure oil pump is driven only when unit is stopped or started.

6.2 Block Diagram For Turbine’s

Oil Lubrication System

Oil
reservoir
Page 34 of 41
 Oil Pump

Filter

Individual N.R valve Flow control Flow control

valve valve

Pressure Pressure
switches switches
Oi
l

THRUST BEARING OIL INJECTION SYSTEM

Chapter
no 7

Protection and
Instrumentation
Section

Page 35 of 41
 Isolation of effective parts from energized parts is called protection. While the
physical display of these parts is called instrumentation .

7.1 Transformer
Instrument transformers are used to reduce high currents and voltages to
ranges that can be handled and measured by standard meeting relaying equipment. These
transformers are generally used for protection as well as measuring purposes.

7.1.1 Potential Transformer:

The potential transformers (PT) steps down a high voltage to a normal low
value that can be effectively and safely used for operation of instruments such as
ammeters, voltmeters, watt meters and relays used for various protective purposes.

7.1.2 Current Transformer:

The current transformer steps down a high current of a circuit to lower value
and is used in same type of equipments as for potential transformers. This is done by
constructing the secondary coil consisting of many turns of wire, around the primary coil,
which contains only a few turns of wire. In this manner measurements of high current can
be obtained.
A current transformer should always be short circuited when not connected to external load.
Because the magnetic circuit of current transformer is designed for low magnetizing current
when under load this large increase in magnetizing current will build up a large flux in
magnetic circuit and cause the transformer to act as step-up transformer, inducing an
excessively high voltage in the secondary under no load.

7.2 Automatic Voltage Regulator (AVR)

The generator’s excitation system maintains its voltage and controls the
reactive power flow. As change in real power demand affects essentially the frequency,
whereas a change in reactive power affects mainly the voltage magnitude. The sources of
reactive power are generators, capacitors and rectors. The generator’s reactive power is
controlled by field excitation. The primary mean of generator’s reactive power control is
generator’s excitation control using automatic voltage regulator (AVR). The role of AVR is to
maintain the terminal voltage of a synchronous generator to a specific level. An increase in

Page 36 of 41
reactive power load of a generator is accompanied by a drop in terminal voltage. The PT
senses the voltage on one phase, rectified and compared to the DC set point signal. The
amplifier error signal controls the exciter field and increases the exciter terminal voltage.
Thus the generator’s field current is increased resulting in the increase of generator’s emf.
The reactive power generation is increased to a new equilibrium, raising the terminal
voltage to a desired value. While the AVR get the 440V AC from the excitation transformer
(11kv/440v) which is then converted to DC using thyristors at each of the line combined it
from the output of all three thyristors. As DC have +ve as well as –ve so to obtain these, the
three phases are connected to the thyristors in forward biased and the same there phases
are then connected in reverse biased. Then the 440 v DC is supplied to the stator of the
exciter generator whose rotor induces the AC which is again converted to AC using Diodes
(6 Diodes) and then supplied to the main generator’s rotor. In this way the more flux is
induced in the generator’s rotor thus increasing the rotating speed.

7.3 RELAYS
A relay is an electromagnet switch which opens or closes under the control of
another electrical circuit. The switch is operated by an electromagnet to open or close one
or many sets of contacts. Since its controls an output circuit of higher power than input
circuit, it is considered to a form of an electrical amplifier.
In the Chashma Hydropower Project many different types of relays have been used
for alarm and protection systems.
Some of these important relays are described below:

7.3.1 Electromechanical Relay:

Electromechanical relay consist of multi-turn coil, wounded on an iron core, to

form an electromagnet. When the coil is energized, the core magnetized and attracts the
armature and hence the contacts are joined. While de-energized, the contacts are released.
In this multiple circuit switching is performed by this type of relay.

7.3.2 Solid State Relay:

A solid state relay (SSR) is a solid state electronic component providing the
similar function of a relay but does not have any moving part thus increasing long term
reliability. With early SSRs the trade off came from the fact that every transistor has a small
voltage drop across it. This voltage drop limited the amount of current a given SSR could
handle. As transistors improved, higher current SSR’s able to handle100 to 1200 Amperes.
Compared to electromagnetic relays, they may be falsely triggered by transients.

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7.3.3 PLC (PROGRAMMABLE LOGIC CONTROLLER) RELAY:

In this relay we have been facilitated by the company to vary the range of the
relay using the serial or parallel connector to the relay and setting the required current
value.

7.3. 4 Protection Relays:

This relay is a complex electromagnetic apparatus, often with more than one coil,
designed to calculate operating conditions on an electrical circuit and trip that circuit
breakers in case of a fault. Unlike other relays protection relays have well established,
selectable, time/current curves. Hundreds of protection relays are installed in Chashma
Hydropower project for alarm and protection system. These relays have quick response to
the conditions like the over current, over voltage, reverse power flow, over and under
frequency, and even distance relays that would trip the circuit for faults up to a certain
distance away from the substation. The various functions of protection relays are denoted
by standard ANSI device number. For example, a relay including function 51 would be a
timed over current protective relay. These relays provide various types of electrical
protection by detecting abnormal conditions and isolating them from the rest of electrical
system through breaker. Such relays may be located at the service entrance or at major
load centers.
By combining several functions in one case, numerical relays also save capital and
maintenance cost.

7.3.5overcurrent Relays:
An over current relay is a protective relay which operates when the load current
exceeds a preset value.

7.3.6 Distance Relay:

The most common form of protection on high voltage transmission systems is
distance relay protection. Power lines have set impedance per KM and using this value and
comparing voltage and current and the distance to fault can be determined. The ANSI
standard device number for distance relay is 21. The main types of distance relay
protection schemes are:

 Three step distance protection

 Switched distance protection
 Accelerative or permissive intertrip protection
Page 38 of 41
  Block distance protection

In three step distance protection, the relays are separated in three separate zones of
impedance measurement to accommodate for over reach and under reach conditions.

7.3.7 Synchronic Check Relay:

This relay is used to interconnect the load to the bus bar after synchronizing the
phases, voltage and frequency.

The CT & PT are mainly used for protection and measuring purpose. CT & PT can
be utilized to perform only these two functions.

7.4 Transducers
A devise that transforms one type of energy into another, e-g a microphone, a
photoelectric cell or an auto mobile horn is called a transducer. In Chashma Hydropower
Project, the transducers being used are of the types converting mechanical energy into
electrical.

7.5 Circuit Breakers

They isolate the electronic device from the exciting circuit during the load conditions,
when there is an emergency.

7.5.1Types of Circuit Breakers:

 Low voltage circuit breakers
 Medium voltage circuit breakers
 High voltage circuit breakers

(a) Low Voltage Circuit Breakers:

Low voltage (less than 1000V AC) types are common in domestic,
commercial and industrial applications. Low-voltage power circuit breakers can be mounted
in multi-tiers in low-voltage switchboards.

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 (b) Medium Voltage Circuit Breakers:
These are between 1 and 72 kV may be assembled into metal enclosed
switchgear line ups for indoor use, or may be individual components installed outdoors in a
substation. Air break circuit breakers replaced oil filled units for indoor applications but are
now themselves replaced by vacuum circuit breakers (up to 35kV). Medium voltage circuit
breakers nearly always use separate current sensors and protection relays instead of
relying on built in thermal and magnetic over current sensors. Vacuum circuit breakers with
rated current up to 3000A interrupt current by creating and extinguishing an arc in a
vacuum container. These are generally applied for voltage up to 35000 volts. Vacuum
circuit breakers tend to have long life expectancies between overhaul than do air circuit
breakers. Air circuit breakers rated value up to 10,000A. Trip characteristics are often fully
adjustable including configurable trip thresholds are delays are usually electronically
controlled, though some models are microprocessor controlled via an integral electronic trip
unit, often used for main power distribution in large industrial plants, where the breakers are
arranged in draw-out enclosures for ease of maintenance.

(c) High Voltage Circuit Breakers:

Electrical power transmission networks are protected and controlled by high
voltage breakers. The definition of “high voltage” varies but in power transmission work is
usually thought to be 72,500V or higher, according to a recent definition by international
electro-technical commission (IEC) high voltage breakers are nearly always solenoid-
operated, with current sensing protective relays operate through CTs. In a substation the
protection relay scheme can be complex; protecting equipment and buses from various
types of overload or ground/earth faults. Most commonly used circuit breakers are sulfur
Hexafluoride (SF6) high voltage circuit breakers SF6.

sulfur hexafluoride circuit breaker uses contacts surrounded by sulfur

hexafluoride gas to quench the arc. They are most often used for transmission-level
voltages and may be incorporated into compact gas-insulated switchgear. In cold climates,
supplemental heating or de-rating of the circuit breakers may be required due to
liquefaction of the SF6 gas.

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Indoor SF6 Circuit Breaker Outdoor SF6 Circuit Breaker

Page 41 of 41