Lower Kalnai H.E. Project (48 MW), J&K Tojo-Vikas International Pvt. Ltd.

Revised Detailed Project Report (2010) Consulting Engineers

Volume I- Main Report, Section 8, Hydro Mechanical Works

SECTION – 8

HYDRO- MECHANICAL WORKS

8.1 GENERAL

The Hydro-Mechanical Equipment proposed for the project to control the discharge as well
as to facilitate planned and controlled reservoir operation, as also for maintenance
purposes, comprises the following:

• Radial Gates for spillway with hydraulic hoists (10m*15m)

• Stop Log Gates on the Spillway operated by electrically operated traveling crane (10m
*17.37m)
• Bulkhead gate (7m*7m) for diversion tunnel closure with tower crane or any other
suitable arrangement
• Power Intake Gates (two of 2m* 3m) -Vertical Fixed Wheel Roller Type with Rope Drum
Hoist with one set of stoplogs
• Trash Rack for Intake
• Desilting Outlet gate-2 no Vertical Lift gate(2m*3m)
• Valve House with two butterfly valves of 2 m diameter
• 2 no of Draft Tube Gates with individual Rope Drum Hoist

The general description and the design philosophy are explained for each type of gate in the
following paragraphs. General Arrangement Drawings for the above mentioned gates are
given in Report Volume III - Drawings.

8.2 SPILLWAY RADIAL GATES

8.2.1 General Description

The spillway bays are fitted with 4 nos. of 10.0m x 15.0m Radial Gates with crest at EL.
1120.00m and the sill level at EL. 1119.677m. Out of 4 gates, one gate is considered as an
emergency gate (i.e. non-operative due to jamming). The gates are adequate for passing
the PMF of 3340 cumecs at FRL/MWL of EL. 1135.00m. All gates will be operated by
hydraulic hoists. The spillway bays are separated by 4.0m thick intermediate piers and
thickness of end piers is 3.0m.

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Lower Kalnai H.E. Project (48 MW), J&K Tojo-Vikas International Pvt. Ltd.
Revised Detailed Project Report (2010) Consulting Engineers
Volume I- Main Report, Section 8, Hydro Mechanical Works

The radial gates will be operated with Hydraulic Hoists located on the hoist bridge at
EL.1136.50. Normally the gates will remain in the closed position during non monsoon
season to provide diurnal storage for power generation.

An Electrically operated Traveling crane of adequate capacity has been provided at the Dam
top/Road level of EL. 1137.00 m. to operate the stoplog gates.

Radial Gates and Stop Logs-General Arrangement Drawing no. TVIPL/LKHEP/P-5001 (Rev
01) and 5002 (Rev -01) is given in Volume III – Drawings. (These drawings are also given in
Section VI Part C Tender Drawings of Technical Specifications).

Proper gate operation schedule can be prepared for operation of these spillway radial gates
keeping in view the flood moderation. The Maximum Water Level (MWL) which is also the
Full Reservoir Level upstream of the gates is EL 1135.0 m

8.2.2 Design Philosophy

The Maximum Water Level (MWL) and Sill level are, respectively at EL 1135.0 m and EL
1119.677 m and hence the Gate shall be designed for a head of 15.4 m and is normally kept
in fully closed position during non monsoon season. The radius of the gates is proposed to
be 14 m and shall be operated by means of Hydraulic Hoists - each of 140 tonnes capacity.
The Hoist will be mounted on a platform at EL 1136.50 m. The Gate will, in general, be
designed in accordance with the provisions of IS: 4623 and several other related codes and
accepted standards of engineering practice.

8.3. STOP-LOG GATE

8.3.1 General Description

The clear opening of Radial Gates is 10.00 m (width) x 15.0 m (height) as shown in the
Drawing No.TVIPL/LKHEP/P-5001 (Rev-01). The Maximum Water Level (MWL) upstream of
the gates is 1135.00 m and the Full Reservoir level is 1135.0m. It is proposed to provide one
set of Stop Logs upstream of the Radial Gates, to enable inspection and maintenance of the
Radial Gates. The Stop-Logs comprise 9 panels in each set. The Stop-Logs will be of sliding
type having a total size of 10.00 m (width) x 17.37 m (height) with the Sill at EL 1117.63m
(approx). Radial Gates and Stop Logs - General Arrangement Drawing no TVIPL/LKHEP/P-
5001 (Rev -01) & 5002 (Rev- 01) is given in Volume III – Drawings. (These drawings are
also given in Section VI Part C Tender Drawings of Technical Specifications).

J&K State Power Development Corporation (J&K SPDC), Jammu 8-2

Lower Kalnai H.E. Project (48 MW), J&K Tojo-Vikas International Pvt. Ltd.
Revised Detailed Project Report (2010) Consulting Engineers
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8.3.2 Design Philosophy

As the Maximum Water Level (MWL) and Sill Level are respectively at EL 1135.00m and EL
1117.63m, Stop-Log Gate has been designed for a head of 17.37 m. This is normally kept
stored in fully open and dry condition. However, the gates have been checked for extreme
loading condition to open under balanced condition. The top panel has been envisaged to
open under unbalanced condition and other panels opening under balanced condition. All
other panels will close under balanced condition. All the panels will be made inter-
changeable for ease of operation except the top panel. which is non-interchangeable.
Provision of stoplogs has been made on the spillway. Grooves for stop logs have been
made in all the four bays. One set of stoplogs consisting of 8 identical units of 1.91 m each
and the top panel of 2.09 m have been proposed tentatively, so that one spillway bay can be
isolated at a time for inspection and maintenance of Radial Gates. Normally, the stoplog
elements are lowered one above the other in gate grooves of spillway piers with the help of
lifting beam and are operated by Gantry Crane. For storage of stoplogs when not in use, two
storage bays can be provided near the right abutment. The stoplogs will be of downstream
sealing type with double bulb seals to provide better sealing capability.

It is proposed to provide slot fillers for making the stoplog grooves, which will eliminate the
possibility of damage to the grooves or spillway profile due to debris and hydraulic
turbulence, as also eliminate possibility of sediment/debris deposition in the grooves.

The Stop-Log panels are operated by means of an electrically operated Gantry Crane of
capacity 8 tonnes, running over rail provided on the dam crest for handling the stoplog units
as well as slot fillers. The Stop-Logs will be vertical lift, sliding type, having skin plate and
sealing arrangement on the downstream side using a Lifting Beam. The Gate will in general,
be designed in accordance with the provisions of IS: 5620 and several other related codes
and accepted standards of engineering practice.

8.4 DIVERSION TUNNEL BULK HEAD GATE

8.4.1 General Description

For the construction of Concrete Gravity Dam and appurtenant works, the river diversion is
proposed to be carried out through a 7.0m diameter and about 325m long concrete lined D-
shaped diversion tunnel located on the right bank of the Lower Kalnai Nallah, u/s of the
upstream cofferdam.

J&K State Power Development Corporation (J&K SPDC), Jammu 8-3

Lower Kalnai H.E. Project (48 MW), J&K Tojo-Vikas International Pvt. Ltd.
Revised Detailed Project Report (2010) Consulting Engineers
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A 7-m diameter D-shaped tunnel with 300mm thick concrete lining (M-20 grade) has been
designed with a velocity of flow in the tunnel of the order of over 10.00m/s.The diversion
tunnel shall be closed before filling of the reservoir with 7.m wide*7m high bulkheadgate
which will be lowered by a Tower Crane or any other hoist mechanism provided at EL
1118.00m.

8.4.2 Design philosophy

The diversion tunnel has been provided with 7m wide*7 m high vertical lift Bulkhead which
will be lowered by a Tower Crane or any other hoist mechanism provided at EL 1118.00 m.
The bulkhead gate shall be designed for an unbalanced head of 18.0 m.

8.5 POWER INTAKE GATE

8.5.1 Power Intake Gate with One Set of Stoplogs

8.5.1.1 General Description

A D-shaped Head Race Tunnel, 4m in size conveys water to the Powerhouse. A Power
Intake Structure is proposed on the left bank of Lower Kalnai River just upstream of the
Diversion Dam. The Intake is designed to draw a total discharge of 37 m3/s (including
overload requirements & 25% silt flushing requirement) from the reservoir. A 7.9 m wide x
11.55 m long x 13.91 m high Intake structure has been proposed for the Power Intake. The
Intake is provided with two bell-mouth openings each having an Intake gate of 2.0m (w) x
3.0m (H) size operated by Rope Drum Hoisting structures. In addition, gate grooves for
stoplogs has been proposed upstream of each Intake Service Gate groove, but only one set
of stoplogs is proposed. Two Intake Service Gates have been proposed at the Intake
structure to facilitate segregation of each chamber of the de-silting chamber during its
cleaning & maintenance operation during lean season. Suitable transition has been
proposed to convert each rectangular intake opening into a D-shaped opening to match the
D-shaped feeder tunnels of 3.0m diameter each, one for each chamber of the Desilitng
Chamber.

The Intake Gate will be of Fixed Wheel Type having a size 2 m x 3 m with its sill at EL.
1123.01 m, whereas the FRL/MWL at the Intake is 1135.00m. Power Intake Gate - General
Arrangement in TVIPL/LKHEP/P-5006 (Rev-01) & 5007 (Rev-01) are given in Volume III –
Drawings.(These drawings are also given in Section VI Part C Tender Drawings of Technical
Specifications).

J&K State Power Development Corporation (J&K SPDC), Jammu 8-4

Lower Kalnai H.E. Project (48 MW), J&K Tojo-Vikas International Pvt. Ltd.
Revised Detailed Project Report (2010) Consulting Engineers
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8.5.1.2 Design Philosophy

The Power Intake Gates each of size, 2 m x 3 m in size, will be of Fixed Wheel type
provided with rollers. As the FRL/ MWL is 1135.0m and the Sill Level is at 1123.10 m, the
Gates have been designed for a head of 12 m. It is normally kept in fully open condition. It
will be lowered only for inspection and maintenance of Head Race Tunnel and is envisaged
to operate under unbalanced condition. The Gates will be provided with Ballast, if found
necessary, during Detailed Engineering, to enable self-closure during the gate operation.
The Gates will have upstream skin plate and seals, which allow the inspection of gate
framework when the gate is closed and the downstream side is dewatered. A Hydraulic
Gate with upstream seal also reduces the hoisting capacity due to the absence of down-pull
forces during opening of the gate - thus resulting in lower costs. It is proposed to operate the
gate by means of electrically operated Rope Drum Hoist located on the Hoist Platform
installed over the trestles. The Gates will in general, be designed in accordance with the
provisions of IS: 5620 and several other related codes and accepted standards of
engineering practice.

Stop logs
One set of Stoplogs has been provided before the service gates of the Power Intake .The
stoplog gate of 2 m x 3 m in size, will be of Fixed Wheel type provided with rollers. As the
FRL/MWL is 1135.0 m and the Sill Level is at 1123.10 m, the Gates have been designed for
a balanced head of 12 m.operated by electrically operated rope drum hoist.

8.5.2 TRASH RACK

8.5.2.1 General Description

Clear openings of intake structure is 3 nos of 4.0m. To ensure that no floating trash or
coarse particles enter the intake, a circular arc shaped trashrack structure has been
proposed upstream of the Intake Shaft. This comprises 12 panels of 4.6m (w) x 3.10 (H) size
provided in 3 bays, This structure is 18 m(W) x 12.4 m(H) in the beginning tapers to 8.5m
outer (w) (15, innter to 5.5 m innrer) near the Intake Structure. The trashrack has been
designed in accordance with IS: 11388 for a flow through velocity of 1.5 m/s keeping an
allowance for 50% of trashrack area getting clogged. The cleaning of trashrack shall be
done by trashrack cleaning machine which shall be operated by a EOT crane. The details of
Power Intake Structure are shown in Drawing No. TVIPL/LKHEP/P-3001 (Rev -01). The
fabrication details of trashrack are given in Drawing No. TVIPL/LKHEP/P-3002 (Rev -01).

J&K State Power Development Corporation (J&K SPDC), Jammu 8-5

Lower Kalnai H.E. Project (48 MW), J&K Tojo-Vikas International Pvt. Ltd.
Revised Detailed Project Report (2010) Consulting Engineers
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(These drawings are also given in Section VI Part C Tender Drawings of Technical
Specifications).

8.5.2.2 Design Philosophy

A Trash Rack is provided at the entry of the Power Intake structure. The Trash Rack is
proposed to be installed in 12 panels of 4.6m (w) x 3.10 (H) size provided in 3 bays. Each
panel is fitted on edge with 75mmx16mm size MS Flats, rounded on u/s edge and spaced at
50 mm c/c. Each panel is provided with lifting hooks and slots at the top and lugs at the
bottom to snugly fit into the panel below.

The trashrack has been designed in accordance with IS: 11388 for a flow through velocity of
1.5 m/s keeping an allowance for 50% of trashrack area getting clogged. Since the river
does not carry much floating material, such velocity is permissible. This aspect will be
reviewed during the Detailed Design Stage. The cleaning of the Trash Rack is by a
Trashrack Cleaning Machine provided at EL 1137 m. The Trash Rack details are shown in
Drawing No TVIPL/LKHEP/P-3002 (Rev-01) is given in Volume III – Drawings. (These
drawings are also given in Section VI Part C Tender Drawings of Technical Specifications).

8.5.3. Desilting Chamber Outlet Gates & Silt Flushing Valves

A twin chamber underground Desilting Chamber has been proposed on the left bank of
Lower Kalani River to exclude all silt particles below 0.2 mm size. The arrangement
comprises two underground chambers 60 m (L) x 12 m (W) x 9.8 m (D) each having four
nos. tapering hoppers at the bottom. The silt that settles in the hoppers of each chamber
falls into the silt collecting conduits below and can be flushed out through them by operation
of a silt flushing valve at the end of each conduit. Located below the silt flushing tunnels.
The upstream transition of each of the chambers is proposed to be located at the end of
feeder tunnel and downstream transition of each chamber ends into a small D- Shaped
tunnel of 3m dia. These small tunnels of 3m dia merge into a single 4m dia D-Shaped Head
Race Tunnel taking off d/s of Power Intake structure. The Desilting Chamber has been
provided with two chambers to ensure uninterrupted generation of power at the powerhouse
even when these chambers are being cleaned or maintained, one by one, during lean
season by closing respective U/S & D/S gates of the chamber being cleaned and
maintained. The other chamber would be kept operational to feed one of the units under
operation. At the end of downstream transitions of each chamber 1 No vertical lift outlet gate
of size 2.0m (w) x 3.0m (H) is proposed. These gates would be operated from a gate
chamber proposed at a level higher than HFL, corresponding to PMF, in the reservoir. The
J&K State Power Development Corporation (J&K SPDC), Jammu 8-6
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Revised Detailed Project Report (2010) Consulting Engineers
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outlet gate of each Desilting Chamber would be approachable by a common approach

tunnel. For maintenance & cleaning purposes during lean season, each of two chambers
can be segregated from the other, one by one, by operating the respective u/s Power Intake
Gate and the outlet gate of downstream corresponding chamber. A 3m dia D-Shaped tunnel
takes off from each of the chambers and both tunnels merge into a single Headrace Tunnel
of 4m dia D-Shaped which would terminate at the Surge Shaft.

The coarser sand particles and pebbles settle in the reservoir itself. The silt coarser than
0.2mm that enters the Desilting Chambers would settle in the hoppers of the Desilting
Chamber and can be flushed out through operation of 8 no of knife edge driven gate valves
of 300 mm dia provided at the end of silt flushing conduits below the hoppers operated at a
level of 1105.88 m from chambers and designed for a head of 29.12 m and checked for
FRL/HFL condition

8.6. VALVE HOUSE ON THE PRESSURE SHAFT / PENSTOCK LINE

8.6.1 General Description

A Valve House is proposed to control flow into any or both of the branch penstocks for any
inspection or maintenance of the penstocks or turbines or their MIVs. After the valve house,
the branch penstocks would run as inclined penstocks for about 220m length after which
these shall run as Pressure Shafts for 80.0m upto power house with suitable bends at bend
locations

8.6.2 Design Philosophy

Two (2). 2.0 m dia Butterfly valves, suitable for maximum water pressure are required to be
installed on the 3000 mm dia steel lined underground Pressure Shaft located downstream of
the Surge Shaft which bifurcates into 2 m diameter penstocks The normal combined flow
through the Butterfly valves would be 26.86 m3/s, which is the expected rated discharge for
simultaneous operation of two generating units, each generating rated capacity output. The
valve will also be subjected to overload discharge upto 30.00 cumecs (to be intimated by the
turbine supplier) when the two units fed from it are generating 10% overload capacity output.
The Butterfly Valve shall be housed in a Valve house (8m x 18.6m) located about 58 m
downstream of the Surge Shaft and provided with Movable EOT Crane of 30/5 tonnes
capacity spanning 8 m. The valve shall meet the requirements of IS: 7326 pertaining to
butterfly valve or equivalent international standards.

J&K State Power Development Corporation (J&K SPDC), Jammu 8-7

 Lower Kalnai H.E. Project (48 MW), J&K Tojo-Vikas International Pvt. Ltd.
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Penstock/Pressure Shaft in its downstream reach near the Powerhouse will be steel lined to
feed two generating units.

The Butterfly Valve is required primarily for the purpose of isolation of the respective turbine
Main Inlet Valves (Spherical type), for inspection and maintenance/replacement of its
maintenance seal and for providing safe access to the particular Pressure Shaft for its
inspection, when needed.

Normal position of valve disc in open position shall be horizontal and in closed position
vertical. The valve shall be kept either in fully open or fully closed position depending upon
operating requirements.

Normally the opening and closing of the Butterfly Valve will be done under balanced water
conditions. However, the valve shall be designed to close, in the shortest possible time, for the
expected water flow considering the bursting of the largest tap-off (in size) among various tap-
offs on the penstock. The possibility of achieving valve closure under full flow conditions shall
also be desirable.

The valve shall be complete along with servomotors, counter weights, lever arm assembly,
by-pass valve, differential pressure switch, hydraulic & electrical control panels,
upstream/downstream connecting pipe pieces along with companion flange compatible for
joining with the pressure shafts, dismantling joint etc. required to make a complete unit.

The Butterfly valve shall be designed/constructed as if it would enable maximum components

to be assembled at works and at the same time permit easy transportation. The weight and
size of the component packages shall be within permissible transportation limits of about 30
tonne.

8.7 PRESSURE SHAFT CUM PENSTOCK STEEL LINER

8.7.1 General Description

One number Pressure Shaft of 3.0m dia and 45 m length is proposed to take off at the bottom
of vertical riser of Surge Shaft to carry flows further to the Powerhouse, The pressure shaft is
designed to carry a discharge of 30m³/s. The Pressure Shaft is laid in the horizontal
construction adit at the bottom of vertical riser of Surge Shaft which is almost at 142°
horizontal angle to the HRT alignment. After it emerges out of the hill, this pressure shaft is
bifurcated into two branches of 2m dia of Surface Penstocks,. just u/s of a Valve House
proposed to control flow into any or both of the branch penstocks for any inspection or
maintenance of the penstocks or turbines or their MIVs. After the Valve House, the branch
J&K State Power Development Corporation (J&K SPDC), Jammu 8-8
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penstocks would run as inclined penstocks for about 220m length after which these shall run
as Pressure Shafts for 80.0m upto Powerhouse with suitable bends at bend locations at EI.
921.0m.Between the anchor blocks, the penstocks shall be supported on saddle supports @ 6
m c/c. To avoid provision of expensive expansion joints the penstocks are burred in trenches.
The entire length of the Pressure Shaft shall be steel lined of thickness varying from 16mm to
22mm.

8.7.2 Design Philosophy

The design data for the penstock and steel lining is broadly appended below:

Full Reservoir Level (FRL) 1135.00 m

Max Water Level (MWL) 1135.00 m
MDDL 1129.00 m
Axis of Butterfly valves 1110.00m.
Max. Tail water level (Corresponding to PMF) 1139.40 m

General Requirements

Plates of normalized fine grain steel conforming to ASTM 537/285 Grade C or approved
equivalent shall be used and shall be 100% ultrasonically tested and certified at the
Manufacturer’s shop. The Pressure Shaft and Penstock steel liners, bends and branch pipes
bifurcation etc shall be subjected to hydrostatic testing. The welded joints shall be subjected to
appropriate Non-Destructive Testing (NDT) as specified. It is intended that all shop fastenings
and field fastenings shall to be of welded type unless otherwise specified. Wherever possible,
fabrication at site should be done by automatic welding. Suitable equipment for doing such
type of work is a pre-requisite for a tender being considered. Fabrication of steel work shall be
at the manufacturer’s regular workshop or at a field workshop to be set up by the Contractor in
the project area. Shop fabrication of heavy parts and other specials, requiring precession
finishing such as bends, bifurcation and branch pipes shall be done in regular workshops

8.8 POWERHOUSE

8.8.1 Main Inlet Valve

Details of the MIV -Turbine Inlet Valve (Butterfly Valve) are covered in the write up on the
Power Plant Equipment in the following Chapter 9.

J&K State Power Development Corporation (J&K SPDC), Jammu 8-9

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8.8.2 Draft Tube Gates

8.8.2.1 General Description

There are two no. Draft tubes for each of the Turbine-Generator Units having an overall
opening of size 3.75 m (width) x1.31 m (height) at the exit which lead to a tail pool, as shown
in Drawing No TVIPL/LKHEP/P-5007 (Rev-01) in Vol-III -Drawings. The combined flows from
these draft tubes are led back to the river through this tail pool. The flow into each draft tube is
controlled by Draft Tube Gates, which are located at a deck downstream of the Power House
at EL.931.0m. This deck is 38.5m long and 3.0m wide. The draft tube gates shall be operated
by rope down hoists mounted on trestles. A Draft Tube Gate for each of the openings with
individual Rope-Drum Hoists ensures quick and more reliable closure as compared to two
sets of Gates operated with a moving Gantry Crane, since the Draft Tube openings will in
general be always under water. The Draft Tube Gates will be of Fixed Wheel Type Gate
having a size 3.75m (width) x1.31m (height) with its Sill at EL 918.00m and has a Maximum
Tail Water Level at 929.40 m corresponding to PMF. The Draft Tube Gate of a unit under
repairs can be closed to check entry of water from the river/tail pool downstream.

8.8.2.2 Design Philosophy

The Draft Tube Gates, each of 3.75.m x 1.31 m size will be of Fixed Wheel Type provided with
Rollers. As the Maximum Tail Water Level (MWL) is at 929.40 m and the Sill level is at 918.00
m, the Gates will be designed for a head of 11.40 m and are normally kept in fully open
condition. They will be lowered only for the repair, inspection and maintenance of Turbine
Generator and will be designed to close under balanced condition. However, the Gates will be
designed to open under unbalanced condition for quick filling of Draft Tube openings after
inspection. The Gates will have upstream skin plate and seals, which allows for the inspection
of gate framework when the Gate is closed and the downstream side is dewatered. A
Hydraulic Gate with upstream seal also reduces the hoisting capacity due to the absence of
down-pull forces during opening of the Gate resulting in lower costs. It is proposed to operate
the gate by means of electrically operated Rope Drum Hoist located on the Hoist Platform
installed over the trestles. It is essential that the Butterfly Valve be closed first before closing
the Draft Tube Gates, since the Draft Tube Gates are not designed for the large pressure that
would otherwise result from the high water level at the Surge Shaft. Similarly, the Draft Tube
Gates should be opened first after inspection before opening the Butterfly Valve. The Gate will
in general, be designed in accordance with the provisions of IS: 5620 and several other
related codes and standards of engineering practice.

J&K State Power Development Corporation (J&K SPDC), Jammu 8-10