THUNAG MINI HYDRO PROJECT

400KW

CHAPTER-VII ELECTRICAL & MECHANICAL DESIGN

General
Thunag MHEP utilizes the flow of Debla nallah tributary of Beas river and is located in Distt-Mandi of Himachal Pradesh. A net head of 118.56m has been utilized which generates 400 KW of power at surface power house. The salient features of Thunag MHEP are as under:* * * * * * * * * * Net head Installed Capacity Number and size of units: Type of power house Design discharge of plant Turbine type Speed of turbine Generation voltage Transmission voltage Step-Up Transformer : : : : : : : : : : 118.56 m 400 KW 400KW ( one unit) Surface 0.40 cumecs Horizontal Francis 500rpm 0.415KV 11KV 600KVA

7.1 POWER HOUSE

In a Mini hydropower scheme the role of the powerhouse is to protect the electromechanical equipment that convert the potential energy of water into electricity. The number, type and power of the turbo-generators, their configuration, the scheme head and the geomorphology of the site determine the shape and size of the building.

1 Developer:- Tek Singh Rathore

THUNAG MINI HYDRO PROJECT

400KW

In Thunag MHEP, the surface of power house will have a generating unit of 400KW along with all auxiliary facilities such as cooling water/potable water supply system, fire protection system, compressed air supply, oil system, ventilation and air conditioning system etc. The control room, LT room, battery room, offices, cable spreading area will be accommodated in different floors adjacent and parallel to the machine hall, the service bay shall be located at one end of the machine hall. The generator transformer will be located in the switchyard located up stream of the machine hall and will be connected to generating units through 11KV bus ducts.

MEDIUM AND HIGH HEAD SCHEME

In medium and high head schemes, powerhouses are more conventional with an entrance for the penstock and a tailrace. Although not usual, this kind of powerhouse can be underground.

2 Developer:- Tek Singh Rathore

THUNAG MINI HYDRO PROJECT

400KW

The following equipment will be displayed in the powerhouse: Inlet gate or valve Turbine Speed increaser (if needed) Generator Control system Condenser, switchgear Protection systems DC emergency supply Power and current transformers

7.2 TURBINE Particulars of Hydro Turbine

S.N. Technical Particulars 1. 2. 3. a. b. 4. 5. a. b. c. Type of Turbine/Shaft orientation No. of unit Output Rated output at rated net head Max. Output at rated net head Efficiency Speed Rated speed in r.p.m. Maximum runaway speed in r.p.m. 500 rpm 900 rpm 400 Kw 480 Kw 90% Specifications/Parameters Horizontal Francis 1

Direction of rotation when viewed from Clockwise generator end/top.

3 Developer:- Tek Singh Rathore

THUNAG MINI HYDRO PROJECT

400KW

General
The maximum gross head is 124.81 m. Total head losses in the penstock corresponding to design discharge of 0.40 Cumecs mainly comprises of frictional losses. Net head works out to 118.56. Alternatives of installing single unit of appropriate capacity have been examined. The provision of one units appear advantageous and has been proposed. Therefore, one number turbines are proposed to fulfill the following design requirements A mini hydropower scheme converts hydro potential energy into mechanical energy and then to electrical energy. Energy is power delivered in unit time. Output power = P Turbine output power (kW) = T G x Q g H Where: T - Efficiency of turbine (90 %) G-Efficiency of generator (95%) g - Gravity (9.81 m2/s) H net - Net head available at the turbine (118.56 m) Q - Water volume enters into turbine per second (0.40 m3/s) Turbine output power (kW) = 0.90x0.95x0.40x9.81x118.56 =397.87KW, say 0.40MW Therefore, out power of unit = 400 = 400 kW Specific speed It is the speed in revolution per minute at which the given turbine would rotate, if reduced homologically in size so that it would develop unit power under unit head at full gate. Low specific speeds are associated with high heads and high specific speed is associated with low heads. The selection of a high specific speed for a given head will result in a smaller turbine and generator with saving in capital cost. However the turbine will have to be placed lower for which the cost may offset the saving. Also at high specific speed lower efficiency is expected.

4 Developer:- Tek Singh Rathore

THUNAG MINI HYDRO PROJECT

400KW

Specific speed is given by the formula. nP ------------H (5/4)

Ns = Where:

Ns = Specific speed in r.p.m = Speed of turbine in r.p.m P = output power of turbine in KW H = Net head in meter A set of curves showing specific speed versus head of Francis, propeller, and Francis turbines are shown in Fig. given below. Curves for cavitation coefficient for francis and Kaplan turbines are also shown in the same figure. Assuming Francis Turbine n = 375 Ns = (375x400)/118.565/4 = 19.17 Assuming Francis Turbine n = 500 Ns = (500x400)/118.565/4 = 25.56 Assuming Francis Turbine n = 750 Ns = (750x400)/118.565/4 = 38.34 Assuming Francis Turbine
5 Developer:- Tek Singh Rathore

THUNAG MINI HYDRO PROJECT

400KW

n = 1000 Ns = (1000x400)/118.565/4 = 51.12

6 Developer:- Tek Singh Rathore

THUNAG MINI HYDRO PROJECT

400KW

The ranges of specific speed for various types of turbines are given below: Type of runner (i)Impulse Francis/Turgo (ii)Cross flow (iii)Reaction Francis (iv)Propeller and Kaplan = = = = Specific speed (Ns) 12-70 20-80 80-400 340-1000

On the basis of above data we can considered Francis turbine for this project. Due to small capacity of the unit it would be economical and beneficial to install Francis Turbine with speed of 500rpm and specific speed is 25.56rpm, at Thunag MHEP, as higher the speed of turbine lesser will be the cost of Generator. One number of horizontal Francis turbines each 400 KW 90% of efficiency was used in order to increase the part flow efficiency, increase reliability and easiness in overhauling the turbines without shutdown the plant. Effective head was same for both units. But flow was shared equally and subsequently output power was divided equally.

7.2

Generator
Particulars of GENERATOR

Sl. No. 1. 2. 3. 4. 5. 6. a. b.

Description. Type. Rated output in kw Continuous Over Load Capacity. Power Factor. Shaft orientation. Speed. Rated Speed. Runaway Speed. 500 RPM. 900 RPM.
7

Synchronous 400 kW 10% 0.85 Horizontal

Developer:- Tek Singh Rathore

THUNAG MINI HYDRO PROJECT

400KW

(i) Type of Generator Generators transform mechanical energy into electrical energy. Although most early hydroelectric systems were of the direct current variety to match early commercial electrical systems. Now days only three-phase alternating current generators are used in normal practice. Synchronous generators: They are equipped with a DC electric or permanent magnet excitation system (rotating or static) associated with a voltage regulator to control the output voltage before the generator is connected to the grid. They supply the reactive energy required by the power system when the generator is connected to the grid. Synchronous generators can run isolated from the grid and produce power since excitation is not grid-dependent . (ii) Class of insulation Present practice is to specify class F insulation system for the stator and rotor winding with class B temperature rise over the ambient. Ambient temperature rise should be determined carefully from the temperature of the cooling water etc. Accordingly maximum temperature for the insulation class under site conditions should be specified. a) Stator: Class F insulation level and Class B temperature rises are recommended. b) Rotor: The insulation level should normally be Class-F and temperature raises Class-B. (iv) Type of cooling Losses in a generator appear as heat which is dissipated through radiation and ventilation. The generator rotor is normally constructed to function as an axial flow blower, or is equipped with fan blades, to circulate air through the windings. Small-generators up to 5 MW may be partially enclosed, and heated generator air is discharged into the generator hall, or ducted to the outside. Adequate ventilation of the generator hall preferably thermostatically should be provided in this case.
8 Developer:- Tek Singh Rathore

THUNAG MINI HYDRO PROJECT

400KW

Water to air coolers normally is provided for all modern hydro generators rated greater than 5MW. The coolers are situated around the outside periphery of the stator core. Normally, generators should be furnished with one cooler than the number required for operation at rated MVA. This allows one cooler to be removed for maintenance without affecting the unit output. (v) Generator inertia The moment of Inertia of the generator together with the moment of inertia of the turbine shall be such that the maximum momentary speed rise under Governor Control on full load rejection shall not exceed 45% of rated speed for the grid connected generator as station power is supplied from main generator and adverse effect of this speed rise on motor driven station auxiliaries is not desirable. Additional flywheel required shall be built in the rotor. Separate flywheel shall not be permitted.

(vi) Starting method The starting method used in Thunag MHEP should be in Manual and Auto both mode.

7.3 Generator-transformer connections

The power shall be generated at 0.415 kv which is economical voltage for generators in the capacity range 0.5-2.5MW and also in view of transportation weight limitation. Unit system layout of the generating unit shall be adopted at the power station. The generating units will be connected through 0.415/11kv step up transformers to the outdoor 11 kv bus bar. The electrical scheme proposed for the power station and the switch yard is shown in the single line diagram.

7.4 Transformer
The generator step up and auxiliary power supply transformers shall be installed in the switchyard of the power station. The detail of transformers is given below: Generator Transformer step up Station auxiliary

suppply Transformer

9 Developer:- Tek Singh Rathore

THUNAG MINI HYDRO PROJECT

400KW

Voltage ratio Rated capacity No of transformers Voltage range Cooling type Rated Frequency Frequency variation

0.415/11 kv 600 KVA 1 10% ONAN 50 Hz 3%

11/0.415 kv 75KVA 1 10% ONAN 50 Hz 3%

7.5 Switchyard equipment

Switchyard consists following equipments:(a) 11 KV circuit Breaker (b) 11 KV C/R Panel (c) 11 KV Isolator without Earth switch (d) 11 KV CTs (e) 11 KV/110V PTs (f) 11KV LAs (g) 11 KV Isolator with Earth switch

7.6 Single line scheme

Single line scheme is shown in the SLD Drawing.

10 Developer:- Tek Singh Rathore

THUNAG MINI HYDRO PROJECT

400KW

7.7 Control & protection equipment Controls of Switchgear Panel,Protection Panel & Power Transformer TG control,Relay,Metering cum PLC based Governor panel
ANSI 21 24 27/59 32 37 40 46 49 50/27 Protection Under Impedance relay Over fluxing relay Voltage protection relay Reverse power relay Under power relay Field failure relay Negative sequence relay Thermal overload protection Unintentional energisation of standstill

50V/51V Voltage controlled over current 51BF 60FL 64S 81 87G 86B 86C Breaker failure relay VT fuse failure Stator earth fault relay Under frequency relay Generator differential relay Electrical Action Shutdown Control Action Shutdown Emergency Action Shutdown

86E

11 Developer:- Tek Singh Rathore

THUNAG MINI HYDRO PROJECT

400KW

1.1 KV Breaker panel

ANSI 86 94 Protection Master Trip relay Trip circuit supervision relay Bus Earth fault relay

64B

Transformer cum Line Relay metering and protection panel

ANSI 67 67N 27 59 64REF 86L Protection Directional overcurrent relay Directional Earthfault relay Undervoltage rerlay Overvoltage relay Resticted Earth fault relay Master Trip relay for Line Transformer Differential relay

87T

Line Relay metering cum protection panel(Receiving End)

ANSI 67 67N 27 59 Protection Directional overcurrent relay Directional Earthfault relay Undervoltage rerlay Overvoltage relay Master Trip relay for Line 12 Developer:- Tek Singh Rathore

86L

THUNAG MINI HYDRO PROJECT

400KW

LTAC panel(415V)
ANSI 50 Protection Overcurrent relay Earth fault relay

51N

Power Transformer Accessories

ANSI WTI OTI BZ Protection Winding Temperature Indicator Oil Temperature Indicator Bucholz relay Magnetic oil level gauge

MOG

(A) GOVERNORS Governing system shall be complete with actuator unit comprising of speed response element, restoring mechanism having adjustable temporary and permanent drop setting, load limiting device and speed level control. The oil pressure system will comprise of sump tank and an oil pressure oil tank and one electrically operated governor oil pumps, one with normal running and other acting as stand by unit shall be provided. Governor shall be suitable for selected turbines. In the event of any abnormal operation, generator will be isolated from main line and turbine will be stopped by closing inlet/gate valve. Over current and earth fault protection are provided on H.T switch gear and transformers, against voltage surges lightening arrestor will be provided. All electrical equipment in the power house and switch yard area will be protected, grounded and rubber mats will be used wherever necessary in order to protect the workers from electric shock. All electrical equipment in power house and switch yard area will be properly insulated
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THUNAG MINI HYDRO PROJECT

400KW

wherever necessary in order to protect the workers from electric shock, noncurrent carrying parts of all equipment will be connected to earth net. (B) ELECTRICAL MASTER CONNECTIONS AND CONTROL Electrical master connections are composed of generators, transformers, circuit breakers, current and voltage transformers, including conductor between them for generation, transmission and distribution of electrical energy. proposed to fulfill the following essential requirements:(i) To ensure quality and reliable supply of electrical energy as per the requirement of power grid and consumers. (ii) (iii) (iv) To achieve economy and low investment on Maintenance and Operation. To ensure reliability and flexibility in operation. To ensure convenience in maintenance. A central control panel will be provided from where all functions of the generating units, transformers and lines etc. will be controlled. The generators manufacturer shall be asked to supply all equipment and devices for control instrumentation and safety relating to the generators. These together with equipment supplied by the turbine manufacturer shall constitute a complete and coordinated set of instruments, control and safety devices for the control of these units during normal running and in an emergency. The AVR shall control the voltage within the limits specified. The AVR shall have a provision for operation in both power factor and voltage control mode. The AVR shall also have a manual channel supplied independently of the auto channel and proper follow up to facilitate the switching between auto and manual channels. The AVR shall have provision for quadrate droop compensation for stable operation. The control/indication and power handling components though housed in the same cabinet shall be suitably isolated. The AVR shall also have following features:Under/Over Excitation protection.
14 Developer:- Tek Singh Rathore

Electrical master connections are

THUNAG MINI HYDRO PROJECT

400KW

Maximum/Minimum excitation limiters. Grid paralleling features.

(C) EMERGENCY CONTROL AND PROTECTION Emergency control shall be provided to protect the equipment and auxiliary system during emergency. Control board and H.T. gear panel will be provided for each turbine generator set so that all functions of machine are monitored and controlled. The 110V DC supply will be provided for emergency lights, indicators and control equipment. Over voltage, restricted earth fault, over speed, over current, under voltage and speed action equipment shall be provided for turbine and generators. Suitable circuits shall be provided for abnormal conditions such as increase in bearing temperature, low oil pressure etc. A protection scheme with automatic control circuit shall be provided to stop the turbine in the event of power supply failure or any other fault by operating emergency solenoid of power pack. It is proposed to provide: Control switch, indicating meters and position indicator lamps on the control panel. Protective relays for machine control and alarm units etc. on the units control board. Control and relays for the power circuit are provided on the separate gear cubical which also houses the incoming and outgoing LT bus. Suitable provision for all the electrical equipment in power house and switch yard etc. to provide full protection to equipment and working persons in the event of short circuiting and other faults. Generator Protection and Metering a) LAVT Panel The lightening arrestor and the voltage transformer panel shall be located near the generator and shall house the surge arrestor and PT with necessary fuses etc.

15 Developer:- Tek Singh Rathore

THUNAG MINI HYDRO PROJECT

400KW

b)

NGC The neutral grounding cubicle shall have leads from all the three winding and shall house the protection CTs for differential protection, neutral forming link and earthing resistor, CT for stator earth fault protection.

c)

Protections Following protections shall be provided for the Turbine generator set in Generator Control panel. - Generator differential protection. - Voltage restrained over current relay. - Earth fault relay. - O/V and U/V relay. - Phase unbalance relay. - Over speed relay and switch. - Stator Temperature Detector. - Field failure/Diode Failure relays. Following indicating and logging meters too shall be provided. - Current for all the three phases. - Voltmeter with selector switch. - KW meter with Kwh logging. - Pf meter. - Unit running hour meter.

16 Developer:- Tek Singh Rathore

THUNAG MINI HYDRO PROJECT

400KW

Electrical Auxiliaries and Equipments:Power plant controls and monitoring system shall have microprocessor based controls comprising controls for unit control, switching equipment and auxiliaries. The system shall also have provision for data logging periodical report generation and alarm and annunciation. The control and monitoring equipment shall also have provision for remote control and remote alarm and annunciation.

7.8 Auxiliary Mechanical services

(i) HOT Crane It is proposed to install a 10 tonne capacity HOT crane with auxiliary hooks of 5 tonns designed to travel the full length of the power house. The capacity of the HOT crane has been selected on the basis of preliminary assessment of rotor weight including the lifting arrangement. (ii) Ventilation & air conditioning The powerhouse shall be provided with ventilation and air conditioning as required to maintain the work areas, powerhouse at the selected temperature and humidity levels would be provided for control room and offices. The temperature and humidity levels would be selected to suit the requirement of equipment and plant staff. (iii) Fire protection

Fire protection system complete with CO2 cylinders, ring headers, discharge nozzles shall be provided. This system shall be complete with manual operation facility to release carbon dioxide. (iv) Water Cooling A pumping system would be provided to supply adequate quantity of water from the tail race channel for cooling of the turbine and generator bearings generator air coolers and selected plant services.

17 Developer:- Tek Singh Rathore

THUNAG MINI HYDRO PROJECT

400KW

7.9 Electrical services

(i) A.C.auxiliary services 3 phase,11kv/415v delta/star 75KVA capacity step down transformer will used for station lighting and heating load for power house, staff ,illumination for road and switch yard. Emergency lights on important places will be operated by D.C.battery provided in the power house. 50 KVA diesel generator set will also be provided for illumination in power house, staff, street lights & switch yard during shut down of machine. (ii) D.C. auxiliary service Float and boost type 110 Volts,200AH battery charger and tabular battery will be provided for feeding power to indication lamps, protection relay ,initial impulse to the self excitation system by means of field flashing and to operate few emergency light. (iii) Cables H.T. cables shall be used. Heat shrink type cable termination shall be provided for H.T. cable connecting generator to generation transformer, neutral grounding end. (iv) SWITCH YARD In designing Switchyard layout, the need for simple features, closeness to power house, equipment specifications according to Indian standards, ease of operation have been kept in view. Fencing will be provided for security reasons. 0.415KV high voltage cable laid in underground trenches will connect the feeders panel with the step up transformer. Step up transformer with normal protection such as restricted earth fault, differential etc. as per manual with circuit breakers will be provided for disconnection of the transformers and control of the outgoing line taking off from the power station. Lightening arrestor will be provided to protect lines and transformer from the surges. The required rating of CT (current transformer) and PT (potential transformer) is provided in the switchyard.

18 Developer:- Tek Singh Rathore

THUNAG MINI HYDRO PROJECT

400KW

(v)TRANSMISSION LINES

General

It is proposed to evacuate the power from switchyard of Thunag MHEP to substation at Thunag through the 11kv single circuit line near about 2.0km long.

Power Evacuation
It is proposed that the electricity shall be generated at 0.415kV and evacuated at 11 kV switchyard. One step up transformer, 0.415kv/11kv for each machine shall be provided switchyard near the power house. The switch yard shall be 11kv outdoor type.

19 Developer:- Tek Singh Rathore