USHP-II

HYDROELECTRIC POWER PROJECT REPORT

Submitted in partial fulfillment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY

In

MECHANICAL ENGINEERING

Submitted by

NARGIS MANZOOR (15206145058)

UZMA RASHID (15206145050)

DEPARTMENT OF MECHANICAL ENGINEERING

INSTITUTE OF TECHNOLOGY, ZAKURA CAMPUS, UNIVERSITY OF KASHMIR

HAZRATBAL-190006

MAY 2019

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CERTIFICATE
I, hereby certify that we have completed Four weeks Training carried out in partial fulfillment for
the award of Bachelor of Technology in “MECHANICAL ENGINEERING” from Institute of
Technology during the academic year w.e.f 14-01-2019 to 26-02-2019 in USHP-II Power House
Kangan.

The matter presented in this report has not been submitted by me for the award of any degree
elsewhere.

Signature of Student

Signature
Examined by:

COORDINATOR
MECHANICAL Engineering Department

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ACKNOWLEDGEMENT

The success and final outcome of this training required a lot guidance and assistance and we
are extremely privileged to have got this all along the completion of the training. All that I
have done is only due to such supervision and assistance and I would not forget to be
thankful.

We owe our deep gratitude to our training guides; Ashraf sir (AEE) for giving me support and
guidance which made me complete the report duly. I am extremely thankful to them for
providing such a nice support and guidance and provided me with all the necessary
information for developing a good system.

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CONTENTS
CHAPTER 1

INTRODUCTION
HYDROPOWER
3*35 MW USHP-II, KANGAN HISTORY AND FEATURES

CHAPTER 2
GENERAL OVERVIEW
MAJOR COMPONENTS OF A HYDRO-SYSTEM

CHAPTER 3
COMPONENTS AND OPERATION
TURBINES GENERATORS
CONTROL AND RELAY PANELS GOVERNORS
COOLING SYSTEM

CHAPTER 4
MAINTENANCE OF HYDRO-TURBINE
PREVENTIVE MAINTAINANCE LOAD
MANAGEMENT SYSTEM EMERGENCY SHUTDOWN
SYSTEM

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CHAPTER1
INTRODUCTION
HYDROPOWER

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GLOBAL STATUS
Hydropower is the leading renewable source for electricity generation globally, supplying 71% of
all renewable electricity. Reaching 1,064 GW of installed capacity in 2016, it generated 16.5% of

ofworld’s electricity from all sources.

Installed utility capacity of India

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

Hydropower utility capacity in J&K

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

3*35 MW UPPER SINDH HYDRO-ELECTRIC POWER PROJECT STAGE-2, KANGAN

HISTORY

Jammu & Kashmir State Power Development Cooperation Limited developed Upper Sindh Hydel Power
Project Stage 2 in Ganderbal district of J&K. Upper Sindh 2 dam has been constructed on Sindh Nallah
and Wangath Nallah tributaries of Jhelum River. It is located 40 km from Srinagar. The catchment area of
the dam is 927sq. km out of which 697sq. km lies in Sindh basin and the rest 230sq. km in Wangath
basin. The tail waters of Upper Sindh 1 are diverted into Upper Sindh 2 for power generation in the
project. This project utilizes the head of about 220m between Sumbal and Wangath.

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

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

SALIENT FEATURES-
COST OF THE PROJECT: Rs. 42,500 LACS
NET HEAD: 231.45 M (759 ft)
PEAK GENERATION: 105 MWs
UNIT SIZE: 3*35 MWs
TOTAL UNITS TO BE GENERATED ANUALLY: 448 million units

SUMBAL LINK WANGATH LINK

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SOURCE SINDH NALLAH WANGATH NALLAH

 DESIGNED DISCHARGE 1384 CUSECS 416 CUSECS
 LENGTH 16.95 KM 6.687 KM
 TUNNEL 2.104 KM _
 BALANCING RESERVOIR STORAGE CAPACITY 216 SFT 98 SFT

LOCATION LATITUDE LONGITUDE

WANGATH HEAD WORKS 34-13 N 75-08 E
SUMBAL HEAD WORKS 34-20 N 74-56 E
POWER HOUSE 34-16 N 74-54 E
TECHNICAL DETAILS
WANGATH LINK SUMBAL LINK
HEAD WORKS ROCK FILLED WITH MASONARY BODY WALL RCC RAFT TYPE STRUCTURE
WATER CONDUCTOR
TOTAL LENGTH 6.78 KM 16.80 KM
OPEN CHANNAL 4.45 KM 7.24 KM
CUT & COVER CONDUNT 1.94 KM 6.02 KM

TUNNEL LENGTH NIL 2.94 KM

DISCHARGE 450 CUSECS 1400 CUSECS
B.R. CAPACITY 98 ACRE FT 216 ACRE FT
FULL SUPPLY DEPTH 2.30 M 3.80 M
PENSTOCK CONDUCTOR 02 N0’s
LENGTH 955 M EACH
DIAMETER 3.0 M PHASE (UNIT 1&2)
2.25 M PHASE (UNIT 3)

03 N0’s
TURBINE

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TYPE OF TURBINE FRANCIS VERTICAL SHAFT MATERIAL CONSUMPTION
NET HEAD 231.68 M CEMENT 2,600,000 BAGS
OUTPUT 35 MW STEEL REINFORCEMENT 18,480 METRIC
TONS YEARLY GENERATION 535,000,000 U LAND ACQUIRED 7,000 KANAL
COST OF GENERATION AT BUS 94 PAISA PER UNIT TOTAL CONCRETING 4,000 CUBIC
METERS TOTAL COST OF PROJECT Rs.399.50 CRORES TOTAL EARTH
WORK EXCAVATION 9,000,000 CUBIC METER

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CHAPTER 2
OVERVIEW

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HYDRO SYSTEM OVERVIEW

Major components of a hydro system

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

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

Wangath balancing reservoir.

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

Forebay.
 WATER DIVERSION (INTAKE): The intake is typically the highest point of the hydro system,
where water is diverted from the stream to the pipeline that feeds the turbine.

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

Diversion Anchor Block For 1, 2, 3 Unit.

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

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

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

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

Head 45 – 400 meter

Flow Rate 10-700 cubic meter per second
There are 24 guide vanes outside the runner of the Turbine which controls the flow
rate of water. The opening and closing of guide vanes is done by using servo
motors, automatically as well as manually.

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CHAPTER 3

COMPONENTS AND OPERATION

TURBINE

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

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

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

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

The formula clearly shows that the total power that can be generated from the hydro
Electrical power plants depends on two major factors: the flow rate of water, and volume of flow of
water and height or head of water. More the volume of water and more the head of water more is
the power produced in the hydro electrical power plant.

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

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 Impulse turbines change the direction of flow of a high velocity fluid or gas jet. The resulting
impulse spins the turbine and leaves the fluid with diminished kinetic energy. There is no
pressure change of the fluid or gas in the turbine blades. Before reaching the turbine, the fluid’s
pressure head is changed to velocity head by accelerating the fluid by a nozzle. Impulse turbines
do not require pressure casement around the rotor since the fluid jet is created by the nozzle
prior to reaching the blades of the rotor. Newton’s second law describes the transfer of energy
for impulse turbines. These turbines are most efficient for use in cases where the flow is low and
inlet pressure is high.
 Reaction turbines develop torque by reacting to the gas or fluid’s pressure or mass. The pressure
of the gas or fluid changes as it passes through the turbine rotor blades. A pressure casement is
needed to contain the working fluid as it acts on the turbine stages or the turbine must be fulL

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immersed in the fluid flow. The casing contains and directs the working fluid and, for water turbines,
maintains the suction imparted by the draft tube. Francis turbines and most steam turbines use this
concept. For compressible working fluids, multiple turbine stages are usually used to harness the
expanding gas efficiently. Newton’s third law describes the transfer of energy for reaction turbines.
These turbines are better suited to higher flow velocities or applications where fluid head is low.

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

Components: A Francis turbine consists of following main parts:

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

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

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

SYNCHRONOUS GENERATOR

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

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

A three-phase synchronous generator.

1. Active power =35000 KW

2. Apparent Power = 38888 KVA

3. Power Factor (cosØ) =0.8 Lag

4. Synchronous Speed = 120×f ÷ p = 120 × 50 ÷ 10 = 600 rpm.

5. Stator V= 11000 V and I = 2041 A

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

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

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Control and relay panels.

Control system.

ELECTRONIC LOAD GOVERNORS

An electronic load governor works by automatically adjusting the load so the generator works exactly
the right speed. In effect, it is always slowing the generator down just enough to produce correct
voltage and frequency.
Electronic load governors constantly monitor voltage or frequency, adding or subtracting electrical
loads as necessary to compensate for human usage.

Cooling System: To remove heat from the components, water cooling and oil cooling is used.
Cooling water is the water removing heat from a machine. The advantage of using water cooling
includes water’s higher specific heat capacity, density, and thermal conductivity. While in oil cooling
configuration, the oil is recirculated continuously when the turbine and generator are operating.

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

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HIGH/LOW PRESSURE COMPRESSOR UNITS:

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

TAIL POOL:

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

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TAIL RACE:

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

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

CHAPTER 4
MAINTENANCE OF HYDRO-TURBINES

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PREVENTIVE MAINTENANCE OF HYDRO TURBINE

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

Load management system

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

EMERGENCY SYSTEM SHUTDOWN

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

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