Page |1

SUBMITTED TO

Mr. Faraz Ahmad

SUBMISSION DATE
TH
16 August 2019

INTERNSHIP REPORT
(MANGLA POWER STATION)

PRESENTED BY:

Muhammad Qaisar Gulzar

Haseeb Ali
Imtiaz Ali
Anees Ur Rehman
 Page |2

TABLE OF CONTENTS

I. ACKNOWLEDGEMENTS….………………………………………………………………………………....... 5
II. EXECUTIVE SUMMARY..………………………………………………………...…………………………… 6
III. WHAT IS HYDRO ELECTRICITY ………………………………...………………………………………… 7
IV. GENERATION METHOD …………………………………………………………….....………………….. 7

A. CONVENTIONAL (DAM)………………………………………………………………………………… 7
B. PUMPED STORAGE…………………………………………………………………….……………… 7 C.
RUN OF THE RIVER…………………………………………………………………………………… 7 D.
TIDE………………………………………………………………………………………………….…… 7
E. UNDERGROUND……………………………………………………………………………………….. 7

V. DAM BASED HYDRO ELECTRICITY …………………………………………………………….………… 7

VI. DAMS IN PAKISTAN……………………………………........................................................…………………. 8

A. TARBELADAM
……………………………………………………………...……………………………..……. 8
B. MANGLA DAM
…………………………………………………………………......………………………….. 8
C. WARSAK DAM
……………………………………………………..……………………………………………. 9 VII. MANGLA
POWER STATION ………………………………..……………………………………………………………. 9

A. TURBINE……….………………………………………………………………..................…………….................. 9
a. Impulse Turbine ……………………………………………………………………………………….……………………
9
b. Reaction Turbine ……………………………………………………………………………………………………………
9
c. Flow of Water from Reservoir to Turbine ……………………………………………….……………………………..
10
d. Runner ………………………………………………………………………………………………..……………………
10
e. Lower & Upper Guide Bearings ……………………………………………………………………………………….. 10
B. GENERATOR…..……………… …………………………………………………………………………………. 10
a. How Generator Works ………………………………………………………………………….. …... 10
b. Exciter ………………………………………………………………………………………….............. 11
D. AUTOMATIC VOLTAGE REGULATOR … ………………………………….……………………………. 11
E. TRANSFORMER …………………….……………………………………...….………….…………… 11 a.
Step Up Transformer ………………………………………………………………………………………… 12
b. Step Down Transformer ……………………………………………………………………………………… 12
c. Auto Transformer …………………………………………………………………………………………… 12
d. Potential Transformer ……………………………………………………………………………………… 13
e. Current Transformer ………………………………………………………………………………………… 13
F. COOLING SYSTEM AT MANGLA POWER STATION ……………………………………………………… 15 a.
Components of Cooling Water System (Valves &Filters) …………………………………………………………… 15
 Page |3

b. Cooling of Transformers ………………………………………………………………………………………………… 17

c. Heat Exchanger ………………………………………………………………………………………………………. 18
G. PROTECTION SYSTEM INSTALLED AT MANGLA POWER STATION ………………….…………… 18 a. Guide
Vane Protection ……………………………………………………………………………………….….. 18
b. Generator Protection (Types of Relays)…………………………………………………………..……
18
c. Transformer Protection …………………………………………………………………………………..…… 20
d. Protection Against Fire……………………………………………………………………………
20
H. STATION AUXILIARY SUPPLY ………………………………………………………………………….. 20
I. MECHANICAL AUXILIARY ……………………………………………………………………………… 21 a.
Pumping System …………………………………………………………………………………………… 21
b. Over Head Crane System ……………………………………………………………………………………… 21
c. Air System ………………………………………………………………………………………..……….……… 21

J. OPERATION OF HYDRO POWER PLANT ……………………………………………………………………… 22

a. Starting Sequence
……………………………………………………………………………………….…………. 22
b. Off Sequence
………………………………………………………………………………………………… 22
c. Frequency Maintenance
…………………………………………………………………………………… 22
d. Hydro Control Desk
………………………………………………………………………………………. 22
e. Auxiliary Control Desk
…………………………………………………………………………………… 23
f. Power Control Desk
……………………………………………………………………………………. 23 VIII. SWITCH
YARD………..………………….…………...……………………………………..…………………… 23

A. SYSTEM INSTALLED AT MANGLA SWITCH YARD …………………………………………………. 23 a.

Circuit Breaker ……………………………………………………………………………………….. 23
b. Isolator Switch
………………………………………………………………………………………. 24
c. One & Half Breaker Scheme
………………………………………………………………………… 24 IX. THE NEW BONG ESCAPE
……………………………………………………..………….………………….. 25

A. CONCEPT DESIGN …………………………………………………………………………………….. 25

B. BULB TURBINE ………………………………………………………………………………………… 25
X. OPERATION & MAINTENANCE OF SPILLWAY ………………………..………………...………………. 26
XI. MANGLA FORT VISIT …………………..………………………………………….……...…………….…. 27
XII. MISC DRAWINGS …………..……………..……………..……………..……………..……………..……… 28
 Page |4

LIST OF ILLUSTRATIONS

Table 1.1. PRIMARY ENERGY MIX BY COUNTRY 2003-04 …………………………………………………... 8

Table 1.2. ENERGY SUPPLYING PAKISTAN 2003-04…. …………………………………………………......... 8

Fig 1.1 TARBELA DAM………..……………………………………………………………………….……………… 8

Fig 1.2 COMPARISON BETWEEN IMPULSE & REACTION TURBINE……………………………….……………… 9
Fig 1.3 TURBINE SPECIFICATIONS…………………………………….……………………………….……………… 10
Fig 1.4 GENERATOR SPECIFICATIONS …………………………….……………………………….……………… 10
Fig 1.5 GENERATOR/TURBINE SCHEMATIC……………………………………………………………………… 10
Fig 1.6 TRANSFORMER BASIC PRINCIPLE……….……………………………………..…………….……………… 11
Fig 1.7 13.2/132 KV TRANSFORMER………………………………..……………………………….……………… 12
Fig 1.8 AUTO TRANSFORMER SPECIFICATIONS…………………….……………………………….……………… 12
Fig 1.9 AUTO TRANSFORMER………………………………………..……………………………….……………… 13
Fig 1.10 COOLING WATER SYSTEM…………………………………………..………………………….……………… 15
Fig 1.11 INDICATION AT GENERATOR………………………………………………………………….……………… 18
Fig 1.12 METERS AT GENERATOR………………………………………………………………….…………..…… 18
Fig 1.13 DPR SCHEME………………….………………………………………………………………….……………… 19
Fig 1.14 UNIT BOARD SECTION………………………………………………………………….…………………… 20
Fig 1.15 CO2 CYLINDER………………..………………………………………………………………….……………… 20
Fig 1.16 GOVERNOR OIL PUMP MECHANISIM………………………………………………………….……………… 20
Fig 1.17 STATION AUXILIARY SUPPLY SCHEMATIC………………………………………………………………… 21 Fig
1.18 OIL TANK…………………………………..………………………………………………………………………. 22 Fig
1.19 HYDROLIC CONTROL DESK……………………….……………………………………………………………. 23 Fig 2.0
AUXILIARY CONTROL DESK……………………………………………………………………………… 24
Fig 2.1 POWER CONTROL DESK……………………………………………………….………………………………… 24 Fig
2.2 NEW BONG PROJECT (SIGHT MAP)…………………………………………………………………………… 26
Fig 2.3 NEW BONG PROJECT (CONSTRUCTION)…………………………………………………………………… 27
Fig 2.4 HORIZONTAL BULB TURBINE………………………………………………………………………………… 27
Fig 2.5 SPILLWAY……………………..………………………………………………………………………………….. 28
Fig 2.6 MANGLA FORT VISIT……….…………………………………………………………………………………… 29
Fig 2.7 POWER STATION AUXILIARY SUPPLY………………………………………………………………………… 29 Fig
2.8 MANGLA SWITCH YARD SCHEMATIC………………………………………………………………………… 29
Fig 2.9 OIL SUM TANK………………………………………………..……………………………………………………. 29
 Page |5

I. ACKNOWLEDGMENTS

The whole praise is to Almighty Allah, creator of this universe, Who made us the super creature with great knowledge and who
able us to accomplish this work. We feel great pleasure in expressing our deepest appreciation and heartiest gratitude to the staff
of Mangla Power Station for their guidance and great help during the internship period.

We would like to express our deepest affection for our parents and our friends who prayed for us success and encouraged us during
this internship period. We appreciate and acknowledge the patience, understanding and love provided by employees of
Mangla Power Station

We would like to express our deepest thanks to Mr. Faraz Ahmad, who really gave their best of time to us and we really learned a
lot from them in a very short period.
 Page |6

II. EXECUTIVE SUMMARY

The purpose of this report is to explain the working of Mangla Power Station.

Mangla Power Station is hydel Power Station having capacity of 1000MW of electricity. 10 units each of capacity of 100MW are
working at Mangla. Recently a project of extension of reservoir has been completed. In coming years this extension will definitely
increase the efficiency of units. Moreover, advancements in windings of generators are in progress.

Report will describe working of station according to the different departments in the station. Moreover we will discuss about the
maintenance and protection systems installed at Mangla. New Bong Escape project, operation and maintenance of spill way and
Jari Intake gate is also covered.
 Page |7

potential energy in water is proportional to the head. A large

III. What is Hydroelectricity pipe (the "penstock") delivers water to the turbine.

Hydroelectricity is the term referring to electricity generated B. Pumped-Storage

by hydropower; the production of electrical power through the
use of the gravitational force of falling or flowing water. It is
the most widely used form of renewable energy, accounting for
16 percent of global electricity consumption, and 3,427
terawatt-hours of electricity production in 2010, which
continues the rapid rate of increase experienced between 2003
and 2009.
Hydropower is produced in 150 countries, with the AsiaPacific
region generating 32 percent of global hydropower in 2010.
China is the largest hydroelectricity producer, with 721
terawatt-hours of production in 2010, representing around 17
percent of domestic electricity use. There are now three
hydroelectricity plants larger than 10 GW: the Three Gorges
Dam in China, ItaipuDam in Brazil, and Guri Dam in
Venezuela.
The cost of hydroelectricity is relatively low, making it a
competitive source of renewable electricity. The average cost of
electricity from a hydro plant larger than 10 megawatts is 3 to 5
U.S. cents per kilowatt-hour. Hydro is also a flexible source of
electricity since plants can be ramped up and down very quickly
to adapt to changing energy demands. However, damming
interrupts the flow of rivers and can harm local ecosystems, and
building large dams and reservoirs often involves displacing
people and wildlife. Once a hydroelectric complex is
constructed, the project produces no direct waste, and has a
considerably lower output level of the greenhouse gas carbon
dioxide (CO2) than fossil fuel powered energy plants.
This method produces electricity to supply high peak demands
by moving water between reservoirs at different elevations. At
times of low electrical demand, excess generation capacity is
used to pump water into the higher reservoir. When there is
higher demand, water is released back into the lower reservoir
through a turbine. Pumped-storage schemes currently provide
the most commercially important means of large-scale grid
energy storage and improve the daily capacity factor of the
generation system.
C. Run-of-the-river
Run-of-the-river hydroelectric stations are those with small or
no reservoir capacity, so that the water coming from upstream
must be used for generation at that moment, or must be allowed
to bypass the dam.
D. Tide
A tidal power plant makes use of the daily rise and fall of ocean
water due to tides; such sources are highly predictable, and if
conditions permit construction of reservoirs, can also be
dispatch able to generate power during high demand periods.
Less common types of hydro schemes use water's kinetic energy
or undammed sources such as undershot waterwheels.
E. Underground

IV. GENERATING METHODS An underground power station makes use of a large natural
height difference between two waterways, such as a waterfall or
A. Conventional (dams) mountain lake. An underground tunnel is constructed to take
water from the high reservoir to the generating hall built in an
Most hydroelectric power comes from the potential energy of underground cavern near the lowest point of the water tunnel
dammed water driving a water turbine and generator. The power and a horizontal tailrace taking water away to the lower outlet
extracted from the water depends on the volume and on the waterway.
difference in height between the source and the water's outflow.
This height difference is called the head. The amount of
 Page |8

V. DAM BASED HYDROELECTRICITY as well as from different other sources including gas, coal,
diesel and nuclear.
Dam based hydroelectricity is the cheapest source of electricity
as water is free of cost. Pakistan is generating power from water

Source wise primary energy supply in Pakistan in 2003-

04 is indicated below: .

VI. DAMS IN PAKISTAN

Three main dams Mangla, Tarbela and Warsak were
constructed for the purpose of generating electricity and
irrigating agricultural land. In addition, there are 23
barrages/head works/ siphons; main irrigation canals are 45,
which have extended up to 40,000 miles. Similarly, there are
90,000 water courses, which are extended up to one million
miles.
The dam was completed in 1976 at a cost of Rs.18.5 billion.
Over 15,000 Pakistani and 800 foreign workers and engineers
worked during its construction. It is the biggest hydel power
station in Pakistan having a capacity of generating 3,478 MW
of electricity. Its reservoir is 97 km long with a depth of 137
Meters while total area of the lake is 260 Sq Km.
B. Mangla Dam

A. Tarbela Dam
The world's largest earth-filled dam on one of the world's most
important rivers the Indus is 103 km from Rawalpindi.
The Mangla Dam on the River Jhelum is one of the longest
earth-fill dams in the world.The Indus Basin treaty of 1960 with
India paved the way for its construction. The treatyprovided for
two dams, one on the River Jhelum at Mangla and the other on
the Indus atTarbela.World's third
 Page |9

largest earth-filled dam is only 115 km south-east of Rawalpindi. The area

of the dam is 100 square Km.The rated head of the dam is 295 feet. Mangla
Power House was completed in four stages. The initial phase comprising
of four units of 100 MW each was completed in 1967-69. The first
extension of Unit No. 5&6 (2X100 MW) was completed in 1974 while
second extension comprising Unit No. 7&8 (X100
MW) was completed in 1981. The project attained its

Fig1.1- Tarbela Dam

maximum capacity of 1000 MW with the final extension of Unit direction. Pelton and Turgo turbines are the examples of
No. 9&10 (X 100 MW) in 1993-94. Impulse Turbine.

C. Warsak Dam b. Reaction Turbine

The gigantic multi-purpose Warsak Dam on RiverKabul is Reaction turbines develop torque by reacting to the water. The
situated 30 KMs north-west of Peshawarin the heart of tribal pressure of the water changes as it passes through the turbine
territory. It has a totalgenerating capacity of 240,000 KW and rotor blades. A pressure casement is needed to contain the water
willeventually serve to irrigate 110,000 acres of land. as it acts on the turbine stage(s) or the turbine must be fully
immersed in the fluid flow. The casing contains and directs the
The 250 ft. high and 460 ft. long dam withreservoir of 4 square working fluid and, for water turbines,
miles had a live storagecapacity of 25,300 acre-feet of water for
irrigationof 119,000 acres of land and meeting powergeneration
requirement. A spillway with ninegates is capable to discharge
540,000 cusecs offlood water. There are also small dams like
Dohngi Dam, GomalZam Dam, Hub Dam, Kahnpur Dam etc.

VII. MANGLA POWER STATION

Mangla power station is generating 1000 MWatt of electricity

at rated capacity and 1500 MW at overload condition.
Numerous machines are using there for generation of
electricity. Main parts of hydel generation are:

Turbine Generator Transformer

A. Turbine
A turbine is a rotary mechanical device that extracts energy
from a fluid flow and converts it into useful work. 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. Early turbine examples are
windmills and water wheels. Different types of turbines are used
in power generation.

a. Impulse Turbine

In impulse turbine water is thrown through a nozzle on to the

blades of turbine. This water flow moves turbine in a specific
 Page | 10

Fig 1.2- Comparison between Impulse and Reaction Turbine

maintains the suction imparted by the draft tube. Kaplon,

Propeller, Fransist are the examples of the Reaction Turbines.

Fransist type turbine is medium head turbine. In Mangla all the

turbines are Fransist turbines.

Fig1.3- Turbine specifications

 Page | 11

c. Flow of water from reservoir to turbine Frequency 50 Hz Poles 36

Overload 115% Speed 166.67rpm
Water being stored in the reservoir of 100 Km2 is travelled Phase 3 Ex. Volts 261 V
through a tunnel of diameter of 30 feet. This tunnel is called Ex.Amperes 990 A
“Penstock”. The 5×30 feet tunnels make “Y” connection and
each tunnel is divided into two tunnels of 15feet diameter. Here
potential energy stored in water is converted into kinetic energy
due to gravity. This high pressure water is thrown to the runner
of the turbine. Cover around the turbine is called “Spiral
Casing”. This casing is designed in such a way that it gives rotor
of the turbine anticlockwise rotation.

Butterfly inlet valves are used to stop the flow of water. In case
of any emergency valve is closed and water is provided a bypass
path through the emergency irrigation valve to release.

d. Runner

The runner of the turbine has 24 blades on which water flow.

There are 24 guide wanes and wicket gates which can be
adjusted to control the flow of the
water. These guide wanes adjust \
themselves in order to maintain the
speed of the rotor. All the gates are
operated hydraulically by using oil
and servo motors.
Fig1.4- Generator Specifications
e. Lower and Upper Guide bearings
Generation voltage at Mangla power house is 13.2 KV. Each
Whenever we stop our turbine it sits itself onto a base. Now
generator of 125000 KVA working at 0.8 power factor is
when we want to run the turbine again we cannot run it in its
generating 100 KW of power. The frequency/speed relationship
rest position. In such condition we pass an impulse through
of the generator/turbine can be find out with the formula
governor. Oil is filled in the lower guide bearings form the oil
tank which uplifts the rotor 2 mm. Now turbine is ready to start.
These bearings also help to maintain the balance of the rotor.
B. Generator
Generator is the second most important part of the electricity a. How Generator Works
generation. The kinetic energy of the water moves turbine and
produces mechanical energy. Generator uses this mechanical
It works according to the Faraday’s Law of Electromagnetism.
energy and convert it into electrical.
Whenever a coil is moved in a magnetic field an induced current
is produced.
At Mangla Power Station 10 generators are working following
are the specifications of these generators.

Rated Output 125000 KVA Voltage 13200 V

Power Factor 0.8 Amperes 5467 A
 Page | 12

exciter is rotated by the AC generator through a drive belt. The

distinguishing feature of the brush-type exciter is that stationary
brushes are used to transfer the DC exciting current to the
rotating generator field. Current transfer is made via slip rings
that are in contact with the brushes

• Static Exciter

Static exciter contains no moving parts. A portion of the AC

from each phase of generator output is fed back to the fields
winding, as DC excitations, through a system of transformers,
rectifiers, thyrestors and reactors.

Fig1.5- Generator /Turbine Schematic

b. Exciter
Theoretically permanent magnets are required to give magnetic
field but in practical we cannot use permanent magnets because
there is a lot of heat inside the generator and magnetism
drastically reduce with heat. Secondly such large permanent
magnets are inevitable to produce and maintain. That is why we
use Electromagnets in generators. Electromagnets are
developed according to Ampere’s Law which states that:
C. Automatic Voltage Regulator
Voltage transformers provide signals proportional to line
voltage to the AVR where it is compared to a stable reference
voltage. The difference (error) signal is used to control the
output of the exciter field. For example, if load on the generator
increases, the reduction in output voltage produces an error
signal which increases the exciter field current resulting in a
corresponding increase in rotor current and thus generator
output voltage.

The magnetic field at a distance r from a very long straight wire, Due to the high inductance of the generator field windings, it is
carrying a steady current I, has a magnitude equal to difficult to make rapid changes in field current.

This introduces a considerable "lag" in the control system which

makes it necessary to include a stabilizing control to prevent
instability and optimize the generator voltage response to load
To start a generator its field winding must be excited changes.
(magnetized). Generator voltage is directed related to the
excitation current. So if the voltage of the generator is dropping, Without stabilizing control, the regulator would keep increasing
it can be managed by increasing excitation current. and reducing excitation and the line voltage would continually
There are two type of exciter used in Mangla power Station. fluctuate above and below the required value.

• Brush Type Exciter Modern voltage regulators are designed to maintain the
• Static Exciter generator line voltage within better than +/- 1% of nominal for
wide variations of machine load.
Unit 1-6 use brush type exciter while 7-10 use static
exciter.
D. Transformer
• Brush Type Exciter
A transformer is a device that transfers electrical energyfromone
circuit to another through inductively coupled conductors—the
The brush type exciter can be mounted on the same shaft as the
transformer's coils. A varying current in the first or primary
AC generator armature and can be housed separately from, but
winding creates a varying magnetic flux in the transformer's
adjacent to, the generator. When it is housed separately, the
core and thus a varying magnetic field through thesecondary
 Page | 13

winding. This varying magnetic field induces a varying

electromotive force (EMF), or "voltage", in the secondary
winding.

Fig1.6- Transformer’s Basic Principal

 Page | 14

If a load is connected to the secondary, current will flow in the

is the difference current that flows in the common part of the

winding (8 amps). There is also considerable potential for
savings on the core material as the apertures required to hold
the windings are sma ller. The advantage is at its greatest with
a 2:1 ratio transformer and becomes smaller as the ratio is
greater or smaller.
Autotransformers are often used to step up or down between
voltages in the 110 -117-120 volt range and voltages in the
220-230-240 vo lt range, e.g., to output either 110 or 120V
(with taps) from 230V input, allowing equipment from a 100
or 120V region to be used in a 230V region.

We have to working and one stand by auto transformer . The

function of auto -transformer is load sharing betw een 220KV
and 132 KV bus bars. Whenever we have more load at 132
side, Tx. switches 220 KV to 132 KV and share the load and
vice-versa.

Fig 1.7- 13.2/132 KV Transformer

Fig 1.8- Auto Transformer specifications

 Page | 15

secondary winding, and electrical energy will be transferred b. Step-down Transformers

from the primary circuit through the transformer to the load. In
an ideal transformer, the induced voltage in the secondary We have two Station Transformers which step down 132 KV to
winding (Vs) is in proportion to the primary voltage (Vp) and is 11 KV. These two Transformers are of 7.5 MVA each. Power
given by the ratio of the number of turns in the secondary (N s) through these transformers is fed inside the station to run
to the number of turns in the primary (N p) as follows:
different equipments at station and in switch yard.
c. Auto Transformers

In an autotransformer portions of the same winding act as both

the primary and secondary. The winding has at least three taps
Several transformers are used for different purposes. Just after
generation we need to step up or step down the voltage. Then where electrical connections are made. An autotransformer can
we have some auto transformers in Mangla. Many current and be smaller, lighter and cheaper than a standard dual-winding
transformer however the autotransformer does not provide
potential transformers are used which will be discussed later.
electrical isolation. As an example of the material saving an
autotransformer can provide, consider a double wound 2 kVA
a. Step-up Transformers transformer designed to convert 240 volts to 120 volts. Such a
transformer would require 8 amp wire for the 240 volt primary
and 16 amp wire for the secondary. If constructed as an
After generation at 13.2 KV at Mangla, step-up transformers autotransformer, the output is a simple tap at the centre of the
step-up the voltage to 132 KV and 220KV. We have two 240 volt winding. Even though the whole winding can be
wound with 8 amp wire, 16 amps can nevertheless be drawn
13.2/132 KV transformers and eight 13.2/220 KV transformers. from the 120 volt tap. This comes about because the 8 amp
After stepping up voltages these voltages are transmitted 'primary' current is of opposite phase to the 16 amp 'secondary'
through bus bars. current and thus it

Direct measurement of high voltage by a voltmeter is a potential

safety hazard.

Designing, installing, and maintaining a voltmeter capable of

directly measuring 13,800 volts AC would be no easy task. The
safety hazard alone of bringing 13.8 kV conductors into an
Fig 1.9- Auto Transformer instrument panel would be severe, not to mention the design of
the voltmeter itself. However, by using a precision step-down
d. Potential Transformers transformer, we can reduce the 13.8 kV down to a safe level of
At transmission side potential Transformers are used. The voltage at a constant ratio, and isolate it from the
purposes of potential transformer are as follows: • instrument connections, adding an additional
• Voltage Measurement level of safety to the metering system.
• Overvoltage protection
Transformers can also be used in electrical instrumentation
systems. Due to transformers' ability to step up or step down
voltage and current, and the electrical isolation they provide,
they can serve as a way of connecting electrical instrumentation
to high-voltage, high current power systems. Suppose we
wanted to accurately measure the voltage of a
13.8 kV power system
 Page | 16

Instrumentation application: “Potential transformer” precisely

scales dangerous high voltage to a safe value applicable to a
conventional voltmeter.

Now the voltmeter reads a precise fraction, or ratio, of the actual

system voltage, its scale set to read as though it were measuring
the voltage directly. The transformer keeps the instrument
voltage at a safe level and electrically isolates it from the power
system, so there is no direct connection between the power lines
and the instrument or instrument wiring. When used in this
capacity, the transformer is called a Potential Transformer, or
simply PT.

Potential transformers are designed to provide as accurate a

voltage step-down ratio as possible. To aid in precise voltage
regulation, loading is kept to a minimum: the voltmeter is made
to have high input impedance so as to draw as little current from
the PT as possible. As you can see, a fuse has been connected
in series with the PTs primary winding, for safety and ease of
disconnecting the PT from the circuit.

A standard secondary voltage for a PT is 120 volts AC, for full-

rated power line voltage. The standard voltmeter range to
accompany a PT is 150 volts, full-scale. PTs with custom
winding ratios can be manufactured to suit any application. This
lends itself well to industry standardization of the actual
voltmeter instruments themselves, since the PT will be sized to
step the system voltage down to this standard instrument level.

d. Current Transformers

These transformers are used for the following purposes:

Current measurement
Over current Protection

Following the same line of thinking, we can use a transformer

to step down current through a power line so that we are able to
safely and easily measure high system currents with
inexpensive ammeters, such a transformer would be connected
in series with the power line.
 Page | 17

“Current transformer” steps high current down to a value

applicable to a conventional ammeter.

Note that while the PT is a step -down device, the CT is a step -

up device, which is what is needed to step down the power
line current

Current conductor to be measured is threaded through the

opening. Scaled down current is available on wire leads.

Some CTs are made to hinge open, allowing insertion around

a power conductor without disturbing the conductor at all. The
industry standard secondary current for a CT is a range of 0 to
5 amps AC. Like PTs, CTs can be made with custom winding
ratios to fit almost any application. Because their “full load”
secondary current is 5 amps, CT ratios are usually described
in terms of full-load primary amps to 5 amps, like this:

Because CTs are designed to be powering ammeters, which

are low-impedance loads, and they are wound as voltage step -
up transformers, they should never, ever be operated with an
open-circuited secondary winding. Failure to heed this
warning will result in the CT producing extremely high
secondary voltages, dangerous to equipment and personnel
alike. To facilitate maintenance of ammeter instrumentation,
short-circuiting switches are often installed in parallel with the
CT's secondary winding, to be closed whenever the ammeter
is removed for service.
 Page | 18

Short-circuit switch allows ammeter to be removed from an

active current transformer circuit.

Though it may seem strange to intentionally short-circuit a

power system component, it is perfectly proper and quite
necessary when working with current transformers.
 P a g e | 19

E. Cooling system at Mangla Power Station This valve reduces the pressure of the water that goes
through it, and is used to obtaining a regulated and
Cooling of heavy equipment is very important at Mangla. constant value at its outlet.
Huge amount of current and voltages makes equipments
very hot specially generators and transformers. Due to the It is installed at the water mains (for a bungalow as for a
importance of cooling we have working as well as flat). It protects the whole installation from problems due
multiple stand-by cooling systems in Mangla. Water is to excess pressure noises in the pipes, water hammer,
taken from reservoir through 24 inch pipeline and then splashes, premature wear of household electrical
distributed to the different sections in Mangla in green appliances and taps. The pressure reducing valves are
pipes. Following is the Schematic diagram of cooling of completely automatic.
two of the units.
Types of Pressure reducing valve

There are two types of water pressure reducing valves,

direct acting and pilot operated. Both use globe or angle
style bodies. Valves used on smaller piping diameter units
are cast from brass; larger piping diameter units are made
from ductile iron. Direct acting valves, the more popular
type of a water pressure reducing valves, consist of globe-
type bodies with a spring-loaded, heatresistant diaphragm
connected to the outlet of the valve that acts upon a spring.
This spring holds a pre-set tension on the valve seat
installed with a pressure equalizing mechanism for
precise water pressure control.

Fig 1.10- Cooling water system

Following valves are used as per different requirement.

• Normally open
• Normally closed
• No return valve
• Safety valve
• Motor opened valve
• Pressure reducing valve

Following filters and strainers are used for filtering of

water

• Vokes Filter
• Y- Strainer
• Duplex Filter
• C.W Strainer

a. components of cooling water system Motor Operated Valve:

Pressure reducing Valve Motor Operated valve is a valve where the Actuator Part
of the Valve is replaced by a motor instead of pneumatic.
MOV are normally used for Larger Process lines where
 P a g e | 20

the Pneumatic pressure is not enough to provide torque or The small droplets of water are intercepted by fibers and
pressure for the Valves movement. because of the hydrophilic nature of the fibers, are
retained. As the number of droplets collected increases
Since Motors have good torque they are used to open or they join together to form a layer of water.
close the valves, these are also called as electrical
Actuators.

Advantage of MOV over Pneumatic valve:

Usually motor operated valve used in big pipe

lines sizes which it is need strong torque and for ON/OFF
condition not to control the process, We can use rather
than M.O.V pneumatic ON/OFF valve with piston
actuator (Double Acting) but in this case the accessories
it will cost you more because you need to provide
pneumatic amplifier and big actuator depend on the pipe
size.
That is why better to use M.O.V the motor will rotate the
gears and the gears will rotate the valve with low cost.

Non Return Valve :

A device for automatically limiting flow in a

piping system to a single direction.Also known as no
return valve.

Vokes Filter:

The Vokes Filter Coalescer is a static device for the

removal of solids and free water from Distillate and Light
Liquid Fuels and Mineral Lubricating Oils.

The cartridge combines a long life depth type

pre-filter media designed to give extended life by the
removal of pipe scale, rust, waxes and asphaltenes that
would otherwise cause the coalescent media to blind.

The pre-filter, together with the first and second

stage coalescing Medias effectively combine small
droplets of water into large droplets which are then
separated from the oil flow by gravity.

A final stripper screen is fitted to further

minimize any risk of carryover of small droplets into the
clean oil discharge.

The purified oil is discharged at the top of the

housing, while the water is drained from the bottom.

Principal of Operation
 P a g e | 21

The flow of the oil then pushes this water through the
media to the outside where it forms large droplets on the
sock surrounding the cartridge. b. Cooling of Transformers
Though it is not uncommon for oil-filled transformers to
These droplets then grow until they reach a size which
have today been in operation for over fifty years .High
causes them to fall off and drop to the bottom of the
temperature damages winding insulation, the accepted
housing through gravity.
rule of thumb being that transformer life expectancy is
Y.Strainer : halved for every 8 oC increase in operating temperature.
At the lower end of the power rating range, dry and liquid-
Eaton Y strainers are a cost-effective solution for immersed transformers are often self-cooled by natural
the mechanical removal of unwanted solids from liquid, convection andradiation heat dissipation. As power
gas or steam lines by means of a perforated or wire mesh ratings increase, transformers are often cooled by such
straining element. They are used in pipelines to protect other means as forced-air cooling, force-oil cooling,
pumps, meters, control valves, water-cooling, or a combinations of these. The dielectric
steam traps, regulators and coolant used in many outdoor utility and industrial
other process equipment. service transformers is transformer oil that both cools
and insulates the windings. Transformer oil is a highly
refined mineral oil that inherently helps thermally
stabilize winding conductor insulation, within
acceptable insulation temperature rating limitations.
However, the heat removal problem is central to all
electrical apparatus such that in the case of high value
Duplex Strainer transformer assets, this often translates in a need to
monitor, model, forecast and manage oil and winding
A duplex strainer is used in applications where conductor insulation temperature conditions under
fluid flow cannot be interrupted when the basket is varying, possibly difficult, power loading conditions. Air-
removed for cleaning. It maintains a continuous flow by cooled dry transformers are preferred for indoor
utilizing two separate basket chambers with integral applications even at capacity ratings where oil-cooled
valves to direct flow into one of the basket chambers construction would be more economical, because their
cost is offset by the reduced building construction cost.
The oil-filled tank often has radiators through which the
oil circulates by natural convection. Some large
transformers employ electric-operated fans or pumps for
forced-air or forced-oil cooling or heat exchanger-based
water-cooling. Oil-filled transformers undergo prolonged
drying processes to ensure that the transformer is
completely free of water vapor before the cooling oil is
introduced. This helps prevent electrical breakdown under
load. Oil-filled transformers may be equipped with relays,
After filtering of water, water is fed to the different which detect gas evolved during internal arcing and
sections of the generator and to the transformer where it rapidly de-energize the transformer to avert catastrophic
cools down the temperature of oil used in transformer. failure. Oil-filled transformers may fail, rupture, and burn,
The sections are: causing power outages and losses. Installations of oil-
filled transformers usually include fire protection
• Generator Surface air cooler measures. They have properties that once favored their
• Main Guide Bearing use as a dialectic coolant, though concerns over their
• Thrust lower guide bearing environmental persistence led to a widespread ban on
• Upper guide bearing their use. Today, non-toxic, stable silicone-based oils, or
• Stuffing box fluorinated hydrocarbons may be used where the expense
• Governor oil sump tank of a fireresistant liquid offsets additional building cost for
 P a g e | 22

a transformer vault. Some "dry" transformers (containing F. Protection System Installed at Mangla
no liquid) are enclosed in sealed, pressurized tanks and
cooled by nitrogen or sulfur hexafluoride gas. Different protection system for different equipments is
installed at Mangla Power Station.
Experimental power transformers in the 2 MVA range
have been built with superconducting windings which a. Guide Vane Protection
eliminates the copper losses, but not the core steel loss.
These are cooled by liquid nitrogen. Sometimes large stuff like trunk of trees or large stones
comes into the penstock with the flow of water. These
c. Heat Exchanger
things stuck in the runner and stop the operation of guide
vanes and hence wicket gates cannot move. In such
A heat exchanger is a specialized device that assists in the
situation the Fig 2.0share pin - Meters at installed with the
transfer of heat from one fluid to the other. In some cases,
vane is Generator broken and control room gets the
a solid wall may separate the fluids and prevent them from
indication of problem in guide vane and is alarmed.
mixing. In other designs, the fluids may be in direct
contact with each other. In the most efficient heat
b. Generator Protection
exchangers, the surface area of the wall between the fluids
is maximized while simultaneously minimizing the fluid At the front of the units different gauges and meters are
flow resistance. Fins or corrugations are sometimes used installed. These meters measure the temperature, voltage,
with the wall in order to increase the surface area and to oil level, generation capacity; speed etc. in case of any
induce turbulence. problem alarm is active. Moreover generators have auto
switch of system in case of very serious problem.
Common appliances containing a heat exchanger include
air conditioners, refrigerators, and space heaters. Heat
exchangers are also used in chemical processing and
power production

There are three primary flow arrangements with heat

exchangers: counter-flow, parallel-flow, and cross-flow.
In the counter-flow heat exchanger, the fluids enter the
exchanger from opposite sides. This is the most efficient
design because it transfers the greatest amount of heat. In
the parallel-flow heat exchanger, the fluids come in from
the same end and move parallel to each other as they flow
to the other side. The cross-flow heat exchanger moves
the fluids in a perpendicular fashion.

AT MANGLA
Fig 1.11- Indications at Generator
Each unit installed have 2 external heat exchanger
installed which include one stand by while the other one
used as a main heat exchange system .this is used for the
same purpose as of cooling water system.

Heat exchanger include boiler through which hot oil (

passed from machine) is cooled down by using tubes of
cooling water supply system .

Fig 1.12- Meters at Generator

 P a g e | 23

GENERATOR PROTECTION RELAYS Excitation is concern to maintain the terminal voltage of

This includes
• Generator Differential Relays
• Split Phase Relay
• Restricted Earth Fault (REF)
• Stator Earth Leakage
• A Symmetrical load
• Loss of Excitation
Generator Differential Relays
The generator differential relay is sensitive enough to
detect winding ground fault with low impedance
grounding. It is operate due to Phase Split relay and
restricted earth fault.
generator. It is necessary to stable the terminal voltage.
This relay is activate after some specific time period when
there is suddenly load surge then it decrease the frequency
and AVR sense it if due to any reason AVR couldn’t sense
it then field loss is occur and if AVR do not sense it for
40sec then this relay trip the unit.
LINE RELAYS
Those relays which are used in switchyard is
known is line relays. Line relays includes:-
• Distance Protection Relay
• Over current Relay
• Under Frequency
Distance Protection Relay

Split Phase Relay

This is line protection. Each line is divided into
At output there are three windings and each is three zones and it is depend upon impedence. Each zone
then divided into three parallel path. Four Current has a relay if any fault is occur at any zones the relative
Transformer is connected to each winding. If any open relay sense it and give indication.
circuit fault is occurs the current passes from other path
and the relative CT noted high current and relay sense it
and give relative indication.
Over Current Relay

Restricted Earth Fault relay

These relays simply sense the over current when there is
high current then this relay is activated.
This relay is connected in between 13.2kv and
132kv or 220kv.The neutral point of CT feed and the CT
of HV side is also feed and when fault occurs at any side
Under Frequency
relay sense it and trip frequently.
At Mangla Power Plant the frequency of generated power
is 50Hz. If frequency decreases due to any reason
Stator Earth Leakage relay
and reach 48.6Hz to 48.8Hz Then
this relay produce indication.
There is protection of generator winding. Current
transformer is connected to the neutral point. If three
phase supply is short to neutral then this relay activate
immediately and trip the unit.

A symmetrical Load relay

This relay continuously sensing the

unbalancing in three phase voltage. Three phase voltage
will be unbalance when the load is unbalance. If the
symmetrical load is 7% then relay activate alarm and
when it increases to 20% then it trips the unit.

Loss of Excitation
 P a g e | 24

Fig 1.13- DPR scheme Right Bank Drawing

F
L.B.G Station
c. Transformer Protection

In Transformers we have bubble sensors in order to

sense any chemical reaction present in transformer.
Conservation tanks are there for extra oil. In case if oil
expands all the extra oil is transferred to conservation
tank. Water cooling system cools down the oil. We
have spare tank for transformer oil. The top of the
tanks is filled with nitrogen gas.

d. Protection Against fire

In Mangla fool proof system against fire is present. A

bank of cylinders containing CO2 is for generators for
fire. Water nozzles are installed all around the
Transformers. As soon as sensors sense fire, nozzles
start sprinkling water onto the transformers and CO2
to the Generators. Red color pipes throughout station
Fig 1.14- Unit Board Section
contain water for fire protection.

G. Station Auxiliary Supply

Two station transformers each of 750 MVA step down

132 KV/11 KV for station aux supply. This supply,
through 11 KV bus bar, transmitted inside the station.
Unit board is the section where all the equipments
regarding protection and working of generators are
present like circuit breakers, switches etc. 11 KV is
further step down to 440 V and 440 V is fed to the all
the equipments in unit board section. For protection
isolators are used here.

The 440 V supply is transmitted to the following units

inside and outside the power station. Fig 1.15- CO2 cylinder

• Switch Yard Plant House Board

• Common Services Board
• Intake Control Station
• Essential Services Board
• Spill Way Switch Fuse Board

11 KV is supplied to the following units

• Mangla Grid
• P/T Adit Tunnel
• Instrument House

Fig 1.16- Governor Oil pump mechanism

 P a g e | 25

Fig 1.17- Station Auxiliary Supply Schematic

b. Overhead crane system

H. MECHANICAL AUXILLARY
Twooverhead cranes are installed at Mangla power station
a. PUMPING SYSTEM each having weight 200 tons (along with spare 30 tons
weight).These are used for lifting heavy machinery like
There is oil pumping system along with two motors. One rotor, runner etc.
pump is on main and other one is standby. When there is
pressure of 310 psi then pump will operate and load oil
from sump tank when pressure increases to 340 psi then
pump will OFF automatically. In case of fault when
pressure increases to 375 psi then safety valve will operate
and it will close and vice versa.

While indication & alarm for emergency shutdown is at

245 psi.

c. AIR SYSTEM

The Air compressor system uses pre-compressed air from

an available compressed air network or is supplied
directly by a dedicated compressor set to its standard
pressure of 10 Bar.

Fig 1.18- Oil tank The pre-compressed air (intake pressure up to 10 bars) is
compressed to the desired higher final pressure - simply,
 P a g e | 26

safely, economically. There is no need therefore to invest
in a dedicated high-pressure network or to have a separate,
decentralized compressor system. The slowrunning, air-
cooled compressors can be adapted to almost all operating
conditions due to their welldesigned modular principle.
This also applies to the robust Booster (located after the
compressor) for operating pressures of up to 40 bars
I. OPERATION OF HYDEL POWER PLAN
It includes
• Breaker is OFF (open) mean isolator get open.
• Then stopping pulse is given as a result space
heater is getting OFF and transformer and
governor oil pump get OFF.
• As speed reached to 50 rpm,then breaking
system is introduced.
• Speed reached to zero T.B oilinjunction is zero
and break is done.

• Starting &stopping sequence of Machines

• Frequency maintenance c. FREQUENCY MAINTENANCE

• Hydraulic control desk As load increases speed of generator is decreased,thus

frequency get depressed ultimately
• Auxiliary control desk because
“frequency is directly proportional to speed”
• Power control desk
Now permanent magnet generator sense the speed and
signal is given to reaction motor installed at governor
a. STARTING SEQUENCE: which runs the oil pump then servor motor is operate and
as a result guide vanes are open as per load requirement
• First open inlet valve from Hydraulic control and as result frequency is maintain to 50 Hz.
desk
d. HYDRAULIC CONTROL DESK
• Give starting impulse to turbine
It is basically used for mechanical operations. By using
• Thus transformer oil pump along with T.B hydraulic control desk we can provide starting and
oilinjunction pump and cooling water system is stopping pulse along with operation of guide valve is
operated. ThenGovernorOil pump is operated at maintained.
the mean time. But space heaters are OFF. At 50
R.P.M T.B oilinjunction pump get OFF and Here different meters are installed which shows the
Hydraulic locking is disengaged. amount of water coming and exhaust through outlet.

• After achieving rated speed closed field switch

(70 E) placed at Power control desk which
reduces field resistance and maintain terminal
voltage .Then AVR is introduce into circuit.

• Then using Power control desk generator is

synchronized and feed the particular
circuit(synchronizing time is 4 mint).
Fig 1.19-Hydraulic control Desk
b. OFF SEQUENCE:

• First load is taken to zero e. AUXILLARY CONTROL DESK

• Field is switch is open (1-8) thus excitation or
Following boards are control by auxiliary control desk:
generator gets OFF.
 P a g e | 27

• Essential service board 3 to 15 from which 18 are functional while 1 is on

maintenance .
• Unit board
Here bay from -3 to 6 is consist of 132 kV lines while
• Common service board
remaining (7-15)are of 220 kV lines and in between these
All the auxiliary system of the machine installed at power two partitions 4 autotransformers are operated which are
station is fed by these above mention boards. used as interconnected transformers. If load exceed at 132
kV lines then autotransformer operate automatically and
transform power from 220 KV line to 132 kV line or vice
versa.

From 4 autotransformers:

Fig 2.0- Auxiliary control Desk
f. POWER CONTROL DESK (PCD)
19 bays (circuit) are operated manually from power
control desk .one and a half breaker scheme is used
while 2 bus bars are used to energized.
• 2 are working
• 1 is on maintenance
• While remaining 1 is spare
In previous years oil filled underground cables (used to
connect switchyard to power station) are replaced by
overhead conductors while only 9 & 10 bay are still
operating with underground system. In the mean time bay
14 have 2 generators as well.

Switchyard is also operated with 8 compressors which

compressed 40 kg air at a time (26 kg is utilized by air
blast circuit breaker while 16 kg by isolator)

Isolators installed at switchyard have 2 contacts

• Male
• Female

A. SYSTEM INSTALLED AT
MANGLA SWITCHYARD

Fig 2.1-Power control Desk a. Circuit Breaker

A circuit breaker is an electrical device used in an

electrical panel that monitors and controls the amount of
amperes (amps) being sent through the electrical wiring.
Circuit breakers come in a variety of sizes. Its basic
function is to detect a fault condition and, by interrupting
continuity, to immediately discontinue electrical flow.
VIII. SWITCHYARD
If a power surge occurs in the electrical wiring, the
breaker will trip. This means that a breaker that was in the
Switchyard is compromise of 2 bus bar and one and a half "on" position will flip to the "off" position and shut down
breaker scheme and is consist of 19 bays(circuits) from - the electrical power leading from that breaker.
 P a g e | 28

Essentially, a circuit breaker is a safety device. When a Why air Circuit Breaker are replace by SF6 Circuit
circuit breaker is tripped, it may prevent a fire from Breaker:
starting on an overloaded circuit; it can also prevent the It is because of two reasons:
destruction of the device that is drawing the electricity.
• Its spare parts are not available in Pakistani
There are two type of circuit breaker are used in Mangla Markets.
Power Station. • Current making capacity is low.

• Air Circuit Breaker b. Isolator Switch

• SF6 Circuit Breaker
Circuit breaker always trip the circuit but open contacts of
breaker cannot be visible physically from outside of the
breaker and that is why it is recommended not to touch
Air Circuit Breaker: any electrical circuit just by switching off the circuit
breaker. So for better safety there must be some
If a power surge occurs in the electrical wiring, the arrangement so that one can see open condition of the
breaker will trip. This means that a breaker that was in the section of the circuit before touching it. Isolator is a
"on" position will flip to the "off" position and shut down mechanical switch which isolates a part of circuit from
the electrical power leading from that breaker. system as when required. Electrical isolators separate a
Essentially, a circuitbreaker is a safety device. When a part of the system from rest for safe maintenance works.
circuitbreaker is tripped, it may prevent a fire from
starting on an overloaded circuit; it can also prevent the So definition of isolator can be rewritten as “Isolator is a
destruction of the device that is drawing the electricity. manually operated mechanical switch which separates a
part of the electrical power system normally at off load
condition.”
The main function of air circuit breaker is
A switch intended for isolating an electric circuit from the
• Open and close a 3 phase circuit, manually or source of power; it has no interrupting rating and is
automatically. intended to be operated only after the circuit has been
• Open the circuit automatically when a fault opened by some other means.
occurs. Faults can be of various types under or
over voltage, under or over frequency, short
circuit, reverse power, earth fault etc.
• The main feature of ACB is that it dampens or
quenches the arcing during overloading.

SF6 Circuit Breaker:

c. ONE & Half Breaker Scheme
In this circuit breaker, sulphurhexa fluoride(SF6) gas is
A method of interconnecting several circuits and breakers
used as the arc quenching medium. The SF6 gas is an
in a switchyard so that three circuit breakers can provide
electro negative gas and has a strong tendency to absorb
dual switching to each of two circuits by having the
free electrons. The contacts of the breaker are opened in a
circuits share one of the breakers, thus a breaker and one-
high pressure flow of SF6 gas and an arc is struck between
half per circuit; this scheme provides reliability and
them. The conducting free electrons in the arc are rapidly
operating flexibility, and is generally used at 500 kV when
captured by the gas to form relatively immobile negative
more than five lines terminate in a substation.
ions. This loss of conducting electrons in the arc quickly
builds up enough insulation strength to extinguish the arc.
Advantages of this Scheme are
The SF6 circuit breakers are very effective for high power
and high voltage service • Flexible operation and high reliability.
 P a g e | 29

• Isolation of either bus without service disruption.

Isolation of any breaker for maintenance without
service disruption.
• Double feed to each circuit. Bus fault does not
interrupt service to any circuits.
• All switching is done with circuit breakers.

IX. The New Bong Escape

operate at about 100 rpm. It is proposed to procure the

bulb units, governing, protection, and automation and
control systems from Alstom Power Hydro.

The direct-drive generator placed within the turbine

housing will have a rated capacity of about 23MVA
without undue stress.

Fig 2.2-New Bong Project Site Map

The Project involves construction of a run-of-the-river,
low head, 84MW hydel power generating complex. Four
generators of 21MW of each are used. It is located at the
New Bong escape, some 7.5 km downstream of the
Mangla Dam, on the Jhelum River, in AJ&K. It will be
fed by water originating from the Mangla Reservoir,
which is released, through the Mangla powerhouse into
the Bong Canal. There is no new reservoir or other water
storage envisaged for the Project. .
Bulb units horizontal type units are used. Bulb units have
high efficiency, low maintenance and are suitable for such
sites with low head, large and variable water flow. Four
low speed bulb-turbine units and synchronous direct drive
generators within the bulb housing which, together with
transformers and balance of electrical plant will provide
basis of the generating equipment. The selected bulb
turbine/generators will
 P a g e | 30

A. Concept Design (NTDC) under a long term power purchase agreement

with a 25 year term.
The key components of the Project include intake,
headrace channel, powerhouse complex, and tailrace B. Bulb Turbine
channel, switchyard, interconnection facility, roadbridge
and subsidiary outfall structure. The switchyard will Bulb turbine used at Bong project has 4 blades. Following
provide connectivity with the existing 132 kV grid are the key benefits to use bulb turbines instead of Francis
system. All the power generated by the Project will be turbines.
sold to the National Transmission and Dispatch Company
 P a g e | 31

• Most efficient solution for low heads up to 30

Fig 2.3- New Bong Project (Construction Phase)

area, typically being the river that was dammed. In the

UK they may be known as overflow channels. Spillways
release floods so that the water does not overtop and
 P a g e | 32

meters

• Negligible need for flooding of landscape due to

run-off-river type of the operation

• Reduced size, cost and civil works requirements

of up to 25% thanks to the straight water passage
in the draft tube that improves the hydraulic
behavior of the bulb unit and also results in a
lower need for excavation

• Meet the needs of any particular application our

Bulb turbines also operate as pumps in both flow
directions for tidal plant applications

• Sluice operation may also impact favorably both

the hydro mechanics and the navigability close
to the dam

Fig 2.4- Horizontal Bulb Turbine

 P a g e | 33

X. Operation and Maintenance of Spillway

 P a g e | 34

A spillway is a structure used to provide the controlled release of

restore the fuse plug and channel after such an

operation, the total damage and cost to repair is less than
if the main water -retaining structures had been
overtopped. The fuse plug concept is used where it
would be very costly to build a spillway with capacity
for the probable maximum flood.

There are two spillways at Mangla dam

Main spillway
Emergency Spillway

Each spillway comprises of 9 gates each gate of capacity

100000 cusec so one spillway can flow total 900000
cusec of water in normal days main spillway is operated
as required and emergency spillway is functional in an
emergency or in high flood seasons so the structure of
dam can be safe and would not be damaged by
overflow.

Fig 2.5- Spillway

XI. Mangla Fort Visit

After hectic routine of working we planned one day to
visit Mangla fort. Mangla Fort,named after Mangla
Devi, the daughter of King Porus, is situated on the hill
feature dominating the Mangla Dam lake. The fort dates
back to times before Christ. The fort is almost at the
same place from where Alexander the Great crossed the
Jhelum River, and 10 miles away at a place called
"Khari" the forces of Alexander and Raja Porus fought a
final battle in which Alexander's armies succeeded.
 P a g e | 35

flows from a dam or levee into a downstream damage or even

destroy the dam. Except during flood periods, water does not
normally flow over a spillway. In contrast, an intake is a structure
used to release water on a regular basis for water supply,
hydroelectricity generation, etc. Floodgates and fuse plugs may
be designed into spillways to regulate water flow and dam height.
Other uses of the term "spillway" include bypasses of dams or
outlets of a channels used during high water, and outlet channels
carved through natural dams such as moraines. Spillway gates
may operate suddenly without warning, under remote control.
Trespassers within the spillway run the risk of drowning.
Spillways are usually fenced and equipped with locked gates to
prevent casual trespassing within the structure. Warning signs,
sirens, and other measures may be in place to warn users of the
downstream area of sudden release of water. Operating protocols
may require "cracking" a gate to release a small amount of water
to warn persons downstream.

A spillway is located at the top of the reservoir pool. Dams may also have bottom outlets with valves or gates which may be
operated to release flood flow, and a few dams lack overflow spillways and rely entirely on bottom outlets.
There are two main types of spillways Controlled and Uncontrolled.
A controlled spillway has mechanical structures or gates to regulate the rate of flow. This design allows nearly the full height of
the dam to be used for water storage year-round, and flood waters can be released as required by opening one or more gates.

An uncontrolled spillway, in contrast, does not have gates; when the water rises above the lip or crest of the spillway it begins to
be released from the reservoir. The rate of discharge is controlled only by the depth of water within the reservoir. All of the storage
volume in the reservoir above the spillway crest can be used only for the temporary storage of floodwater, and cannot be used as
water supply storage because it is normally empty.
 P a g e | 36

In an intermediate type, normal level regulation of the reservoir is controlled by the mechanical gates. If inflow to the reservoir

XII. Misc Drawings

Following are the drawings we found in Mangla Power
station which help us a lot in understanding different
sections of Power Station.

Fig 2.7-Power Station Auxiliary Supply

 P a g e | 37

exceeds the gate's capacity, an artificial channel called either an auxiliary or emergency spillway that is blocked by a fuse plug
dike will operate. The fuse plug is designed to over-top and wash out in case of a large flood, greater than the discharge capacity
of the spillway gates. Although it may take many months to Fig 2.8-Mangla Switchyard Sche

Fig 2.6-Mangla Fort visit

P a g e | 38
 P a g e | 39

Fig 2.9-Oil Sump Tank Schematic

 P a g e | 40

Fig 2.8-Oil sump Tank