INTERNSHIP REPORT

7/27/2012

GROUP MEMBERS: Hafiz Affan Ahmed Muhammad Bilal Hassan Hafiz Umair Abdullah Athar Baig 2009-EE-158 2010-EE-34 FA09-EPE-100 2010-SCET-47

SUBMITTED TO: Hafiz Ghulam Hussain (Resident Engineer, Chashma hydel Power Plant)

HYDRO ELECTRIC POWER GENERATION

Hydroelectricity is the term referring to electricity generated 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 terawatthours 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 Asia-Pacific 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. 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. 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.

Generating methods These are five methods of hydel power generation. 1-Conventional (dams) 2-Pumped-storage 3-Run-of-the-river 4-Tide 5-Underground CHPP (Chashma Hydro Power Project) works under run of the river method.

HYDEL POWER IN PAKISTAN

152 million acre-feet annually flow, 104 MAF (68%) is diverted for irrigation major hydel potential 42,000 MW on rivers and large canals. Unfortunately only 6,600 MW hydro electric power plants has been installed

TOTAL ENERGY GENERATION OF PAKISTAN

Hydel Generation Thermal Generation I.P.P Nuclear Other Total 6462 MW 4750 MW 5706 MW 300 MW 25 MW 17,243 MW

Principal power demands of provinces of Pakistan is as follow

CHASHMA HYDROPOWER STATION

Chashma Hydropower Project (CHPP) is located on the right abutment of Chashma Barrage. The barrage is located on the Indus River near the village Chashma in Mianwali District, about 304 kilometer, North West of Lahore. The Project has been estimated at Rs. 17, 821.77 million including foreign exchange component of Rs. 9264.25 million. The installed capacity of Power Station is 184 MW comprising of 8 bulb type turbine units each of 23 MW capacity. The bulb turbines have been installed for the first time in Pakistan. The first unit was commissioned in January 2001, while final commissioning of all units was completed in July 2001. Apart from effective water management through barrage; CHPP has generated 7096.153 million KWh of cheap Hydel Energy since commissioning. Annual Generation in 2007-08 was 987.494 million KWh while the station shared peak load of 184 MW. Maximum pond level = 649ft. Normal pond level = 642ft. Minimum pond level = 637ft.

Output Distribution Power generated in this power plant is distributed to 4 grid stations through 132 kv transmission lines 1. D.I. Khan 2. Chashma left bank 3. Wanbachran circuit 1 4. Wanbachran circuit 2

WATER TURBINE
Kaplan type with moveable blades No. of blades Runner diameter Maximum Output Net Head Range Nominal Discharge Speed Runway Speed 4 6300 mm 23.7 MW 3.0 m to 13.8 m 250 cubic meter/sec 85.7 rpm 300 rpm

1.Stay Cone and Stay Column

Stay cone and stay column are fabricated from steel plates and consists of outer, inner stay cone and stay column. The outer and inner stay cone are rigidly joined with stay column. The outer stay cone is installed and embedded in the concrete.

Watertight type flanges are provided on the inner stay cone to be joined with the generator stator frame, inner gate and outer gate ring respectively. The stay column is of triangular shape hollow-construction of fabricated steel blades. The upper and lower of stay column project out from the outer stay cone are embedded in concrete, due to water thrust, rotating torque, maximum torque due to short circuit on the terminals of the generator. 2.Runner The Runner having inlet diameter of 6300 mm is adjustable blade type and has four blades made of stainless steel, mounted to the cast steel runner hub complete with necessary mechanism for adjusting blades. The runner cone made of steel blades is attached to the bottom of flange of the hub by bolts and forms a good water passage extending below the runner blades. In the side of the hub and runner cone, the necessary mechanism and hydraulic servomotor for adjusting the blades are accommodated. Opening or closing operation is carried out by changing reciprocating motion of

servomotor cylinder to rotating motion of the blade stem by means of links and levers. 3.Main Shaft The shaft is made of forged carbon steel and has two integrally forged coupling flanges. The hollow shaft carries two concentric pipes for carrying the pressure oil for closing and opening operation of the runner blades servomotor and central restoring pipes for carrying lubrication oil from oil gravity tank to the runner hub. Turbine Starting Sequence Lube oil motor start for bearing lubrication. Generator blower motor. Cooling water pump. Shaft seal cooling water pump. High pressure oil. At the same time DTG(draft tube gate) open 0-100% Lube oil pump to collect water in the elevated oil tank. Generator brake release. Wicket gate open. Unit starts rolling. Controlled oil flow through proportion valve, wicket gate distribution valve and wicket gate servomotor.

Operation involves: First of all when wicket gates of turbine opens, water applies a force on runner blades through which shaft rotates which is connected to generators rotor. At very start of units, a diesel generator set is used to provide 100 volts DC supply to exciter generator, for this purpose battery set can also be used. Exciter generator (20 poles) generates 275 volts AC, which is converted to DC by using 18 rotating diodes which are coupled with the same shaft,so with rotation generator produces 3 phase AC of 11000 volts at its stator winding (armature). Once a unit is started then DG set or battery set is removed automatically, after this it works on selfexcitation system, in which 11000 volts is stepped down to 400 volts using excitation transformer which is given to AVR(automatic voltage regulator) which provides supply to exciter according to load.

DIESEL GENERATOR
In case of complete shutdown of electric energy for the supply to auxiliary equipment , the emergency diesel generator is used, this can start and take over the load of the services, it can bear the load of 2 units at start up condition. Characteristics

neutral grounded output voltage power factor speed 800 KVA 400 V 0.8 lagging 1500 rpm

ELECTRICAL GENERATOR
An electric generator is a device that converts the mechanical energy into electrical energy under the rules of electromagnetic induction. Main parts of the generator in mechanical terms are rotor and stator. Rotor is the rotating part while stator is the stationary part. Main parts of generator in electrical terms are armature and field. Armature is the power producing component. It can be stator or rotor. Armature winding generates the electric current. Field is the magnetic field component of the generator. Magnetic field can be provided either by electromagnet or by permanent magnets. In CHPP Synchronous Generator is used. Synchronous Generator Synchronous speed = 120f/p To keep frequency 50Hz, synchronous speed is 85.7 rpm.

Conditions of Synchronization 1. Armature must have equal line voltage to the bus voltage. 2. Armature must have equal frequency to the bus frequency. 3. Armature must have equal phase sequence to the bus phase sequence. Synchronous generator specifications: Output Voltage Current Ex. Voltage Ex. Current Frequency Power Factor Poles Speed Insulation class Max. Temp. of Stator Max. Temp. of Rotor 26 MVA 11 KV 1365 A 275 V 688 A 50 Hz 0.9 70 85.7 rpm F 120 C 130 C

TRANSFORMER
A transformer is an electrical device that transfers energy from one circuit to another circuit purely by magnetic coupling. Transformers are often used To convert between high voltage and low voltage. To change impedance. To provide electrical isolation. Transformer Characteristics: Phases Frequency Type 3 50 Hz TTHE

Rated Power Rated Voltage Rated Current Highest voltage for equipment Insulation Level

HV 27.5 MVA 140.2+10%, 140.25% KV 113.2 A 145 KV 650/275 KV

LV 27.5 MVA 11 KV 1443.4 A 17.5 KV 95/38 KV

GOVERNOR
A device which regulates the speed of a prime mover. Main Governor System Manufacturer: Woodward Governor Company. Type: 517 digital control governor. This is used to control the angles of runner blades and opening or closing of wicket gates. The whole system works under oil pressure. Blade servomotor increases or decreases the angle of the runner blade (-3o to +34o) and its maximum rotating angle is 37o. Runner blade servomotor operating time: Total closing time = 12.1 sec Opening time = 20 sec There are total 16 wicket gates installed in turbine thats opening or closing control the water pressure on the runner blades. Wicket gate servomotor operating time: Equivalent closing time = 5.91 sec Total closing time = 9.46 sec

Opening time = 10 sec Here main governor system mainly consist of Oil pressure tank Oil sump tank Two distribution valves Oil filters for each D/V Servomotor (blade servomotor, wicket gate servomotor)

Process In oil pressure tank, pressure is maintained by using air compressor about 760 psi. Oil level in this tank is maintained by using oil sump tank through solenoid valve. This pressurized oil is then sent to both distribution valves. Flow of oil through this D/V then operate blade servomotor and gate servomotor. Oil filters are connected after the D/V to prevent oil from any contamination. Flow of oil between the wicket gate servomotor and distribution valve is controlled through three shutdown valves named Manually operated shutdown valves. Electrically operated shutdown valves. Hydraulically operated shutdown valves.

Over speed trip device is used to sense the speed, for over speed it operates the hydraulically operated shutdown valve.

COOLING WATER SYSTEM

This system is used for the cooling of hot oil (VG68) and air by using the phenomenon of heat exchange.

Process The water from the Over Head Expansion Unit is fed into coolers through pumps. In each unit mainly two coolers are used and two pumps, one is in standby for the circulation of water in coolers. The pumps used in this system are Generator bearing cooling water pumps. Transformer cooling water pumps. Generator air coolers cooling water pumps. The operating temperature of the coolers used in this process is 0o C to 80o C and their operating pressure is 1.0 Mpa. The oil from the elevated oil tank is allowed to flow in the bearings through gravity then it is collected in lubricating oil sump tank and leakage oil sump tank. This collected oil becomes hot due to friction of bearings. Then through pressurized pumps this collected hot oil is sent in the coolers. Here the phenomenon of heat exchange takes place between the water and oil. The cool water for this is pumped

through the cooling water pumps. This cooled oil is then again sent back to the elevated oil tank for circulation. Same process of oil cooling takes place in the transformer. The water is pumped in the transformer by using transformer cooling water pumps. The hot air of the four air blowers used in rotor is cooled down by using generator air cooler water pumps. Here water is pumped across the cooling pipes surrounded by hot air of blowers. In cooling water system we used the tape water as a coolant media. During the whole process a closed loop is maintained in the circulation of oil and water.

PROTECTION AND INSTRUMENTATION (P&I)

Isolation of effective part from energized part is called protection. Instrumentation is a physical display of these parts. For protection basic supply is 22 V dc for instrument basic supply is 24-48 V dc. If we do not have any dc supply then protection cannot be achieved. Simple protection scheme A scheme in which a single instruction removes the faults. Redundant Protection scheme In this scheme any fault is reduced by a direct command as well as backups instructions are also used to remove the faults by measuring the time scale. As in the case of soft shutdown mode.

Relays
A relay is an electromagnetic switching device consisting of an armature which is removed by an electromagnet to operate one or more switch contacts. Relays allow a small current flow circuit (220 V) to control a higher current circuit (11 KV up to 132 KV). Some advantages of relays are that they provide amplification and isolation and are straight forward. They can switch difficult voltages (e.g RF or high powered AC) with complete isolation and no worries about level translation. Relay disadvantages, compared to solid state switching, include power efficiency, noise, size, speed and reliability. Analog switches are commonly used instead of relays in signal switching applications. Control Relays These will operate only at 220V Protection Relays CTs and PTs (here 220V is available all the time).

Current transformer In electrical engineering, a current transformer (CT) is used for measurement of electric currents. Current transformers, together with voltage transformers (VT) (potential transformers (PT)), are known as instrument transformers. When current in a circuit is too high to directly apply to measuring instruments, a current transformer produces a reduced current accurately proportional to the current in the circuit, which can be conveniently connected to measuring and recording instruments. A current transformer also isolates the measuring instruments from what may be very high voltage in the monitored circuit. Current transformers are commonly used in metering and protective relays in the electrical power industry.

Potential Transformer Potential transformers are instrument transformers. They have a large number of primary turns and a few number of secondary turns. It is used to control the large value of voltage. WORKING: The potential transformer works along the same principle of other transformers. It converts voltages from high to low. It will take the thousands of volts behind power transmission systems and step the voltage down to something that meters can handle. These transformers work for single and three phase systems, and are attached at a point where it is convenient to measure the voltage.

Types of Shutdown
Normal Shutdown This type of shutdown is done by operator. There are two types of normal shutdown. Permanent Shutdown It is done by operator through push button, after which following events will happen; Unit stopped. Auxiliary stopped. DTG closed. Temporary Shutdown It is also done by operator through push button, after which following events will happen; Unit stopped. Auxiliary running. DTG open.

Shutdown on fault

This type of shutdown in done automatically in case of fault. Here we have four types of shutdowns. Electrical shutdown This type of shutdown in done because of electrical problems. Generally, this type of shutdown is performed by relays but it can also be done by the help of emergency push button. After this following events will happen; Immediate opening of unit circuit breaker. Immediate opening of field circuit breaker. DTG immediately closed. Lockout relays set. Mechanical shutdown This type of shutdown is done because of mechanical problems. After this following events will happen; Power reducing. Then opening of unit circuit breaker. DTG immediately closed. Lockout relays set.

 Soft shutdown This type of shutdown is done due to the loss of 132KV and total flow > 3000 m3/h It is just like electrical shutdown but the wicket gates remain open for some time to avoid wave then lockout relays set.

Partial shutdown This type of shutdown is done because of many reasons, which are as follows; Current unbalanced. Tap changer unlocked. Unmaintained coupling. Over fluxing. After this following events will happen; Immediate opening of unit circuit breaker. Immediate opening of field circuit breaker. DTG remains open.