Internship Report of Gulper Hydropower Project

Daelim & Lotte JV– Gulper Hydropower Project (102 MW)

Submitted by

Umair Altaf
FA15-BEE-045

A report submitted to the

Department of Electrical Engineering
in partial fulfillment of the requirements for the degree of
BACHELORS OF SCIENCE IN ELECTRICAL ENGINEERING

Faculty of Engineering
MIRPUR UNIVERSITY OF SCIENCE AND TECHNOLOGY
Mirpur Azad Jammu and Kashmir
 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 express
ing our deepest appreciation and heartiest gratitude to the staff of Gulpur Hydropower Plant 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 pati
ence, understanding and love provided by employees of Gulpur Hydropower Plant.
 INTRODUCTION
Gulpur Hydropower Plant (GHPP) is an under construction, run-of-the-river hydroelectric
generation project located on Poonch River, a major tributary of Jhelum River near Gulpur in
Kotli District of Azad Kashmir, Pakistan. The site is about 167 km from Federal Capital
Islamabad and 285 kilometers (177 mi) from Punjab's Provincial Capital Lahore and is
approachable directly from Islamabad and Lahore by a two-lane, all weather paved, partly
mountainous road. The location of the Project is about 28 km upstream of Mangla Dam
Reservoir.
 EXECUTIVE SUMMARY
The purpose of this report is to explain the working of Gulpur Hydropower Project.

Gulpur Hydropower Project is a run-of-the-river project designed for the generation of 100 mega
watts (130,000 horsepower) consisting of two Kaplan-type turbine units with average energy out
put of 436 GWh. Gulpur Hydropower Project is a part of least-cost energy generation plan, being
executed by WAPDA to harness the indigenous hydropower resources of the country.

WAPDA awarded the contract to MIRA Power Limited, a subsidiary of Korean company KOSE
P, an independent power producer (IPP) being developed in private sector on BOOT basis (Build
Own Operate and Transfer) under Government of Pakistan Policy for Power Generation Projects
2002 as adopted in Azad Jammu & Kashmir. The project has the capability of generating an aver
age annual energy of 465 GWh.
 Gulpur Hydropower Plant
Location of Gulpur Hydropower Plant in Pakistan
Official name:
Gulpur Hydropower Plant

Location:
Gulpur, Kotli District, Kotli Town of AJK, Pakistan

Coordinates:
33°27′19″N 73°51′45″E

Status:
Under construction
Construction began January 2014

Opening date:
October 2019

Owner(s):
Water and Power Development Authority (WAPDA)

Type of dam:
Gravity, roller-compacted concrete

Impounds:
Poonch River, a tributary of Jhelum River

Height:
35 m (115 feet)

Length:
238 m (781 feet)

Reservoir total capacity:

21,893,000 m3 (17,749 acre-feet)

Catchment area:
3,625 km2 (1,400 square mile)

Gulpur Hydroelectric Plant Operator(s):

Korea South-East Power Company (KOSEP)
Commission date:
October 2019

Turbines:
2 x 51 MW Kaplan-type

Installed capacity:
102 MW gross

Annual generation:
465 GWh
 Background and construction Edit
Gulpur Hydropower Project is the third independent hydropower project in Pakistan. Korean
company has also been awarded other contracts to build hydropower plants in the country on
BOOT basis i.e. under construction 150 MW Patrind Hydropower Plant and 100MW Kotli
Hydropower Project.

The sponsor of the project is Korean South East Power Company along with Daelim Industrial
Co., Ltd. and Lotte Engineering and Construction Co., Ltd.. The Construction of the Project has
been awarded to a joint venture between Daelim and Lotte.

Construction of Gulpur Hydropower Plant commenced in September 2014 and the project is
expected to be completed in early 2019. The total cost of the project is about PKR 34 billion.
Gulpur Hydropower Project is part of the least-cost energy generation plan of the Government of
Pakistan. It is being executed on priority basis to harness indigenous hydropower resources to
improve the ratio of hydel electricity in the national grid and help provide relief to the
consumers.

On its completion, Gulpur Hydropower project will generate about 465 GWh of inexpensive
electricity annually to earn revenue of about Rs 1 billion. Being an environment friendly
hydropower project, it will help reduce dependence on expensive thermal power, thereby saving
foreign exchange amounting to $36 million (equivalent to Rs 3 billion) to the country. According
to estimation, Gulpur hydropower project will add about Rs 10 billion per annum to the national
economy through socio-economic uplift in the country caused by the project. The Asian
Development Bank (ADB) is providing the loan to Mira Power, run by three Korean companies,
which will build and operate a 102MW hydropower plant.
 Salient Features
Basin and Reservoir:
Catchment Area 3,625㎢
NHWL EL.540.0m
L.W.L EL.538.0m
100yr frequency flood 13,340㎥/s
PMF 21,640㎥/s
Reservoir Capacity (NHWL) 21.893 million ㎥

MAIN DAM:
Type CGD

Design Flood 21,640㎥/s(PMF)

Height 35.0m
Crest EL 545.0m
Length 238.0m
Spillway:
Radial Gate Size W10.0mx7Gates (EL .518.0m)
Under Sluice Gate Size W10.0mx4Gates (EL .515.0m)
Energy Dissipation Submerged Bucket
River Diversion:
Type Partial cofferdam (1st) + Sheet File (2nd)

Design Flood 2,517 ㎥/s (25 years’ frequency)

Intake Weir:
Gate Nos 2 EA
Gate Size 10.0 x 12.0m
Headrace Tunnel:
Size D=7.75M
Type modified horseshoe (concrete lined)
Length 3,063.5m
Surge Tank:
Type Simple Type
Size D=29.0M (circular)
Height 54.0m
Max Up Surging Level EL 556.523M
Max Down Surging level EL 525.986M
Vertical Pressure Tunnel:
Type Circular (concrete lined)
Length 71.7m
Steel Penstock:
Type Circular (Steel lined)
Length 11.2m x 1EA 28.9M X 3EA
Powerhouse:
Size W74.0m x L31.5m
Turbine Type Francis
Installed Net Capacity 100MW
Annual Generation 465GWh

Plant Discharge 194㎥/s

Gross head 57.45m

 MACHINERY
GHPP is generating 102 MW of electricity at rated capacity and 150 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 direction. Pelton and Turgo turbines are the examples of Impulse Tur
bine.

b. Reaction Turbine
Reaction turbines develop torque by reacting to the water. The pressure of the water changes as it
passes through the turbine rotor blades.

B. Generator:
Generator is the second most important part of the electricity generation. The kinetic energy of th
e water moves turbine and produces mechanical energy. Generator uses this mechanical energy a
nd convert it into electrical.

a. How Generator Works:

It works according to the Faraday’s Law of Electromagnetism.
Whenever a coil is moved in a magnetic field an induced current is produced.

b. Exciter:
Theoretically permanent magnets are required to give magnetic field but in practical we cannot u
se permanent magnets because there is a lot of heat inside the generator and magnetism drasticall
y reduce with heat. Secondly such large permanent magnets are inevitable to produce and maintai
n. That is why we use Electromagnets in generators. Electromagnets are developed according to
Ampere’s Law.

There are two type of exciter used in GHPP.

Brush Type Exciter

Static Exciter

 Brush Type Exciter

The brush type exciter can be mounted on the same shaft as the AC generator armature and can b
e housed separately from, but adjacent to, the generator. When it is housed separately, the exciter
is rotated by the AC generator through a drive belt. The distinguishing feature of the brush-type e
xciter is that stationary brushes are used to transfer the DC exciting current to the rotating generat
or 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, rectifier, t
hermistors and reactors.
C. Automatic Voltage Regulator
Voltage transformers provide signals proportional to line voltage to the AVR where it is compare
d to a stable reference voltage. The difference (error) signal is used to control the output of the ex
citer field. For example, if load on the generator increases, the reduction in output voltage produc
es an error signal which increases the exciter field current resulting in a corresponding increase in
rotor current and thus generator output voltage.

Due to the high inductance of the generator field windings, it is difficult to make rapid changes in
field current.

This introduces a considerable "lag" in the control system which makes it necessary to include a s
tabilizing control to prevent instability and optimize the generator voltage response to load chang
es.

Without stabilizing control, the regulator would keep increasing and reducing excitation and the l
ine voltage would continually fluctuate above and below the required value.

Modern voltage regulators are designed to maintain the generator line voltage within better than +
/- 1% of nominal for wide variations of machine load

C. Transformer:
A transformer is a device that transfers electrical energy from one circuit to another through indu
ctively coupled conductors—the transformer's coils. A varying current in the first or primary win
ding creates a varying magnetic flux in the transformer's core and thus a varying magnetic field th
rough the secondary winding. This varying magnetic field induces a varying electromotive force (
EMF), or "voltage", in the secondary winding.
If a load is connected to the secondary, current will flow in the secondary winding, and electrical
energy will be transferred from the primary circuit through the transformer to the load. In an idea
l transformer, the induced voltage in the secondary winding (Vs) is in proportion to the primary v
oltage (Vp) and is given by the ratio of the number of turns in the secondary (Ns) to the number o
f turns in the primary (Np) as follows:

Several transformers are used for different purposes. Just after generation we need to step up or st
ep down the voltage. Then we have some auto transformers in Gulper. Many current and potentia
l transformers are used which will be discussed later.

a. Step-up Transformers:
Step-up transformers step-up the voltage to 132 KV and 220KV. After stepping up voltages these
voltages are transmitted through bus bars.

b. Step-down Transformers:
We have two Station Transformers which step down 132 KV to 11 KV. Power through these tran
sformers is fed inside the station to run different equipment’s 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 w
inding has at least three taps where electrical connections are made. An autotransformer can be s
maller, lighter and cheaper than a standard dual-winding transformer however the autotransforme
r does not provide electrical isolation.

As an example of the material saving an autotransformer can provide, consider a double wound 2
kVA 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 autotr
ansformer, the output is a simple tap at the center of the 240 volt winding. Even though the whole
winding can be wound with 8-amp wire, 16 amps can nevertheless be drawn from the 120-volt ta
p. This comes about because the 8 amp 'primary' current is of opposite phase to the 16 amp 'secon
dary' current and thus it 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 requir
ed to hold the windings are smaller. The advantage is at its greatest with a 2:1 ratio transformer a
nd 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 ran
ge and voltages in the 220-230-240-volt 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 between 220KV and 132 KV bus bars. Whenever we have more load at 132 side, TX. sw
itches 220 KV to 132 KV and share the load and vice-versa.

d. Potential Transformers
At transmission side potential Transformers are used. The purposes of potential transformer are a
s follows:

 Voltage Measurement
 Overvoltage protection

Transformers can also be used in electrical instrumentation systems. Due to transformers' ability t
o step up or step down voltage and current, and the electrical isolation they provide, they can serv
e as a way of connecting electrical instrumentation to high-voltage, high current power systems. S
uppose we wanted to accurately measure the voltage of a 13.8 kV power system. Direct measure
ment 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 instrumen
t panel would be severe, not to mention the design of the voltmeter itself. However, by using a pr
ecision step-down transformer, we can reduce the 13.8 kV down to a safe level of voltage at a co
nstant ratio, and isolate it from the instrument connections, adding an additional level of safety to
the metering system.

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 po
wer line so that we are able to safely and easily measure high system currents with inexpensive a
mmeters, such a transformer would be connected in series with the power line. “Current transfor
mer” 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 availa
ble on wire leads.

Some CTs are made to hinge open, allowing insertion around a power conductor without disturbi
ng the conductor at all. The industry standard secondary current for a CT is a range of 0 to 5 amp
s AC. Like PTs, CTs can be made with custom winding ratios to fit almost any application. Beca
use their “full load” secondary current is 5 amps, CT ratios are usually described in terms of full-
load primary amps to 5 amps.
 Cooling system at GHPP
Cooling of heavy equipment is very important at Gulper. Huge amount of current and voltages m
akes equipment’s very hot specially generators and transformers. Due to the importance of coolin
g we have working as well as multiple stand-by cooling systems in Gulper. Water is taken from r
eservoir through 24-inch pipeline and then distributed to the different sections in Gulper in green
pipes. Following is the Schematic diagram of cooling of two of the units.

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:

Pressure reducing Valve

This valve reduces the pressure of the water that goes through it, and is used to obtaining a regula
ted and constant value at its outlet.

It is installed at the water mains (for a bungalow as for a flat). It protects the whole installation fr
om problems due to excess pressure noises in the pipes, water hammer, splashes, premature wear
of household electrical appliances and taps. The pressure reducing valves are completely automat
ic.
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; larg
er piping diameter units are made from ductile iron. Direct acting valves, the more popular type o
f a water pressure reducing valves, consist of globe-type bodies with a spring-loaded, heat-resista
nt 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 pre
ssure control.

Motor Operated Valve:

Motor Operated valve is a valve where the Actuator Part of the Valve is replaced by a motor inste
ad of pneumatic. MOV are normally used for Larger Process lines where the Pneumatic pressure
is not enough to provide torque or pressure for the Valves movement.

Since Motors have good torque they are used to open or close the valves, these are also called as
electrical Actuators.

Protection System Installed at GHPP

Different protection system for different equipment’s is installed at GHPP.

a. Guide Vane Protection

Sometimes large stuff like trunk of trees or large stones comes into the penstock with the flow of
water. These things stuck in the runner and stop the operation of guide vanes and hence wicket ga
tes cannot move. In such situation the share pin installed with the vane is broken and control roo
m gets the indication of problem in guide vane and is alarmed.

b. Generator Protection

At the front of the unit’s different gauges and meters are installed. These meters measure the tem
perature, voltage, oil level, generation capacity; speed etc. in case of any problem alarm is active.
Moreover, generators have auto switch of system in case of very serious problem.

GENERATOR PROTECTION RELAYS

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 impe
dance grounding. It is operating due to Phase Split relay and restricted earth fault.

Split Phase Relay

At output there are three windings and each is then divided into three parallel path. Four Current
Transformer is connected to each winding. If any open circuit fault is occurring the current passe
s from other path and the relative CT noted high current and relay sense it and give relative indic
ation.

Restricted Earth Fault relay

This relay is connected in between 13.2kv and 132kv or 220kv.The neutral point of CT feed and t
he CT of HV side is also feed and when fault occurs at any side relay sense it and trip frequently.

Stator Earth Leakage relay

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 activates 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.
 SWITCHYARD
Switchyard is compromise of 2 bus bar and one and a half breaker scheme and is consist of 19 ba
ys (circuits) from -3 to 15 from which 18 are functional while 1 is on maintenance.

Here bay from -3 to 6 is consist of 132 kV lines while remaining (7-15) are of 220 kV lines and i
n between these two partitions 4 autotransformers are operated which are used as interconnected t
ransformers. If load exceed at 132 kV lines, then autotransformer operate automatically and trans
form power from 220 KV line to 132 kV line or vice versa.

From 4 autotransformers:

 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 syst
em. In the meantime, 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 ut
ilized by air blast circuit breaker while 16 kg by isolator)

Isolators installed at switchyard have 2 contacts

 Male
 Female

SYSTEM INSTALLED AT GHPP SWITCHYARD

a. Circuit Breaker

A circuit breaker is an electrical device used in an electrical panel that monitors and controls the a
mount of amperes (amps) being sent through the electrical wiring. Circuit breakers come in a vari
ety of sizes. Its basic function is to detect a fault condition and, by interrupting continuity, to imm
ediately discontinue electrical flow. If a power surge occurs in the electrical wiring, the breaker w
ill trip. This means that a breaker that was in the "on" position will flip to the "off" position and s
hut down the electrical power leading from that breaker. Essentially, a circuit breaker is a safety d
evice. When a circuit breaker is tripped, it may prevent a fire from starting on an overloaded circ
uit; it can also prevent the destruction of the device that is drawing the electricity.

There are two type of circuit breaker are used in GHPP.

  Air Circuit Breaker
 SF6 Circuit Breaker

Air Circuit Breaker:

If a power surge occurs in the electrical wiring, the breaker will trip. This means that a breaker th
at was in the "on" position will flip to the "off" position and shut down the electrical power leadin
g from that breaker. Essentially, a circuit breaker is a safety device. When a circuit breaker is trip
ped, it may prevent a fire from starting on an overloaded circuit; it can also prevent the destructio
n of the device that is drawing the electricity.

The main function of air circuit breaker is

 Open and close a 3 phase circuit, manually or automatically.

 Open the circuit automatically when a fault 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:

In this circuit breaker, Sulphur hexa fluoride(SF6) gas is used as the arc quenching medium. The
SF6 gas is an electro negative gas and has a strong tendency to absorb free electrons. The contact
s of the breaker are opened in a high pressure flow of SF6 gas and an arc is struck between them.
The conducting free electrons in the arc are rapidly captured by the gas to form relatively immobi
le negative ions. This loss of conducting electrons in the arc quickly builds up enough insulation s
trength to extinguish the arc. The SF6 circuit breakers are very effective for high power and high
voltage service.