A Report on

6250 MW NATHPA JHAKRI HYDROELECTRIC PLANT

Prepared during the six week vocational training at Nathpa Jhakri hydroelectric plant

Submitted to:

Submitted by: Antra Chowdhury Anchal Sood Kusal Chandel

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ACKNOWLEDGEMENT
We are thankful to our respective colleges for providing us an opportunity to undertake six week vocational training at Nathpa Jhakri hydroelectric plant and see in such detail the operation of the largest hydroelectric project in India. We express our sincere thanks to the GM/HOP Er. N.C. Bansal for allowing us to undertake this vocational training. We want to thank our shift in charge at the power house, Er. Shiv Prasad for ensuring that we make most of our time at the power house in the operations department. Also, we acknowledge the help extended by Er. Nishant Thakur, Er. Aman Gupta, and Er. Rohit Verma whenever approached, in introducing, explaining and clearing the concepts of the operation at the power house. Yet again, the moral encouragement and cooperation from all the technicians, foremen and associates has helped us to a successful completion of our training thereof.

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PREFACE
The report attempts to provide an overview of the operation of the largest hydroelectric project of the nation. It begins with an introduction of how the project came into being. It then provides a sequential account of the course that the river Satluj takes and how this water ultimately leads to a generation of 1500MW. The report intends to provide a sufficiently detailed version of the generation as well as transmission of hydroelectric power. Also, it presents the various wisely applied mechanisms, auxiliaries and protection schemes etc. that lead to the successful operation of the power house.

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INDEX
Title Introduction Project statistics Overview of the Project Nathpa Dam Site Service Bay Floor UAB Floor Turbine Floor MIV floor Common Power plant auxiliaries SILT Lab Transformer Hall Fire fighting system GIS-1 POT Head Yard Control Room Unit Start/Stop Sequence RSD1/RSD2/ESD Future Projects Page 5-9 9-10 10-12 12-17 17-20 21-30 31-41 42-45 46-49 49-50 50-54 54-55 55-58 58-62 62-63 63-67 67-69 69-70

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Sjvn Limited- A Profile SJVN Limited, a Mini Ratna & Schedule A CPSU under the Ministry of Power, Govt. of India, is a joint venture between the Govt. of India & Govt. of Himachal Pradesh. Incorporated in the year 1988, the Company is emerging as a major hydro power player in the country. SJVNL is presently operating the Countrys largest 1500 MW Nathpa Jhakri Hydro Power Station (NJHPS) in Himachal Pradesh which has been recognized as an engineering marvel for its unique features. Nathpa Jhakri Project- Salient Features

1) It has a 62.50 m high concrete gravity dam on Sutlej River at Nathpa village of Kinnaur
district of Himachal Pradesh. 2) Worlds largest underground Desilting Complex comprising of four chambers (each 525 m long, 16.31 m wide and 27.5 m deep). 3) One of the worlds longest Head Race Tunnel of 27.39 km length and 10.15 m dia. 4) The HRT divides into 3 pressure shafts and they eventually divide into 6 penstocks. 5) It has the worlds deepest Surge Shaft of 301 m depth. 6) Underground Power House with a cavern size of 222 m x 20 m x 49 m having six Francis Turbine Units of 250 MW each. 7) The generated voltage of each unit is 15.75 KV and transmitted at 420 KV. 8) It is a run-off with small pondage type hydel project in which the river is diverted to the dam which doesnt have a lot of capacity 9) There are three circular steel lined pressure shafts each of 4.9 m dia. and 571 m to 622 m length which feed the six generating units. 10) The six generating units with Francis turbine of 250 MW and utilize a design discharge of 405 cumecs and a design head of 428 m. 11) The draft tubes to the collection gallery for discharging the water back into the river through the 10.15 m diameter and 982 m long tail race tunnel. 12) The project has an underground Transformer hall which has 19 transformers to step up the generated voltage of the 6 units before transmission. There is a Surface Switch Yard for evacuation of power through two transmission lines. 13) The project also has an interesting feature of Sholding Works Complex which enables the diversion of the water of Sholding Stream into the HRT, which is useful during the lean season. 14) Annual energy generation is 6750.85 million units in a 90% (MU) dependable year. 15) A discharge of 1 cumec generates 4 MW power. Location of the Project: The 1500 MW Nathpa Jhakri Hydroelectric Project (NJHEP) is the first project undertaken by SJVNL for execution. The generation component of the 6X250 MW Nathpa Jhakri HydroElectric power project (NJHEP) in the Shimla and Kinnaur District of Himachal Pradesh (H.P.) was sanctioned in April 1989 for execution by the Nathpa Jhakri Power Corporation (NJPC) now known as Satluj Jal Vidyut Nigam Ltd. (SJVNL). NJPC effectively took over
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execution of NJHEP in August 1992. NJHEP envisages harnessing the Hydro power potential in the upper reaches of river Satluj in the South West of Himalaya. The Power House is 150 KM from the nearest Rail Head (narrow gauge) Shimla. The project stretches over a length of about 50 KM from the dam site to the power house, on the Hindustan Tibet Road (NH-22), which also connects the rail head to the project. The major civil works of Nathpa Jhakri Hydro Electric Power Project were awarded during 1993 and the construction commenced in 1994. Expertise in Operation and Maintenance of Hydro Power Station: The 1500 MW Nathpa Jhakri Hydro Power Station (NJHPS) has been running successfully during the past eight years. The power station has generated over 38837 MU of electricity during these years.

Serial No. 1 2 3 4 5 6 7 8 9

Year 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12

Gross Energy Generation (in MU) 1130.121 5170.830 4104.430 6014.490 6448.975 6608.710 7018.810 7140.205 2340.977 (till 22 June 2011)

Beneficiary States The power generated is supplied to the following states: Sr. No. 1 2 3 4 5 6 7 8 9 10 State Haryana Himachal Pradesh Jammu & Kashmir Punjab Rajasthan Uttar Pradesh Uttaranchal Chandigarh Delhi Unallocated quota at the disposal of the Central Government TOTAL Allocation (In MW) 64 547 105 114 112 221 38 08 142 149 1500 Percentage of the installed capacity 4.27 36.47 7.00 7.60 7.47 14.73 2.53 0.53 9.47 9.93 100%

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Power Transmission:

In June 2009, SJVNL entered into a memorandum of agreement with IL&FS Limited, the Power Grid Corporation of India Limited (PGCIL) and the PTC Financial Services Ltd. for the establishment of a joint venture to construct and maintain the Indian part of a transmission line connecting Nepal and India. Grid Scheduling As per the rule, any company selling electricity to PGCIL (Power Grid Corporation Of India Limited) needs to declare its power schedule for the next day in terms of blocks of 15 minutes and the company is paid on the basis of that. If the generated electricity is less or more than the schedule declared, penalty is imposed on the power selling company depending on the grid frequency, i.e. only if the frequency is less than 50 Hz. Deviation from actual energy generation is adjusted on the fourth days generation. As per the bill board agreement between SJVNL and NRLDC (Northern Region Load Dispatch Centre), SJVNL has to declare MW exchanged (ceiling value for each 15 minute time block), MWH for the entire day (ceiling value). In case of any revision in the generation schedule, the grid needs to be informed minimum 6 hours before the change takes place. The tariff plan, on the basis of which the grid pays to SJVNL, takes into consideration the following: a) ABT (Availability Based Tariff) b) Energy Charge c) UI charge (Unscheduled Interchange/ Injection) The term Availability Tariff, particularly in the Indian context, stands for a rational tariff structure for power supply from generating stations, on a contracted basis. The power plants have fixed and variable costs. In the Availability Tariff mechanism, the fixed and variable cost components are treated separately. The payment of fixed cost to the generating company is linked to availability of the plant, that is, its capability to deliver MWs on a day-by-day basis. The total amount payable to the generating company over a year towards the fixed cost depends on the average availability (MW delivering capability) of the plant over the year. In case the average actually achieved over the year is higher than the specified norm for plant availability, the generating company gets a higher payment. In case the average availability achieved is lower, the payment is also lower. Hence, the name Availability based Tariff. This is the first component of Availability Tariff, and is termed capacity charge. The second component of Availability Tariff is the energy charge, which comprises of the variable cost of the power plant for generating energy as per the given schedule for the day. It may specifically be noted that energy charge (at the specified plant-specific rate) is not based on actual generation and plant output, but on scheduled generation. In case there are deviations from the schedule (e.g., if a power plant delivers 600 MW while it was scheduled to supply only 500 MW), the energy charge payment would still be for the scheduled generation (500 MW), and the excess generation (100 MW) would get paid for at a rate
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dependent on the system conditions prevailing at the time. If the grid has surplus power at the time and frequency is above 50.0 cycles, the rate would be lower. If the excess generation takes place at the time of generation shortage in the system (in which condition the frequency would be below 50.0 cycles), the payment for extra generation would be at a higher rate. Thus, the Indian version of Availability Tariff comprises of three components: (a) capacity charge, towards reimbursement of the fixed cost of the plant, linked to the plant's declared capacity to supply MWs, (b) energy charge, to reimburse the fuel cost for scheduled generation, and (c) a payment for deviations from schedule, at a rate dependent on system conditions. The last component would be negative (indicating a payment by the generator for the deviation) in case the power plant is delivering less power than scheduled. As mentioned earlier, the energy charge, at the specified energy charge rate of a generating station, is payable for the scheduled energy quantum. The energy actually supplied by the generating station may differ from what was scheduled. If actual energy supplied were higher than scheduled, the generating station would be entitled to receive a payment for the excess energy (the deviation from schedule, technically termed as Unscheduled Interchange (UI) in Availability Tariff terminology) at a rate dependent on frequency at that time. If the energy actually supplied is less than what is scheduled, the generating station shall have to pay back for the energy shortfall, at the same frequency - linked rate. UI rate: Rs. 0 at 50.20 Hz to Rs. 8.75 at 49.50 Hz Money is reimbursed based on two factors: 1) Plant availability factor 2) Energy generated Plant availability factor: The NJHEP is a 1500 MW project and at the rated generation, the ex- bus is 1482 MW. At 10 % overloading, it can generate 1650 MW. Suppose, for a day maximum ex-bus declared by NJHEP is 1600 MW, then the PAF for that day is 107 % {(1600/1482) *100}. Same is calculated for each day and average yearly PAF is calculated by taking the average of all the daily PAFs. It has to maintain a minimum PAF of 84 %. The total amount payable to NJHEP towards the fixed cost depends on the average PAF over the year. In case, the average PAF actually achieved over the year is higher than the specified norm, it gets a higher payment. For instance, suppose the fixed cost is 1200 crores and the average PAF is 98 %, then the fixed cost paid by the grid will be 1400 crores {(98/84)*1200}. Energy based charges depends on the energy charges of the nearest thermal power plant.

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Project Commissioning Schedule The commissioning schedule of NJHEP was as follows: Unit Unit-V Unit-VI Unit-IV Unit-III Unit-II Unit-I Project Statistics MW 250 250 250 250 250 250 Synchronization Sep. 29, 2003 Nov.23, 2003 Jan. 22, 2004 Feb. 13, 2004 Mar 09, 2004 Mar 31, 2004 Commissioned 06 Oct., 2003 02 Jan., 2004 30 Mar, 2004 31 Mar, 2004 06 May, 2004 18 May, 2004

Description 1. Location State District Vicinity

As Per Revised Cost Estimate Himachal Pradesh Kinnaur/Shimla Dam downstream of Wangtoo bridge at Nathpa & power house near Jhakri village on left bank of river Sutlej.

2. Diversion Dam Type Max. height above foundation level Full reservoir level Min. draw down level

Concrete gravity 62.5m 1495.5 m 1474.00m

3. Desilting Arrangement Type Number & size Flow through velocity Particle size to be removed

Underground Four parallel chambers each 525m x 16.31m x 27.5m 33.0 cm/sec. Particle greater than 0.2 mm

4. Head Race Tunnel Shape & type Diameter

Circular, concrete lined 10.15m

5. Surge Shaft Diameter

Total height
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21.6m circular for height of about 210.0m & a connecting shaft of 8.8 m diameter. And about 90.0m high. 301.0m

6. Pressure Shafts Type

Circular, steel lined with high tensile steel

7. Power House Type Size Type of turbine Gross head Design head Number and capacity of generating units

Underground 222m x 20m x 49m Vertical axis Francis turbine 486m 428m 6 x 250 MW

8. Tail Race Tunnel Size Length

10.15m, circular 982m

9. Power Potential Energy generation in a dependable year

6750.85 MU in a 90% dependable year

Overview of the Project The Nathpa Jhakri Hydro Electric Project is based on the discharge of river Satluj. The water of the Satluj River is not stored in the Dam but some part of the water flowing in the river is diverted into the Dam using radial gates and the rest of the water flows normally in the river. As there is no storage, this project is a run off the river type project. To remove the extra water from the reservoir, spillway gates have been provided. The water enters the HRT from four intake gates, which are followed by four Desilting chambers. The excessive silt needs to be removed from this water and this is made possible due to the Desilting complex in the dam. This complex can be cleaned using the silt flushing gates. The water finally flows into the Head Race Tunnel which is about 27.3 Km long. Its construction is a tedious and time consuming process. Thus, for easy completion of this task, the contract is given to various companies and they start digging from different regions of the same tunnel at the same time. This speeds up the process and after the entire tunnel has been made using the GPS navigation, the sites of digging are closed and then they are called ADIT. The various ADIT employed in the construction of the HRT were: Nathpa Adit Sholding Adit Nulgalsari Adit Waldhal Adit

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Manglad Adit Ratanpur Adit

The Sholding Complex is an important feature during the lean season. The water from this khad goes into the head race tunnel to add to the discharge. At the end of the HRT lies the Surge Shaft (at Ratanpur) to absorb the back hammering of the water in the HRT and hence, avoid its damage from the huge force the water may exert in case of closing of the pressure shafts. The surge shaft is followed by the valve house containing three butterfly valves. The water from the HRT goes into three pressure shafts if these valves are open. These pressure shafts further divide into 6 penstocks, which end in the spiral casings of the 6 generating units. For the rotation of the runner of a particular unit, the Main Inlet Valve after the penstock must be open. The water after passing through the turbine flows through the draft tubes to get accumulated into the tail race tunnel, whose contents are then thrown back into the river at the outfall. The power house at Jhakri is an engineering marvel in itself. It consists of a huge underground complex comprising a massive Machine Hall, which also houses the Control Room, a fully equipped conference hall. The power house measures 222m x 20m x 49m. It consists of a centralized control room, an exhibition room, a medical room, silt testing laboratory and many rooms for the various concerned officials. The benefits of an underground power house, as compared to the over ground one are as follows: 1. Being close to the border with China, an underground power house is comparatively safer from sabotage. 2. An underground power house provides better safety against an earthquake. 3. An underground power house is secure from the danger posed by potential landslides, which may otherwise wreck havoc. The power house at Jhakri receives the water of the River Sutlej from the Dam site through a network of underground tunnels that passes through the Surge Shaft and the Butterfly valve House. Eventually the penstock empties into the MIV located in the lowermost floor of the powerhouse. Before proceeding further, a note must be made of the vertical cross section of this powerhouse. It consists of the following floors, enumerated from top to bottom: Service Bay Floor (Elevation: 1000.5m above mean sea level): It is the topmost floor where each of the six units of the power house are represented as a circular unit. Each unit has a pair of green and red indicator. The red light goes on when unit is in the operating condition. Generator Floor (Elevation: 995m above mean sea level): This floor is directly located below the Unit Bay Floor. It houses the six generators of the power house, one for each one of the six units of the power house. It also houses the bus duct and the various auxiliaries associated with the working of the generator. Turbine Floor (Elevation: 990m above mean sea level): This floor, which is directly below the Generator Floor houses, the six vertical axis Francis turbines. Each one of the six turbines receives water from the six MIV which are opened using hydraulic pressure created by the governor system on this floor.

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MIV Floor (Elevation: 982.5m above mean sea level): This floor is the lowermost floor of the power house. It contains six individual MIVs, each weighing 92 tonnes and being controlled by the lifting of a counter weight of 76 tonnes by means of a servomotor which is operated hydraulically using oil. There is an underground Transformer Hall at an EL. 1044 m and is 270 m long and 7 m Dshaped. There are 19 single phase Transformers, one being a spare transformer. These are used to step up the generated voltage for transmission. Above the transformer hall is the GIS-I (Gas Insulated Switchyard), which is used to synchronize the stepped up voltage to the bus voltage and also to couple the two buses together. This uses the compressed SF6 (Sulphur Hexafluoride) gas for insulation and the circuit breakers and isolators also use the same gas. This switch yard has been made possible underground due to the use of this gas, which makes it safe for such an operation. GIS-I is connected to GIS-II, which opens outside the power house and is also known as POT HEAD YARD (Point Of Transmission Hydro-Electric Aerial Distribution Yard). This is used to synchronize two incoming lines from BASPA-1 and BASPA-2 with the bus and then transmit the same and the generated voltage to Abdullapur and Nalagarh.

Nathpa Dam Site The dam site of Nathpa (Distt Kinnaur) is at distance of 48 Km from the power house at Jhakri (Distt. - Shimla) by road. It is located on the Hindustan Tibet road, which traverses steeps gorges & near vertical slopes as it winds its way along the river Sutlej. The dam at Nathpa is a concrete gravity type diversion dam. As such, it is not a storage dam & can only provide backup water supply for 4 hours during lean periods. The base of the dam site is merely 8m wide. The function of dam is not only to raise the water surface to create artificial head but also to provide the poundage. The height of dam 62.50m on Satluj River at Nathpa to divert 405 cumecs of water through four intakes .The dam is most important part of a hydro electric project. It is built of concrete or stone masonry on a rocky hill. Following are the detailed statistics for the Nathpa dam: Type Base of dam Top of dam Max. height of dam above foundation level Length of dam at road level Full reservoir level Max. water level Min. draw down level Concrete gravity type diversion dam 1433.0m 1495.5m 62.5m 170.2m 1495.5m 1495.5m 1474.0m

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Pondage available Spillway type Number & type of gates

441 hectare meter Overall spillway or solid gravity spillway 5 nos. radial gates

Selection of Dam Selection of the dam to be constructed at a particular site depends upon topography, foundation survey, soil condition and other characteristics of the location. The foundation of the dam must be sufficiently strong to withstand the weight of the structure, water pressure etc. without crushing, sliding or permitting movement of the structure. The foundation of the dam should be sufficient impervious so that there will be no objectionable passage of water. Spill Way Gates There are two spill way gates on the dam situated at NATHPA River SATLUJ. They acts as a safety valve. It discharges the over flow water to outside the dam when reservoir is full. This condition arises during flood and machine tripping. These gates can be opened and shut automatically when water overflows to the level and closes when water reaches in the level. Spillway gates cant be closed manually. The spill way has to bays each of 7.5/2.5m inside and shall be controlled by two counter weight balanced gates used for maintaining level of the reservoir at EL-1495.50m. Crest level Gates Radial Gates There are five sluice radial gates in the dam. Radial gates are always closed. They can be opened during the Dam flushing, at the time of high discharge and in the event of flood in river. The hydraulic motors used open and close radial gates are interconnected through bypass valves so each gate can be opened or closed by any one of hydraulic motor. The opening speed of hydraulic motor is 0.5 meter per minute when opened electrically and half of it when opened from petrol engine driven pumps. It takes 19 minute for full opening of a radial gate when operated electrically.
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EL-1492.50m Two counter weight balanced gate each of size 2.5*7.5m

Intake Gates There are four intake gates through which water goes to desilting chamber. Before Intake gates, trash racks are provided to avoid entry of heavy material like boulders etc to enter in the HRT. The Intake structure, comprising of four intake gates is about 500m long. This inlet of river has been designed to handle a discharge of 486 cumecs. An inclined independent trash rack, four vertical and one horizontal has been purpose in front of each intake with trash racking machine located at the platform provided above following reservoir level to facilitate cleaning of rocks. The rectangular opening of 19.26m*157m at the start of the base is reduced to 6.0m*5.2m through a suitable transition.

Desilting Chambers An underground desilting arrangement comprising of four chambers is made on the left bank of the river Satluj to settle silt particles down to 0.2mm size from water before it enters the head race tunnel. Four intake gates are made to feed the four chambers through each tunnel respectively and independently. The flow into the chambers is regulated by gates at intakes. a proper transition from 6.0m wide approach tunnel to 16.31m wide at the center and 27.5m high, leaving semi circular roof and 5m deep continuous Hooper at the bottom. Each chamber will have a 3m wild collection trench in the center running along its length. The Hooper portion of the chamber slopes towards this trench. The sediments from the collection trench flow down to the flushing tunnel 5m in diameter. The flushing gates will be provided at the junction of flushing conduit and main flushing tunnels. It reduces the flow of water and also prevents the particle of 0.2mm to the turbine. It is the underground complex for the generation of Hydroelectric Power in the world. Underground Four parallel chambers each 525m long, 16.31m wide at center and 27.5m deep. Flow through velocity particle size to be 33.4cm/sec particle greater than 0.2mm. removed Type No. & Size

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Silt Flushing Gates Silt flushing gates are also four. They create a pressure in the desilting chamber and flush out silts and particles at the edge of the desilting chamber. HRT Intake Gate After desalting chamber water goes through HRT intake gates. Like desilting chamber, HRT intake gates are also four. The water at the output of the every HRT intake gates are combined at main Head Race tunnel. Head Race Tunnel The 10.15m diameter circular Head Race Tunnel from the junction point at the link tunnels from desilting chambers to the surge shaft is 27.3 km long. The tunnel diameter is based on techno economic studies for a discharge of 405 cumecs. The rock cover of HRT varies from about 90m to about 1480m along its length. The Head Race Tunnel is provided with steel lining in the Manglat and Daj creek area where rock support is not expected. There are six adits in HRT which were used during the erection work as the access approach to the HRT. 1. Nathpa Adit 2. Sholding Adit 3. Nugalsari Adit 4. Badhal Adit 5. Manglat Adit 6. Ratanpur Adit EL-1450.89m, length 1062.50m. 876m 647m 842m 691m 1357m

It is longest tunnel in the world. Shape Length Diameter Design discharge Velocity circular, concrete lined 27394.59m 10.15m 405 cumecs 5.0m/sec

Sholding Works In order to augment flow during the lean months, the water at Sholding khad is diverted to HRT. It has a 26m long tunnel that will divert a discharge of 8 cumecs through a 2m diameter D-shaped inlet tunnel in the underground desilting chamber. The inlet tunnel will terminate in

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23m long where after water will enter depris choking of 12.5m into 10.15m size and desilting chamber of 56m into 1d0.15m size. Location Type Design discharge Flushing water Length Width Depth -----------------------------------Across Sholding Khad at EL-1544.53m Trench weir 8 cumeces 2 cumeces 26m Varies from 4.625m to 2m 0.82m to 3.92m

Surge Shaft The main surge shaft is located at the intake of the penstock at 27.3 km form head race tunnel. It is 301 m deep. Its function is to avoid the water hummer effect. Three penstocks are taken from the surge shaft at the bottom, two from side of surge shaft and one is taken from the centre of the surge shaft. A 12 m diameter Horse shoe shaped 185m long lower gallery at EL 1370m has also been provided. The minimum water level in the surge shaft is about 30 m. The surge shaft is concrete lined of adequate thickness. It is the deepest surge shaft in the world. Three drainage galleries at different elevations have been provided around the surge Shaft to relieve the external water pressure on the lining.

Fig 3. Surge Shaft Representation

PRESSURE SHAFT Three shafts of diameter 4.9m and length varying from 619m to 660m take off from the surge to an angle of 56 degree to the horizontal. These are lined with high tensile steel of thickness varying from 32mm to 60mm. Each pressure shaft is bifurcated into the branch tunnel of
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diameter 3.45 m. Each pressure shaft is designed to carry a discharge of 315 cumecs .A spherical valve has been provided in each penstock branch tunnel inside the machine hall cavern to enable closing of penstocks whenever required. BUTTERFLY VALVE The butterfly valve is of spherical type, has a diameter of 4.9 m and can be opened only when the counter weights on both sides of valve are lifted upwards. It is called butterfly valve as it is operated by using 2 servo motors .This valve is either open or close. It is located between the surge shaft and penstock. Its purpose is to allow or restrict completely the water supply from the HRT to the penstock. If in any case butterfly valve closed due to any failure ESD occur of both units. The self-closing of the valve is ensured by a counter weight. It is a steel body provided with integrally cast supporting feet, lifting lugs and heads for locking the valve rotor in closed and opened position. The counter weight is lifted by a servomechanism. This is taken care of by nitrogen cylinders maintained at a pressure of 100bar. Whenever due to any leakage pressure goes below 94 bar oil pressure unit starts and maintains its pressure. The counter weight is lifted and only then is the butterfly valve opened. Hence, a constant pressure is to be maintained. It could have been engineered in a way that counterweight would have to be lifted only when butterfly valve was meant to be closed. This meant not having to supply power to keep it lifted till the time the unit was to be functional. However, it has been designed the way it is because if ever there is a power failure and the units cannot run, the BFV shuts down and hence no damage is caused to the rest of the structure and machinery. Had it been designed otherwise, in case of power failure the water would have kept rushing into the whole machinery and destroyed all of it. Service Bay Floor There are three modes for machine operation: Local mode (Unit Control Board manual) Auto mode (UCB auto) Central control room mode The start/ stop, control and operation of machines as well as their auxiliaries rest in the cubicles placed on this floor. Two panels for each unit are present on this floor: Excitation panel and Control Panel. The UCB auto mode is operated from the Service Continuous excitation is demanded by the rotor as its an electromagnet and hence the excitation cannot be removed if the unit is to be kept running. The excitation panel broadly consists of the following cubicles: Measuring cubicle Interfacing cubicle PCC cubicle
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Generator control cubicle Governor electronic cubicle Protection A cubicle Protection B cubicle

The measuring cubicle contains the measurements of current, voltage, temperature, moisture content (of the transformer oil) and all other relevant measurements of the unit it is attached to. Two synchrotacts are present on this cubicle that compare the voltage, frequency and phase sequence of the generator side and of the line side. After 90% of the rated voltage and 97% of rated speed has been achieved, command for synchronization reaches the machine. The interface cubicle is the one through which the information from the measuring cubicle is communicated to the rest of the cubicles. PCC (Programmed/ Process Control Cubicle) is the brain of the UCB panel. All the commands and the processing come from the PCC cubicle. Generator cubicle: This acts as a back-up for the generator if the PCC cubicle fails to perform its required actions on the generator. Governor control cubicle: The governor cubicle consists of a DTL (digital turbine logic), BU-DTL (back up DTL) and Speed Monitor and Alarm Unit. Protection A cubicle: this cubicle is responsible for the protection scheme employed for a given unit and its excitation panel. Protection B cubicle: This serves as a backup to the whole protection scheme provided in the Protection A cubicle. The service bay floor also houses a mini control room in which there is kept an operating system same as that in the main control room. All the ongoing activities in the power house related to any cubicle and any machine can be looked for, and controlled from this mini control room too. Actually all the remote terminal units (RTU) for turbine, generator, transformer, 415V supply and CFA01 are connected to the main chip i.e. AC410 (Motorola) through optical fibre cable known as AF100 bus. As the CFA01 panel is near the chip it is connected to the main chip via coaxial cable. They are connected to the chip via modem. Now all the ongoing activities in any RTU are received by a chip and this chip is connected to the central control room (CCR, housing OS-1) and mini control room (housing OS-2). It is due to this unique feature installed in the UCB (unit control board), we can control any activity in the power house from the control room itself.

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Flood Control Panel: This panel operates the flood controlling pumps in case of flooding of the power house. They are installed at different elevations levels so that each floor can be recovered back during flooding, discharge of these pumps go back outside through MAT. There are 12 pumps each of a capacity of 120 lps. D/W control cubicle: The dewatering pumps are used to dewater the penstocks, spiral casings and the draft tubes. The D/W control cubicle panel holds the control of starting and stopping these dewatering pumps. These pumps are four in number and each has a capacity of 120lps. EOT (Electric Overhead Travelling) Cranes 250 Tonnes: There are two Electrical Overhead Travelling cranes which are used when maintenance of machine parts like runners, turbines, generator parts and lifting of other such heavy machinery is required to be done. The cranes have the following specifications: Span: 20m Main Hoist: 250T Auxiliary Hoist: 50 T Auxiliary Hoist: 10 T Main Voltage: 415V, 50Hz Control Voltage: 230V, 50 Hz/ 24V dc Service Bay: It refers to the portion of the service bay floor where the various equipments such as runner are serviced and maintained.
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Air Conditioner Room: The central air conditioning plants or the systems are used when large buildings are to be air conditioned completely. The window and split air conditioners are used for single rooms or small office spaces. If the whole building is to be cooled it is not economically viable to put window or split air conditioner in each and every room. Further, these small units cannot satisfactorily cool the large halls, auditoriums, receptions areas etc. In the central air conditioning systems there is a plant room where large compressor, condenser, thermostatic expansion valve and the evaporator are kept in the large plant room. They perform all the functions as usual similar to a typical refrigeration system. However, all these parts are larger in size and have higher capacities. The compressor is of open reciprocating type with multiple cylinders and is cooled by the water just like the automobile engine. The compressor and the condenser are of shell and tube type. While in the small air conditioning system capillary is used as the expansion valve, in the central air conditioning systems thermostatic expansion valve is used. The chilled is passed via the ducts to all the rooms, halls and other spaces that are to be air conditioned. Thus in all the rooms there is only the duct passing the chilled air and there are no individual cooling coils, and other parts of the refrigeration system in the rooms. What is we get in each room is the completely silent and highly effective air conditions system in the room. Further, the amount of chilled air that is needed in the room can be controlled by the openings depending on the total heat load inside the room. There are two types of central air conditioning plants or systems: direct expansion air conditioning plant and chilled water central air conditioning plant. SJVNL power house uses the latter. Chilled water central air conditioning plant: This type of system is more useful for large buildings comprising of a number of floors. It has the plant room where all the important units like the compressor, condenser, throttling valve and the evaporator are housed. Earlier, water in the condenser used to be taken from the POT HEAD yard located away from the power house. But later on, it was provided with a separate water supply. The evaporator is a shell and tube. On the tube side, the Freon fluid (F22) passes at extremely low temperature, while on the shell side the brine solution is passed. After passing through the evaporator, the brine solution gets chilled and is pumped to the various air handling units installed at different floors of the building. The air handling units comprise the cooling coil through which the chilled brine flows, and the blower. The blower sucks hot return air from the room via ducts and blows it over the cooling coil. The cool air is then supplied to the space to be cooled through the ducts. The brine solution which has absorbed the room heat comes back to the evaporator, gets chilled and is again pumped back to the air handling unit. The central air conditioner also needs a blower motor which is usually part of the furnace to blow the cool air through the duct system.
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UAB Floor (EL. 995.0 m)

Various DTTS:

A Remote Terminal Unit (RTU) is a microprocessor-controlled electronic device that interfaces objects in the physical world to a distributed control system (DCS) by transmitting telemetry data to the system and/or altering the state of connected objects based on control messages received from the system.

Marshalling box is a of panel which is situated next to transformer, it contains OTI or oil temperature indicator, WTI or winding temperature indicator, heater switch, pump control switch, fan control switch, MCB and contractors.

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GENERATOR: The synchronous generator in the power house is vertically mounted and converts the hydraulic energy of water into electrical energy. It has salient poles with closed air circuit ventilation and coupled to a machine turbine. The field coils are energized by a static excitation system. The slip rings, permanent magnet generator and mechanical over speed device are fitted to a rotor spider. The speed of the turbine wheel must therefore match the synchronous speed of the generator. A combined thrust and guide bearings are located below the rotor. Rated power Maximum power Voltage generated Current Power factor Poles Rpm Runaway Insulation (Both stator and rotor) Air gap Excitation current Rated excitation voltage Stator winding resistance Rotor winding resistance Efficiency 278MVA 305MVA 15.75 5% kV 10190 A 0.9 20 300 545 Type F 30mm 2400A 249V 1.22m ohm 119m ohm 98.65%

Stator: Stator is double layered with 252 slots, 504 bars and laminated core Rotor: Rotor has20 poles, 300rpm speed and Runaway speed 545rpm.

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BRAKING AND LIFTING: Operated at 20% of rated speed, air pressure is 6-8 bars. There are 16 brake pads and 8 dust collectors. Excitation Transformer(EX): It is Dry type transformer which utilizes some of the generated power for self-excitation. It steps down the generated voltage at 15.75kV to 100-150V which is then converted to D.C. with the help of thyristors (3 bridge 6 thyristors)

The specifications are: Rated Capacity Conn. 5-6 Conn. 4-6 Conn. 4-7 Conn. 3-7 Conn. 3-8 1780kVA 16538V 16144V 15750V 15356V 14963V 65.2A 24/1.1kV 5.9% 50Hz Yd5 ANAN 4.15t

Rated Voltage

Rated Current Um Imped. Volt Rated Frequency Vect group Type of Cooling Trans Weight
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Auxiliary Transformer (T1): The generated voltage is 15.75kV. It steps down the 15.75kV to 440 V to run the auxiliaries.

The specifications are: Rated Capacity Phases Insulation class Winding material Vector grp Type of cooling Total Weight Rated Voltage and Current HV LV 630kVA Three Delta Three Star F Copper Dyn11 ANAN 3400kg HV-16537.50V,21.99A HV-16143.75V,22.53A HV-15750.00V,23.09A HV-15356.25V,23.69A HV-14962.50V,24.31A

Conn. 6-5 Conn. 5-7 Conn. 7-4 Conn. 4-8 Conn. 8-3

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Various Panels and their significance: Below is the outline of UAB (Unit Auxiliary Board) panel:

NGT & NGR and their significance: If the system has a neutral which is available, a single phase distribution transformer can be used in conjunction with a loading resistor to provide high resistance grounding. This is particularly well suited for grounding of generators, in that it allows the system to operate like an ungrounded system under normal conditions, while still retaining the ability to limit ground fault current. Such a Transformer is called Neutral Grounding Transformer (NGT). NGR is employed in AC distribution networks to limit the fault current which would flow from the transformer or generator neutral star point in the event of an earth fault in the systems. It is used when the neutral of supply transformer is accessible and its own impedance is not enough to limit fault current. Specifications of NGT are: KVA Rating Voltage Rating (HV side) kV Voltage Rating (LV side)kV Resistance Rps(N-N)milli-ohm Resistance Res(N-G)milli-ohm N-G(Total) milli-ohm 200kVA 20kV 0.22kV 16m 90m 106m

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Bus Duct:

Bus ways, or bus ducts, are long bus bars with a protective cover. Rather than branching the main supply at one location, they allow new circuits to branch off anywhere along the route of the bus way. 400 kV transmission lines are connected to GIS through SF6 to air filled bushings through 400 kV bus ducts.

Turbine Floor (Governor): EL. 990 m FRANCIS VERTICAL SHAFT REACTION TURBINE: The reaction turbine, as the name implies, is turned by reactive force rather than by a direct push or impulse. Francis Turbine is an inward-flow reaction turbine that combines radial and axial flow concepts.

Francis turbines are the most common water turbine in use today. They operate in a head range of ten meters to six hundred and fifty meters and are primarily used for electrical power production. The power output ranges from 10 to 750MW, mini-hydro excluded. Runner diameters are between 1 and 10 meters. The speed range of the turbine is from 83 to 1000 rpm. Medium size and larger Francis turbines are most often arranged with a vertical shaft. Vertical shaft may also be used for small size turbines, but normally they have horizontal shaft. The working fluid changes pressure as it moves through the turbine, giving up its energy. A casement is needed to contain the water flow. The turbine is located between the highpressure water source and the low-pressure water exit. The inlet is spiral shaped. Guide vanes direct the water tangentially to the turbine wheel, known as a runner. This radial flow acts on the runner's vanes, causing the runner to spin. The guide vanes (or wicket gate) may be adjustable to allow efficient turbine operation for a range of water flow conditions.
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As the water moves through the runner, its spinning radius decreases, further acting on the runner. At the exit, water acts on cup-shaped runner features, leaving with no swirl and very little kinetic or potential energy. The turbine's exit tube is shaped to help decelerate the water flow and recover the pressure.

Francis type turbines can be constructed in vertical or horizontally. Horizontal construction is more accessible and has higher speed, but for large machines, vertical construction is preferred to affect the higher speed. As compare to Pelton wheel, a Francis turbine offers advantage of high efficiency at full load and at 75% of full load; this turbine can be designed for higher speed than Pelton Wheel. For this project, the gross head of the turbine is 486m and design head is 428m.

TURBINE: The water from the penstock enters the spiral casing on the opening of the Main Inlet Valve. In the spiral casing, the water is spread all round the circumference through stay vanes. The water is under pressure as it enter the runner and completely fills all its channel as it passes through .

Block Diagram of Turbine Function

The guide vanes are responsible for controlling the amount of water that comes out of the spiral casing onto the runner. These vanes are controlled by the governor via two servomotors on either side of the turbine pit. These servomotors control the guide vanes by performing an action similar to that for a steering on a ring that rests on these guide vanes.

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The guide apparatus has movable vanes, which are controlled by the governor and can be set independent of output. The effect of water hitting the runner is transferred to the Generator, which is connected to the Turbine Shaft. The turbine develops the power partly due to the velocity of the water and partly due to difference in pressure acting on the front and back of Runner buckets. Such a turbine essentially consists of guide apparatus consisting of an outer ring comprising of stationary guide blades fixed to the casing of turbine and an inner ring that consists of rotating blade forming a wheel or a Runner. The guide blades of the turbine are pivoted about an axis parallel to the turbine axis so that quantity of the water entering in the turbine may be regulated by turning them simultaneously in one direction or the other, their motion is automatically controlled by the governor. Turbine Components:

1. Rotating Parts : There are mainly three rotating parts: a) Runner The runner has been formed by welding crown and band of stainless cast steel and the vanes of stainless steel plates. The vanes have been machine worked and the crown band has Roots towards the vanes. Air used for stabilizing purpose is allowed through the Runners centre via the shaft seal and drilled holes in the turbine shaft flange. The moment of force on the runner is transferred to the turbine shaft through the shear pin connection. The coupling bolts between the turbine shaft flange and the runner are tensioned by means of hydraulic wrench.

b) Turbine Shaft The turbine shaft is made of SM steel with flanges hammered out at both ends. The turbine shaft and generator shaft are connected by flanges. The connection is done primarily to transfer the moment of force through the shear studs.

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c) Oil Slinger: The Oil slinger is located below the turbine bearing and connected to the turbine shaft. Its purpose is to collect the oil from turbine bearing and during operation bring the oil into the slinger cylinder from where it is caught by the oil scraper and led to the oil cooler and the bearing oil reservoir.

2. Turbine Guide Bearing Bearing Design The turbine bearing is radial vertical slide / guide bearing. The bearing has a strong construction and a simple manner of operation, which requires minimum maintenance. The bearing house is split and attached to the upper turbine cover. It has two manhole hatches for access and inspection of shaft seal and pipe connections. The bearing shell consists of two segments, which are bolted together and attached to the upper side of the bearing house. The shell has four oil pockets and four Babbitt metal surfaces with machined wedge shaped entrances, which ensure a stable centering of the turbine shaft. The bearing has been fitted with an inspection hatch dip stuck for oil slinger, fluid level gauge for bearing house, thermometers and level switches for surveillance. The bearing has been fitted with external oil cooler. This is automatically put into operation when the cooling water system is started. Bearing Function When the unit starts, the oil slinger starts rotating , oil is slung up into the cylinder section and cover the vertical with a layer of oil. The thickness of this layer will be determined by the position of the oil scraper. The amount of the oil in the oil slinger is regulated by means of the oil scraper, which is attached to the bearing shell. When there is sufficient rotating speed , the damming up pressure becomes strong enough to force the oil up through the ascending pipe through the oil cooler and out into the bearing house. From there the oil flows down through the four windows in the bearing house cover and is spread out to the four oil pockets in the bearing shell. A film of oil follow with the shaft in the wedge shaped entrance on the bearing shell and builds up the guiding oil layer.

3. Turbine cover: The Turbine has two covers: i) Upper Cover: The upper cover is bolted to the spiral casing ring. It serves as a bearing for the regulating ring and a support for the upper stationary labyrinth seal, turbine inner cover with shaft seal as well for the longest trunnion of the guide vanes. The interchangeable upper stationary labyrinth seal is made of forged steel and is bolted to the cover. The seal surface on the labyrinth seal faces the equivalent seal surface on the upper rotating labyrinth seal bolted to the runner ii) Lower cover: The lower turbine cover is bolted to the spiral casing stay ring. It serves as a support for the short trunnion of the guide vanes, the lower stationary labyrinth seal and the draft tube cover. Supporting sleeves made of aluminum and bronze guide vane bearing

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have been installed. Corrosion resistant austenite steel has been welded into the wearing surface of the lower turbine cover between the wear ring and the lower labyrinth seal.

Governor and its auxiliaries: Governor Governor is the brain of the machine and it uses hydraulic oil to generate pressure of 100 bar. It is an arrangement consisting of hydraulic system, electrical/ electronic hardware components and of the software program which is used to regulate the turbine operation under all circumstances. The jacking system to open the M.I.V. (Main Inlet Valve) is controlled by the governor. The governor uses centrifugal pump to create a pressure of 100 bar used for: 1. Controlling guide vane opening using servo motor 2. Opening of the bypass valve 3. Opening of the M.I.V.

Specifications: Governor (Capacity Wicket Gate, E= 336 KNm Max. Working Pressure: 100 bar) Hydraulic pump trip setting (MCB setting): 157A Guide vane opening time: 23.4 sec Guide vane closing time: 13.2 sec

The counter weight of the MIV is lifted by a servomechanism. This is taken care of by a green cylinder filled with oil and maintained at a pressure of 100bar. It is connected to the nitrogen cylinders kept on the turbine floor which help maintain this pressure by compensating for any change, both increase and decrease, in this value of pressure. The sole control of this maintenance of pressure lies with the governor.

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The Turbine has two servomotors. The connection between the servomotor and the regulating ring consist of an adjustable connecting rod and a spherical bearing. It senses the speed of the turbine rotation and generates a signal proportional to the difference between the turbine speed and the governor speed reference and therefore develops a hydraulic control signal sufficient to control the turbine. The adjustable rod is used for pre tensioning the guide apparatus. When pre tensioning the guide apparatus the guide vanes are given a moment which produces a force toward closed position. This compensates for slackening and deformation in the lever and link connection and provides a closing force greater than or approximately equal to hydraulic opening force on the vanes with full pressure in the spiral casing. The governors action on the two main servomotors is transferred via the regulating ring. The actual guide apparatus consists of 23 guide check plates on upper and lower turbine cover as well as guide vane lever and links The guide vanes are made of forged stainless steel and have been shaped to provide the best possible hydraulic conditions. The guide vanes have bearings on upper and lower turbine covers. These are self lubricating slide bearings with Teflon covering. The coupling between guide vane and guide vane lever is a pure friction coupling, thus allowing the guide vane to slide away in case of foreign object is preventing the guide vane from being closed. An alarm in that case will be activated. The guide vane lever and regulating ring are connected by links. The links are
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joined by self - lubricating bushing on stainless steel pins attached to the regulating ring and the guide vane lever respectively
OPENING AND CLOSING OF GUIDE VANES

15o

Regulating Ring

0o Links Axis Of Guide Vane Guide Vanes Water

0%

Guide Vane In Closed Position

OPENING AND CLOSING OF GUIDE VANES

15o

Regulating Ring

0o Links Axis Of Guide Vane Guide Vanes Water

100 %

Guide Vane In Open Position

Components of Governor:

OPU tank: Oil Pressurizing Unit tank OPU pump: Oil Pressurizing Unit pump (96 KW, 415 V, 1485 rpm, 3 ph IM) Hydraulic oil cooler: This is used to cool the oil in the tank of the governor when its temperature is about 50C.

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 Hydraulic safety valves Hydraulic control valve (solenoid operated) Main control valve (distributor valve) Guide vane servomotor: Servomotor moves the guide vanes by applying pressure (piston attached to the lever). Piston accumulator system: Piston Accumulator: 16 cylinder filled with nitrogen are used to produce a pressure of about 100 bar, so that it can be used in an emergency such as power failure, to stop the machine and avoiding it to over speed. Hydraulic oil filter elements MIV hydraulic control valve (solenoid operated) MIV control valve (hydraulics operated) Protection: To avoid overheating of the oil, temperature sensors like R.T.D. and thermistors are used along with thermo-switch. DV Pos. Transmitter Main Control Valve (DV) Accumulator Shut off valve Hydraulic Oil Filter Hydraulic E.S.D. (Emergency Shut Down) valve: In this the brakes are applied without unloading the machine. Start Stop Valve Change over valve: To switch on one of the pumps and closing the other. Servo Valve (DTL): Digital Turbine Logic Servo Valve (BUDTL): Back up Turbine Logic M.I.V. E.S.D. valve ( air bleed) M.I.V. Control valve (hyd. op.)

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Brake Dust Collector: Ratings: Capacity: 1200 cubic metre per hour H.P.: 5, Type: C/Fan, Rating: Cont., KW: 3.7, Volts: 415, Ph: 3, Amp: 7, RPM: 2830. The brake dust collector consists of an extraction unit, hoppers around brake assembly around brake assembly for trapping the brake dust and flexible hoses for connecting hoppers to the extraction unit. The extraction unit will have a motor driven exhaust fan and will be fitted with an easily removable sheet steel bin for collecting heavy dust. The lighter air born particles will be collected by a suitable fabric based filter. The starter panel for motor having provision for automatic start and stop of the motor will also be provided. Two units of brake dust collector are used which work alternately and are used to collect the dust due to the application of the brakes. O.V.E. (Oil Vapour Extractor): This is used to absorb the oil vapour produced due to the heat generated in the U.G.B (Upper Guide Bearing) and L.G.B. (Lower Guide Bearing) where oil is used as a coolant. The oil vapour extraction system sucks off the vapour of the generator bearing. This oil vapour is generated during operation and led to the filters outside in the generator room, the pollution of the machine is this way avoided. As soon as the generator starts running with the operating temperature, the oily fog is developed in the bearing oil container by very finely distributed oil drops. breathing the oil in bearing or pressure differences inside and outside the bearing cause the oil vapour, a mixture of air and oil that produces a different wetting of the parts and surfaces at the outside. These damp places result in providing an ideal background for dirt beginnings. During high speed of rotor or high load the differential pressure increases between the bearing chambers and the environment. In this case the bearing seal and shaft oil separators cannot hold back the oil mist any longer. To prevent this, the generator is equipped with a special oil vapour suction system.

Heat Exchangers: RATINGS OF WATER HEAT EXCHANGER: Nominal capacity: 43,00,000 kcal/hr Heat transfer surface=435.1 m2 Working pressure = 10 bar
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Testing pressure =13 bar Working temperature: 95 degrees (max) 0 degrees (min)

The water enters the turbine through a spiral casing. There are 23 guide vanes surrounding it. The pressure of water in the draft tube is 2bar and that in the spiral casing is more or less 45 bar. The basement of the power house is the dewatering gallery or drainage water gallery. Leaked water from all the machines goes to this gallery. Its 7m below the MIV floor.

Oil circulating pumps: Two controlled oil pumps of the axial piston pump type. Their size is identical, which makes them redundant. Under normal circumstances, one pump is sufficient for all operation conditions. Nevertheless, if the oil pressure should ever fall below the required pressure value, the second pump will automatically switch in. The oils pumps extract the oil from the control oil tank through a suction strainer, and direct it through non-return valve and a shut off valve into the collector. The non-return valve is intended to prevent the oil from flowing back through a stationary pump, which would be otherwise rotate backwards.

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Secondary Cooling water pumps: COOLING SYSTEMS Secondary Cooling Pump rating: 3 Phase Motor, 75 KW, 1480 rpm, 415 V, 50 Hz, cos : 0.86 C/W Pump Control Cubicle has controls for: a) Primary circuits (Raw water) b) Secondary Circuits (Treated water)

The primary pump cools the water that goes into the water heat exchanger via the secondary cooling pump placed at the Turbine floor. The secondary pump further cools the oil-water heat exchanger. While the primary pump is an open loop system, the secondary water pump and the oil-water heat exchanger are closed loop systems. Both oil and water are used as coolants in the machines. The number of primary pumps with each unit is two. However, only one of them is functional at a time. The pump priority is changed every few hours so that a pump doesnt wear out way before the other one.

Primary: present on the MIV FLOOR. Its rating is 37kW. The water enters the pump at a pressure of 2.5bar. They are two in number for each unit but only one is used at a time. These pumps are switched from time to time so that either of the two doesnt get excessively used and hence worn out way sooner than the other. The pumps are three phase squirrel cage induction motor. Rating: 50hp, 37kW, 985rpm, 50Hz, 66A, 415+-10%,delta connected, power factor =0.83. Secondary: present on the Turbine floor. Its rating is double that of the primary one. Its rating is 75 kW. Again they are two in number just like the primary cooling pumps. The water pressure is 5bar. The cool water is taken from the draft tube. The water enters the turbine through a spiral case. There are 23 guide vanes surrounding it. The pressure of water in the draft tube is 2bar. The basement of the power house is the dewatering gallery or drainage water gallery. Leaked water from all the machines goes to this gallery. Its 7m below the MIV floor.

HP oil Pump or H.S. Pump (Hydraulic System Pump): There are two such pumps present together, one operated from A.C. and other using D.C. The D.C. operated pump is required in case of A.C. power failure. It is used for jacking the machine by injecting a line layer of oil below it. This is used while stating and shutting down the machine, as there will be a lot of friction and the machine needs to be lifted a bit to avoid damage to it.
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Servomotor: This is not actually a motor, but it is a hydraulic system used to open the MIV. The pressure created by the OPU (Oil Pressurizing Unit) is transferred hydraulically to lift the counter weight and this pressure acts due the green coloured cylinder and piston pair and this is called the servomotor. Shaft seal system: Shaft seal is a rubber seal to stop the back water flow from the tail race tunnel to the runner. This seal is opened when the machine is to be switched on. The shaft seal in the runner is air operated and the air compressor needs to maintain a pressure of 6.8 bar. Shaft seal flushing system: During the start and stop of a machine and during low rotational speed of the turbine, the flushing water system is functional. It prevents the contaminated (silt containing) water from affecting the shaft seal (which is made of rubber and hence is prone to damage by silt particles and other contamination at such high speed). Hence at such times, the flushing water system provides filtered water at sufficient pressure. The intake is from the pressure equalizing piping between the upper turbine cover and the DT. A centrifugal pump increases the pressure by 15mWC and in automatic back flushing strainer, the particles above 200microns get removed. Turbine Shaft Seal Cubicle 1) Shaft seal System Control 2) Head cover pump Head cover pump: It is used to remove the water leakage around the shaft service seal.

MIV Service Seal system: The service seal in M.I.V. is applied by water pressure and it is to be removed before the unit needs to be started.

MIV Maintenance Seal System: This is to be applied when the unit needs to be opened for maintenance.

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Various panels and their significance:

Governor Control Panels:

MIV control panel

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Governor hydraulic control panel

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Governor accumulator panel: It shows the pressure of both the hydraulic oil in the governor and the nitrogen gas accumulator.

Governor motor control panel

Governor hydraulic terminal MIV terminal box MIV seal control cubicle Governor electronic cubicle Hydraulic Pump Setting

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Turbine Shaft Seal Cubicle

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MIV FLOOR(El 982.00 m): This floor is the lowermost floor of the power house. It contains six individual MIVs, each weighing 92 tonnes and being controlled by the lifting of a counter weight 79.33 tonnes by means of a servomotor which is operated hydraulically. Cooling System: Generator and Turbine have bearings (Upper guide bearing, lower guide bearing, thrust bearing). Cooling system is required for dissipating the head generated in these bearings. There are two cooling systems: Primary Cooling System and Secondary cooling system. Primary cooling Water System: For Primary cooling raw water from tailrace is used. It consists of a 3 phase induction motor (415V, 50 Hz, 37kW) and a pump. Primary Cooling Pump cools the water that goes into the water heat exchanger via the secondary cooling pump placed at the Turbine floor. The secondary pump further cools the oil-water heat exchanger. While the primary pump is an open loop system, the secondary water pump and the oil-water heat exchanger are closed loop systems. Both oil and water are used as coolants in the machines. There are primary pumps for each unit. However, only one of them is functional at a time. The pump priority is changed every 8 hours so that a pump doesnt wear out way before the other one.

The sump area has 3 types of pumps: Flood control pumps, dewatering pumps and drainage pumps. (DW and DR pumps are almost at 6 bar pressure) Drainage pumps: MIV floor is characterized by a sump area which is further categorized as drainage sump and dewatering sump. The drainage sump is for all the leakage (water). For the maintenance purposes when the machines are supposed to be dewatered, the water is thrown into the dewatering sump. The drainage sump is concrete lined.

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The leakage flows through the drain to the sump. The submersible pumps (which remain submersed in water) pump the water from sump to the MAT (Main Access Tunnel). Float switches are present which act as water level sensors, depending on the level of water, pumps are switched ON. Number of Pumps switched ON Water Level.

MAT is 800mm tunnel. Water is then thrown into the tail race. There are 4 drainage pumps. Dewatering pumps: There are 6 gates for 6 tailraces. The river level is 1008m and Draft tube level is 985m which leads to a 30m head, means a pressure of 2 Bar. Water is filled till runner, gate is closed then the valve is opened for dewatering by D/W pumps, then the machine can be opened. Dewatering pumps are used to empty the Draft Tube. There are 4 dewatering pumps. Total capacity (DR and DW) is 2200lbs. The dewatering sump is steel lined. Flood control pumps: There are 12 flood control pumps. In case of a flood, these pumps operate at the rate of 120 litre/sec.

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Main Inlet Valve (MIV) :

MIV floor houses 6 MIVs, one each for the six units. MIV are of spherical type with a diameter of 2.3m. It is located between the spiral casing and the penstock. It allows the water to flow from penstock to spiral casing in open condition and blocks the flow of water when it is closed. MIV can be either fully open or fully close. MIV is bolted between the conical pipe on the upstream side and dismantling pipe on the downstream side. It can be opened only when counter weight is lifted upwards. Counter weight of 79.993t ensures self-closing of valve. It is a steel body provided with integrally cast supporting feet, lifting lugs and heads for locking the valve rotor in closed and opened position. The hydraulically pre-stressed foundation bolts prevent the body from lifting. Pressure required to open MIV is 100 bar. This applied by governor using hydraulic oil pressure. By pass valves are required on both the sides of MIV to avoid damage to MIV. There are two seals viz. Service seal and Maintenance seal on the sides of MIV. When maintenance work is to be done both Maintenance seal and service seals are used for extra security. There are two by pass valves as shown in the diagram which equalize the pressure on either sides of MIV, before the MIV is opened. The counter weight is lifted by a servomechanism. This is taken care of by a green cylinder filled with oil and maintained at a pressure of 100bar.Nitrogen cylinders are kept as a backup. The sole control of this maintenance of pressure lies with the governor. The counter weight is lifted and only then is the MIV opened. Hence, a constant pressure is to be maintained. It could have been engineered in a way that counterweight would have to be lifted only when MIV was meant to be closed. This meant not having to supply power to keep it lifted till the time the unit was to be functional. However, it has been designed the way it is because if ever there is a power failure and the units cannot run, the MIV shuts down and
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hence no damage is caused to the rest of the structure and machinery. Had it been designed otherwise, in case of power failure the water would have kept rushing into the whole machinery and destroyed all of it. Spiral Casing :

The Francis turbine is essentially a modified form of propeller turbine in which water flows radially inwards into the runner and is turned to emerge axially. The runner is mounted in a spiral casing with internal adjustable guide vanes. The water enters from the penstock to the spiral casing which completely surrounds the runner. The cross-sectional area of this casing decreases uniformly along the circumference to keep the water velocity constant in magnitude along its path towards the guide vane. Labyrinth Seal : A labyrinth seal provides a tortuous path to help prevent leakage. A labyrinth seal may be composed of many grooves that press tightly inside another axle, or inside a hole, so that the fluid has to pass through a long and difficult path to escape. Sometimes screw threads exist on the outer and inner portion. These interlock, to produce the long characteristic path which slows leakage. For labyrinth seals on a rotating shaft, a very small clearance must exist between the tips of the labyrinth threads and the running surface.

Draft Tube : The outlet consists of a draft tube and draft tube steel lining continuing with a concrete lined tunnel and forms the water way from the runner to the tail race channel. The draft tube cone is welded and consists of two parts. The upper part is bolted to the lower fixed labyrinth seal. It is made of stainless steel. The lower part is attached to the draft tube steel lining with a flexible flange connection. It has one manhole for access to the draft tube and it is fit with four stub pipes with cover for installation of an inspection platform. The draft tube steel liner is completely set in concrete. The draft tube cone can be emptied into the dewatering pit by slight extension of the cross section in the direction of flow from the runner outlet to the end of the plate covering. The draft tube has 10 segments with a plate thickness of 30mm and total weight 34,000kg.
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COMMON POWER PLANT AUXILLARIES There are certain auxiliaries in the power plant that are used for the proper functioning and operation of the entire power plant in itself. Some of the more important such auxiliaries are enlisted below: 1) HT-LT System It is the lifetime of the entire power plant as it manages the external electricity supply to the power plant and it is constitute system. This system is placed inside a separate room and receives external supplies from two sources, so that if one of the two fails the other can always work. The two sources of supply are: 22KV O/H line Jeori substation 22KV local feeder DG 1 DG 2 The HT feeder is rated for 33kv but we are feeding only 22kv through HT feeder. The supply of the two 22kv feeder is step down by the step down transformer into 415 volts, which is given to LT side. In LT side, there are three service station board SSB#1, SSB#2 and SSB#3.

Service Station Board # 1 It gives supply voltage in the followings: 1. 3. 5. 7. 9. 11. 220 V battery charger-1 Lift-1 PCC station control. Air supply system. Lift-2 48 V battery charger-1 2. 4. 6. 8. 10. Cabling. T/F cover EDT Bus duct lighting. Ventilation-1 Air compressor-1

Service Station Board #2 It is very important service station board because it gives supply voltage for UAB (Unit Auxiliary Board) during the starting of unit which is very important for every unit. 1. 3. 5. 7. 9. 11. GIS 1 S Unit auxiliary board 6 Light and heating for floor 1000.5m Drainage Gallery. Dewatering pumps. Ventilation 2. 4. 6. 8. 10. 12. 420 bus duct tunnel light UAB 2 GIS 2 (Pot head yard) UAB 3 UAB 4 DG incomer

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13. Jacking oil pumps 15. UAB 1

14. UAB 5 16. UAB - 6

Service Station Board # 3 It gives supply voltage to the followings: 1. 3. 5. 7. 9. Inter connected tunnel light. Air condition 2 Powerhouse ventilation motors. Dewatering pump 3. Lightening & heating control room. 2. 4. 6. 8. 10. Dewatering pump control. Operation Station. Ventilation 2 GIS 2 (Pot head yard). 420 bus duct tunnel light.

22 KV line

22 KV line

C.B

C.B

Bus Coupler C.B DG1 415 V 3 750 KVA 22KV/415V 2.5 MVA
3

C.B DG2 415 V 750 KVA

22KV/415V 2.5 MVA

T1
C.B

T2

C.B SSB 3

C.B SSB2 SSB1

From UAT 6 UAB 6 UAB 5

From UAT 5 UAB 4

From UAT 4 UAB 3

From UAT 3 UAB 2

From UAT 2 UAB 1

From UAT 1

Single line diagram of HT/LT Room incomers and outgoing

Red : closed Green: open

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2)

Backup Generators (DG 1 And DG 2) In case the HT-LT System fails due to the some or the other reason, the power plant gets backup power supply from the two DG sets. In case the HT-LT System fails due to the some or the other reason, the power plant gets backup power supply from the two DG sets. These DG sets are located adjacent to the POT HEAD Yard. Rating of the DG: 3 phase, 415 V, 1043 A, 750 KVA, Excitation: 36 V, RPM: 1500 Each Diesel generator is provided with two oil tanks of 1000 litre capacity each and the DG consumes about 150 litre oil in one hour.

Self charging battery of 48 V DC is used to kick start the machine. It moves the pinion which is attached to the rack and which is further attached to the generator shaft and thus in turn it moves the shaft of the generator and hence, 3 phase A.C. power is generated. Priming motor is a low rating motor used to liquefy the jammed oil, which can then be circulated all over the machine. It also has a suction device to suck the clean air from outside for the combustion of the fuel. Radiator is a water tank used for the cooling of the machine and the cooler starts when the temperature of the machine goes above 80C. The water filter uses magnets to remove iron particles from the water and hence, circulate clean and particle free water for cooling purpose. The D.G. Set is equipped with 4 water tanks of 1.5 lakh litre capacity each. The three tanks are used for fire fighting and one tank is used for the supply of the secondary cooling system at the power house. The air in the power house is circulated mainly because of the 3 blower present near the DG set. The rating of the blowers is as follows: No. of blowers installed Drive/Motor Pulley OD blower side (mm) Pulley OD motor side (mm) Groove (mm) Shaft to shaft centre distance (mm) Cycle Motor KW Motor RPM Blower Shaft Diameter (mm) No. of grooves Capacity 3 Nos. Star/Delta Sq. Cage Induction Motor 940 mm 230 mm 28 mmX10 mm (deep) 2100 mm 50 Hz 90 1475 110 8 2,81,250 m3/hr

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3)

Battery Bank This is the last and final backup provision to keep the power supply afloat. A temporary backup power supply in the form of chemical batteries is available for emergency usage. 4) Dewatering System Due to unavoidable reasons there is always some amount of water leakage from and around the turbine. This leakage water accumulates in a leakage sump. Thus a dewatering system is in place to periodically empty the leakage sump. 5) Drainage System As the power house is underground structure, there is some amount of seepage from the walls of tunnels. This seepage water is taken out of the powerhouse building by means of a well-designed drainage system. 6) Air compressor It is used for the proper functioning and working of power plant system such as the shaft seal and bus duct.

SILT LAB: The silt particles can be differentiated on the basis of their size as follows: Coarse particles: size> 0.2 mm Medium particles: size> 0.075 mm and size < 0.2 mm Fine particles: size < 0.075 mm.

The process used in the silt lab for determination of the concentration of the silt is known as gravimetric method of determination of silt. The steps involved in the separation of the silt are: 1. Coarse silt content 1000 ml of sample water is passed through 200 sieve the coarse particles collected in the sieve are dried and weighted Coarse silt (in ppm) = (wt. in gm of coarse particles) * 106/(1.4*1000) = 714.285* (wt. in gm of coarse particles)

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2. Medium silt content 1000 ml of silt sample after passing through 200 sieve is collected in beaker. Stir the sample and wait for 30-40 seconds for the medium particles to settle down. Gently pour the sample from this beaker to other beaker. The settled particles are dried and weighted. Medium silt (in ppm) = (wt. in gm of coarse particles) * 106/(1.4*1000) = 714.285* (wt. in gm of coarse particles) 3. Fine silt content Stir the 1000 ml of sample in beaker and suck 25 ml of sample through pipette. Heat this 25 ml sample in china dish till all the water gets evaporated. Dry fine silt content gets deposited in the china dish. Place this china dish on moisture extractor and weight it after it reaches the room temperature. Original weight of the china dish is taken before the sucked sample is taken in it for our calculations. Fine silt (in ppm) = (weight of the china dish with deposited fine silt original weight of the china dish-0.0035)*106/(1.4*25) Where 0.0035gm is the weight of soluble content

In addition to this silt reading are also taken at Powari and Wangtoo after every 4 hours. The maximum permissible level for silt at Wangtoo is 4000 ppm and that for the draft tube sample is 2000 ppm. If the concentration of the coarse silt particle is more than 75 ppm, then also the plant is shut down.

TRANSFORMER HALL There is an underground Transformer Hall at an EL. Of 1044 m and is 270 m long and 7 m D-shaped. GENERATOR TRANSFORMER In a power plant generator transformers are used to step up the voltage level suitable for the transmission. The main purpose of stepping up the voltage level is to reduce the current level and hence to minimize the transmission loss.. In our power plant there are 19 single phase transformers each of 102MVA capacity (3Phase transformer bank).Three for each unit
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and one in spare (standby unit). The main logic behind using single phase nested of three phase transformers is to remove the problem of transportation due to heavy weight and size and the space limitation in the underground complex. Also the main advantage of single phase transformers is that in case any fault occurs in any phase the faulty transformer can be replaced by the spare one and hence complete shutdown of the unit is not required. In this way the flexibility and reliability of the system is improved. The various specifications of the transformers are given below:

TRANSFORMER SPECIFICATIONS Make - Bharat Heavy Electrical Limited 102 420/3 421 55(deg) 1(single) YNd 11 55095kg 9275kg Types of cooling drift water force) Rating LV (MVA) No load voltage LV (KV) Line current LV (AMPS) Temperature Rise windings Frequency HZ Type Weight of oil ODWF(oil 102 15.75 6476 65(deg) 50 Hz - shell type T/F 18165kg

Rating HV & IV (MVA) No load voltage HV (KV) Line current HV (AMPS) Temperature Rise oil (OC) Phase Connection Symbol Weight of core and winding Total weight PARTS OF TRANSFORMER (i) (iii) (v) (vii) (ix) (xi) (xiii) (xv) Secondary winding Oil level Breather Tubes for cooling Earth Point Temperature gauge Secondary terminal

(ii) Primary winding (iv) Conservator (vi) Drain Coke (viii) Transformer Oil (x) Explosion vent (xii) Buchholz Relay (xiv) Primary Terminal

Winding temperature indicator (xvi) Non Returning valve

(xvii) On Load Tape Changer

Conservator It is used generally to conserve the insulating property of the oil from deterioration and protect the transformer against failure on account of bad quality of oil. It is a small tank mounted on main tank and the two are connected by a pipe. The main tank is completely
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filled with oil but conservator tank is partially filled with oil. Its function is to allow space for expansion of oil due to heating and contraction due to cooling of oil

Buchholz Relay Buchholz relay is a gas actuated relay used for protecting oil immersed transformer. The beauty of this relay lies in the fact that unlike any other relay it gives indication that the system is unhealthy and thus prevents the transformer from severity of fault. The relay operates on the well known fact that almost every type of electrical fault in a liquid immersed transformer gives rise to gas. This gas is collected in the body of relay. If the quantity of gas collected is more than the set value, this relay gives alarm or trip command which ever case may be. The device provides protection against a no. of internal faults, but it also indicates in several cases, the type of fault. This is possible because the gas is collected in relay and from its odour, color and composition, it can indicate what the fault may be and about its nature. Gas Collecting Device The gas collecting device is used to collect the gas is formed as a result of any fault inside the transformer. The device is connected to the Buchholz relay by means of pipe. Whenever an analysis of the gas is to be done, the gas is first made to collect in this, and then it is sent for analysis. The main advantage of this device is that the gas can be obtained for analysis without taking shut down. Hence the operation of transformer is not disturbed. Silica Gel Dehydrating Breather Breather is used to prevent the moisture coming in the transformer oil when the volume of the oil decreases due to fault in temperature. The level of oil in the conservator tank decreases. To compensate this decrease in level, conservator tank takes atmospheric air from the atmosphere through this breather and oil expands, oil level inside conservator increases and air is pushed out through the breather. Breather generally consists of oil sealing arrangement and a reseal containing silica gel crystal. These crystal have a properly of absorbing moisture from air which passed through it. The color of dry silica is blue. After a cycle of operation it changes into faint pink color. The pink color indicates that the crystals are saturated. In this condition these crystal are activated by heating it at a temperature of 150-200degree C for two or three hours when the crystals regain their original color. Pressure Relief Valve This is protective device which is installed on the tank transformer when pressure inside the tank is more than the pre-set value due to any internal fault; this device operates and gives a tripping command to the circuit breaker. It allows the pressure to drop by instantaneously opening a port, gives visual indication of valve operation by raising a flag, and operates a micro switch which has a 1NC & 1 no. contacts which are used in control circuit. Oil Gauge Every transformer is provided with an oil gauge to indicate the oil level.
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Oil Temperature Indicator The function this device is to measure the temperature of oil. This device is set for alarm and trip. When the temperature of the transformer oil rises above the pre-set value, the alarm or trip is given as the case may be. Winding Temperature Indicator This is a precision instrument designed for the protection of transformer. One no. of instrument with three contacts can be provided to indicate the temperature of hottest part of winding. This device performs the fallowing action. It indicates the maximum winding temperature irrespective of the condition of loading temperature of the cooling medium and attitude. Thus the load on the transformer can be kept within the limit. It gives the alarm when the temperature rises above the set value. It gives the trip command to the breaker when the temperature is above the set level.

Bushings Bushings are made from highly insulating material to insulate and to bring out the terminals of the transformer from the container. 420KV oil-SF6 bushing LV bushing Tapping The transformers are usually provided with few tapings on secondary side so that output voltage can be varied for constant input voltage. Radiators The radiators increase the surface area of the tank and more heat is thus radiated in less time. It is generally used in large capacity transformers 50 KVA and above. Non Returning Valve (NRV) It is used where air is produced and is stored in compressor. It is between compressor and air producer. It means that air is not returned back when it reaches in the NVR. OLTC It is known as On Load Tap Changer. If the supply from the previous sub-station is coming according to the requirement and less than the required supply OLTC is used to increase the supply to level of load. Oil Flow Indicator This device indicates the flow of oil in cooler when the transformer is in operation. It indicates the specified rate of flow of liquid in the direction in specified pipe, and operates mercury switches for indicating alarm when the flow drops.
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Water Flow Indicator This device indicates the flow of water through the cooler when the transformer is in operation. The application of this device is same as that of above device. Transformer Oil Pumps Pumps have been used to circulate the oil through the cooler. The oil is cooled by water circulating in the cooler the power rating of this pump is 5.5 KW and the speed is 2660 rpm. Sudden Pressure Relay This is a protection device when the rate of rise of pressure is more than the specified value these devices operates and give the tripping command to the breaker.

FIRE FIGHTING SYSTEM General Arrangement of fire protection in SJVN power station is normally divided into following three groups. i) Fire protection for generators ii) Fire protection for generator transformers iii) Fire protection of area and equipment and power house not covered under above two groups. Generators a. General: Generators are with closed air-circulation systems and are provided with automatic CO2 extinguishing systems. b. System design: (1) General design considerations are as follows: (i) CO2 concentration of 30 percent should be maintained within the generator housing for a minimum period of 20 min without the use of an extended discharge. (ii) CO2 release should be actuated by the following: Generator differential auxiliary relay Thermo-switches in the hot air ducts of each air cooler. Manual operation at the cylinders. Remote manual electrical control. The CO2 fire extinguishing system normally consists of a sufficient amount of CO2 to maintain an inert atmosphere during the deceleration of the machine. Two rates of discharge of CO2 are provided by two groups of CO2 cylinders one group of cylinders, providing the initial discharge, to ensure a rapid build-up of CO2 concentration, to put out fire and other group of cylinders, providing the delayed discharge to ensure concentration of CO2 maintained for an extended period. Capacity of the bank is sized for protection of only one individual generator and CO2 cylinders is arranged for the discharge to any one of the main units. The amount of CO2, for initial and delayed discharge, should be determined by the
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manufacturer, taking into account the volume of the air spaces in the generator enclosure and the deceleration time of the machine. Size and the number of cylinders required in each bank are accordingly determined. Transformers Fire protection at a transformer is provided to limit damage to other nearby transformers, equipment, and structure. It is assumed that a transformer fire will result in loss of the transformer. Water sprinkler systems are provided for single phase step up oil-filled transformers and CO2 systems for other transformers like excitation transformer and auxiliary transformer.

Gas Insulated Switchyard - I:

A high voltage substation in which all or most of the insulation is provided by a gas (SF6) operating above atmospheric pressure within earthed metal enclosure. GIS is compact in size and insulation is not exposed to environment. Furthermore, it has high reliability with an Availability Factor of 99.57%. In NJHP B142 type GIS is used, which is light in weight due
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to compactness. It entails lesser cost in civil work and building due to reduction in size and volume of switchgear. GIS has considerably lower risk of injury to personnel due to enclosed live parts. Electric fields are shielded by grounded GIS enclosures. Magnetic fields due to conductor currents are reduced by GIS enclosure current. Leakage rate is very less- less than 1% per year. SF6 can break 4 Million Amps without deteriorating its quality. Gas is divided into different compartments, so that if a fault occurs in one part , it does not affect the operation of other compartments LCC panels: Local Control cubicles are user for control of bay and SF6 density inside the compartment. It also controls electrical interlocking between various components viz. C.B., Isolators, Earth switches. It also acts as an interface between GIS and central Control Room. Circuit Breaker: Three phase metal enclosed, SF6 gas insulated hydraulically operated Circuit Breaker is used.

Interrupting current level for B is 50 kA with an opening time of 28ms, closing time of 60ms and arc time of 16ms. Pressure inside the breaker is 360 bar. It is like a long instrument that fits into a space when closed. When the pressure falls below 340 bar, the motor (415V) operates. Line breakers are provided with closing resistor (220V) to limit heavy line charging currents. Rated current Line CB Rated current Bus coupler No. of poles. Rated SC current (rms value of ac component) Rated short circuit making current Operating mechanism No. of trip coils 2000A 4000A 3 50kA(1sec.) 125kA Hydraulic 2 per pole

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Isolator: The isolator is used to insulate the various parts of electrical circuits. It is able to make or break loop currents and capacitive load current during energizing or d-energizing the substation. Each isolator is equipped with a moving contact located in the isolator enclosure. The fixed contact is located in the equipped insulator. The visual indicator mechanically linked to the transmission shaft allows verification of the isolators open or closed position. Impulse withstand voltage across open gap Switching impulse withstand voltage Rated normal current Earth Switches: There are two kinds of earth switches. High speed earth switch and low speed earth switch. High Speed Earth Switch: This earth switch is capable of closing on a short-circuiting current. High-speed earth switches are capable of interrupting the inductive and capacitive currents. These switches are fitted with a stored energy closing system to provide fault-making capability. Short Circuit making capacity rating = 125 KA Low Speed Earth Switch: It serves to earth the part of the GIS where it is installed. This is used for providing safety during maintenance work. The live part of Earthing switch can be electrically insulated from the enclosure to facilitate input of signal for certain settings and tests. Bus bar: It is an element in the main current circuit and is made of Al tubing. It can be called a bar fit together in silver-plated multi-finger contacts. Current Transformers: Current Transformers are used for protective and metering functions. They have effective magnetic shield to protect against high frequency transients. CT used is 5 core-type. Rated Voltage 500/1A 500/1A 500/1A 500/1A 500/1A 420/630/425kVA 5VA 5VA 30 VA Rot 75<10, Io<30mA Rot 75 d5E 1665 KVp 1245 KVp 4000 A

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Voltage Transformers: The Voltage transformers are of inductive type. VTs are located inside the independent gas compartment. They are used for protective, metering of synchronization of machines with Grid. They have effective magnetic shield to protect against high frequency transients. Surge Arrester: Surge arrestor is Valve type, made of non-linear resistor discs. Surge arrester is made up of stack of zinc oxide disks. One end of stack connected to live part and the other end of stack is connected to earth. Under normal operation, the discs are resistive and no current circulate between phase & earth. In the event of lightening impulse (rise in voltage in the bar), the disks allow current through, which is evacuated through earth.

Rated voltage of arrestor Max. continuous Voltage capability Max. discharge current Energy level Bushings:

336kV(rms) 265kV(rms) 10kA 10kJ/kV

Oil to SF6 Bushing: The transformer bushings comprise of oil insulation on the transformer end and enclosed by an SF6 gas filled compartment on GIS side. SF6 to Air Bushing: 400 kV transmission lines are connected to GIS through SF6 to air filled bushings through 400 kV bus ducts. Metallic Bellows: These bellows are provided to prevent the expansion in the metal due to overheating (or heating).

Monitorinig Devices: Density Switches: Density switches are fitted to all compartments and are used for monitoring quantity of SF6 gas filled in each compartment. G9 Of GIS-II Circuit Breaker Rated Pressure 5.3 bars Alarm Trip 4.8 bars 4.5 bars 6.3 bar 5.8 bar 5.5 bar

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Rupture Disc: The rupture disc / safety diaphragm is a disc made of varnish coated carbon. It is designed to give away in the event of SF6 gas over pressure within the compartment.

POT HEAD Yard The POT HEAD YARD (Point Of Transmission Hydro Electric Aerial Distribution Yard) 420 KV GIS switchyard is located in such a way that the complete GIS is placed within a building at an elevation of approximately 1173m. GIS-2 switch gear comprises of bus bars, bus isolators, circuit breakers, current transformers, Potential transformers, disconnect switches, high speed make proofing grounding switches, Transition bus, SF6/Air bushing. There are 6 outgoing bays and 2 more bays for future extensions: 2 bays for inter connection to Baspa stage-2 HEP, 2 bays for inter connection to Kol Dam, 2 bays for inter connection to Abdullahpur, 2 bays for future extension. The rating of each bay is 2000A, 50 kA short circuit rating. The rating of Bus bar is 4000A. GIS-1 switch gear at elevation 1051.5 meter is connected to GIS-2 by 420KV, 4000Amps, and Sf6 CGI double bus system. The length of this double bus system is approximately 250m. Incoming and outgoing feeders: There are 2 incoming feeders from Baspa (54km line) and 4 outgoing feeders (2 to Abdullapur (180km line) and 2 to Nalagarh (145km line). Wave trap: It is connected in series with the power (transmission) line. It blocks the high frequency carrier waves (24 kHz to 500 kHz) and let power waves (50 Hz - 60 Hz) to pass through. It is basically an inductor of rating in Milli henry (approx 1 milli Henry for 220 KV 1250 Amp.). Line Trap has three main components: Main coil, Tuning Device, Lightning Arrestor. Capacitor Voltage Transfomer: A capacitor voltage transformer (CVT), or capacitance coupled voltage transformer (CCVT) is a transformer used in power systems to step down extra high voltage signals and provide a low voltage signal, for measurement or to operate a protective relay.

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In its most basic form the device consists of three parts: two capacitors across which the transmission line signal is split, an inductive element to tune the device to the line frequency, and a transformer to isolate and further step down the voltage for the instrumentation or protective relay. The device has at least four terminals: a terminal for connection to the high voltage signal, a ground terminal, and two secondary terminals which connect to the instrumentation or protective relay. CVTs are typically single-phase devices used for measuring voltages in excess of one hundred kilovolts where the use of voltage transformers would be uneconomical. In practice, capacitor C1 is often constructed as a stack of smaller capacitors connected in series. This provides a large voltage drop across C1 and a relatively small voltage drop across C2. CVTs in combination with wave traps are used for filtering high frequency communication signals from power frequency. This forms a carrier communication network throughout the transmission network. Power line carrier communication (PLCC):

Power line carrier communication (PLCC) is mainly used for telecommunication, teleprotection and tele-monitoring between electrical substations through power lines at high voltages, such as 110 kV, 220 kV, 400 kV. PLCC integrates the transmission of

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communication signal and 50/60 Hz power signal through the same electric power cable. The major benefit is the union of two important applications in a single system. In a PLCC system the communication is established through the power line. The audio frequency is carried by a carrier frequency and the range of carrier frequency is from 50 kHz to 500 kHz. The modulation generally used in these systems is amplitude modulation. The carrier frequency range is allocated to include the audio signal, protection and the pilot frequency. The pilot frequency is a signal in the audio range that is transmitted continuously for failure detection. The voice signal is converted/compressed into the 300 Hz to 4000 Hz range, and this audio frequency is mixed with the carrier frequency. The carrier frequency is again filtered, amplified and transmitted. The transmission of these HF carrier frequencies will be in the range of 0 to +32db. This range is set according to the distance between substations.

Battery Bank: There are 2 battery banks. Ni-Cd rechargeable batteries of 48V (645Ah) and 220V (1500Ah) are used for supply to relays and control panels. There are 4 battery chargers. Synchronizing trolley: Synchronization is a process of matching the voltage, frequency and phase angle of the bus bar with the grid. It is done before transmitting the power to the grid. Synchronizing trolley is used for matching the voltage. Relays: A protective relay is a device that detects the fault and initiates the operation of circuit breaker to isolate the defective element from the rest of the system. The relays detect the abnormal conditions in the electrical circuits by constantly measuring the electrical quantities such as voltage, current, phase angle etc. which are different under normal and faulty conditions. Through the changes in any quantity, the fault signals its presence, location and type to the relays and the relay operates to close the trip circuit of the breaker. The different types of relays used are as follows: 1. Time delay relay 2. Impedance relay (distance relay) 3. Synchro-check relay
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4. Under voltage protection 5. Over load relay 6. Instantaneous over current relay 7. Instantaneous earth fault relay 8. IDMT over current relay 9. IDMT earth fault relay 10. Voltage control over current relay 11. Over voltage relay 12. Voltage balance relay 13. Buchholz relay 14. Restricted earth fault relay 15. Stator earth fault relay 16. Rotor earth fault relay 17. Auto recloser relay 18. Under frequency relay 19. Trip circuit supervision relay 20. Combined motor protection relay

CONTROL ROOM: The major feature of the control room is its OS (operating system). This system is so designed that each event whether minor or major, can be viewed and controlled. Each of the six units can be closely monitored. This operating system is connected to the Unit Control Board. The control room consists of 2 screens. On one of them, the time and the location of a particular event are clearly displayed so that the human operators are well aware of the proper/improper functioning of the generating units. The other screen provides for viewing of pictorial representation of individual units, their specific parts and all the related measurements (frequency, rated voltage, set value, discharge, pressure, temperature, labyrinth leakage, active power, reactive power, their set points etc.). The start/stop command of each unit is given from the control room. The command can either be direct or step by step. In case of the direct command the steps of the specified sequence are carried out automatically. In case of step by step command, each step of the specified
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sequence is carried out separately. This is done when a particular step in the sequence refuses to run by direct command. If the step fails to be completed even by step by step command, that step is completed either by local auto mode or manually. The various set points for generation (active power and reactive power) are fed into the OS and hence the operation of the generating units is controlled. The minimum set point (active power) is 25 MW. When the active power falls below 80MW a trip command is sent to the given unit. This is done because if the active power falls below the 25MW mark the machine starts drawing power from the grid itself and hence the power house gets penalized. Unit Start Sequence This is a step by step process involving 6 steps to start a particular generating unit. The next step can only be started if all the conditions specified are fulfilled. 1) Firstly, all the auxiliaries need to be switched on. Shaft seal flushing water is turned on. This is used to remove any undesired particles that may damage the shaft seal. Cooling water system is turned on for effective heat removal from the machines. H.P. oil pump is switched on for jacking and lubrication. Oil vapour extractor is turned on for removal of oil vapours formed due to the heat generated. Generator space heater is turned off. When the machine is at standstill the heater is used to remove the moisture that might be present in the stator of the machine. But while starting it is switched off, as enough heat will be generated as it is. Transformer oil pumps are switched on to circulate oil for insulation as well as cooling and lubrication. The governors hydraulic auxiliaries are switched on for the operation of the governor.

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2) Now, when all the above steps have been completed, the generator brakes and the shaft seal as well as the M.I.V. service seal need to be removed. Hence, the main inlet valve is opened.

3) Once, the above tasks are completed, the digital turbine logic is started to operate.

4) When the speed switch indicates greater than 90% on, the excitation is switched on and the H.P. oil pump is turned off. Also the shaft seal flushing water is switched off.

5) Now, when the speed switch is greater than 97% on and the generated voltage becomes greater than 90%, the auto synchronizer is switched on.

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6) Once, the 420 KV generator circuit breaker is closed and the power controller and the M.I.V are open, the change over takes place from the H.P.S.E.B. supply to the supply from the auxiliary transformer, i.e. from 415 V UA (circuit breaker for the H.P.S.E.B.) open to 415 V UT (circuit breaker for supply from auxiliary transformer) closed.

Unit Stop Sequence

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RAPID SHUT DOWN-1: Genr upper guide bearing temp. Genr lower guide bearing temp. Genr thrust bearing temp. Turbine guide bearing temp. Genr stator temp. Genr air cooler temp. Genr turbine temp. Bearing vibration Turbine guide bearing RSD. Gen lower guide bearing RSD. Thrust bearing temp. Genr upper guide bearing RSD.
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Genr air cooler temp. GE(governer) common RSD. Guide vane position high 85%. Rapid shut down PB(push button). Electrical rapid shut down. SM AU watchdog fault. SM 595 fault. Pickup speed signal failure. Excitation transformer high temp. Penstock pressure low. Cooling water system circuit fail. MIVC common RSD. MIV ESD valve position failure. MIV 48V DC supply failure. MIV 220V DC supply failure. GHC(govr. Hydraulic control) common RSD. Accumulator shutoff valve position failure. GMC common RSD. Piston accumulator level low. Hydraulic pump 1 & 2 fault. Accumulator manual valve close. Nitrogen shut off valve close. Accumulator pressure low. Nitrogen pressure too low. Oil system failure. Bearing insulation failure. Auxillary transformer temp. high Transformer R phase oil temp. high. Transformer R phase winding temp high. Transformer Y phase oil temp high. Transformer Y phase winding temp high. Transformer B phase oil temp high. Transformer B phase winding temp high.

RAPID SHUT DOWN -2: EL rapid shut down 2A. El rapid shut down 2B. Genr. CO2 system operated. Transformer R on fire.

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Transformer R buchholz operated. Transformer R PR reliev der. Operated. Transformer R emulsify system ON. Transformer Y on fire. Transformer Y buchholz operated. Transformer Y PR reliev der. Operated. Transformer Y emulsify system ON. Transformer B on fire. Transformer B buchholz operated. Transformer B PR reliev der. Operated Transformer B emulsify system ON. Excitation trip. SF6 too low on genr CB. Auto trip 1 pressure. Auto trip 2 pressure. EMERGENCY SHUT DOWN

Emergency shutdown PB. Butterfly valve ESD PB> GE 220V dc supply failure. GE 24V dc supply failure. GE 48V dc supply failure. Change over position failure. DTL and BU DTL failure. GE common ESD. Speed switch 140%. BFV 1 trip via RTU. BFV 1 trip via hardware. Mech over speed. GHC common ESD. GHC 220V dc supply failure. GHC 24V dc supply failure. GHC 48V dc supply failure.

Future Projects

Since the commissioning of the largest underground 1500 MW Nathpa Jhakri Hydro Power Station, the Corporation has expanded its base from a single project to a Multi Project and thereafter from a single state to an international Corporation. The Corporation is executing the following Projects which are under various stages of construction/ investigation:

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S. No. 1 2 3 4 5 6 7 8 9 10

Name of Project Rampur HE Project Luhri HE Project Dhaulasidh HE Project Devsari HE Project Naitwar Mori HE Project Jakhol Sankri HE Project Arun-III HEP Kholongchu HE Project Wangchu HE Project Tipaimukh HE Project (in JV with NHPC)

Capacity in MW 412 775 66 252 60 51 900 650 600 1500

Location Himachal Pradesh Himachal Pradesh Himachal Pradesh Uttarakhand Uttarakhand Uttarakhand Nepal Bhutan Bhutan Manipur

In pursuit of expansion of the Corporation in the neighboring countries, a MoU was signed with the Govt. of Nepal on March 02, 2008 for the development of 900 MW Arun-III Hydro Electric Project which was bagged by SJVN in open global competition. SJVN has been allocated two Hydro Electric Projects in Bhutan for the preparation of DPR by the Ministry of Power. These are 650 MW Kholongchu HE Project and 900 MW Wangchu HE Project. The water that exits from the tail race tunnel is free from silt and has the required pressure and hence can be used to operate another set of turbine and generator without having to invest in the construction of the dam and the desilting chamber and e.t.c. Such plants are said to be in tandem operation. An example of such a plant is the upcoming plant at Rampur (412 MW). The Rampur Project has its intake structure at the outfall of the NJHEP and it also has 4 intake gates and a surge shaft of 38 m diameter and 140 m deep. Initially it was proposed that a HRT of 13 m diameter be made for this project. However, after reconsideration as the size of this diameter is unstable, it was decided that instead of a single huge HRT, two smaller HRT of 9 m diameter each be constructed. The advantages of this project are that it saves a lot of construction cost which is the area in which majority of the capital is invested and also, a new project can be completed in a very less time and also, there is no need for any desilting complex as the water is already free from it. However, it has a drawback that if any unit of the NJHEP trips then, it will mean that the corresponding unit of the RHEP will also not work as they are in Tandem operation.

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