SINGUR HYDEL POWER PLANT

DAM :- M.BAGAREDDY PROJECT RIVER :- MANJEERA CAPACITY :- 30.0 TMCFT FRL :- 523.60 MTS MANJEERA BARRAGE FRL :- 504.0 MTS

CATCHMENT AREA
MAHARASHTRA KARNATAKA ANDHRA PRADESH TOTAL :- 10250 SQ.KM :- 3069 SQ.KM :- 1692 SQ.KM :- 15910 SQ.KM

SALIENT FEATURES
MAXIMUM GROSS HEAD :MAXIMUM NET HEAD :MINIMUM GROSS HEAD :MINIMUM NET HEAD :AVERAGE GROSS HEAD :AVERAGE NET HEAD :DESIGN HEAD :523.60 501.81 = 21.79 M 21.79 1.1 = 20.69 M 517.80 504.00 = 13.80 M 13.80 1.1 = 12.70 M 520.70 502.90 = 17.80 M 17.80 1.1 = 16.70 M 18.29M

TURBINE DETAILS
TYPE OF TURBINE RATED OUTPUT AT RATED HEAD MAXIMUM OUTPUT AT : MAXIMUM HEAD MINIMUM HEAD DISCHARGE AT RATED OUTPUT & RATED HEAD RATED SPEED RUN AWAY SPEED :- ON CAM OFFCAM RUNNER DIAMETER NO. OF. BLADES :- KAPLAN :- 7815 KW :- 9000 KW :- 3750 KW :- 4731 M/SEC :- 250 RPM :- 575 RPM :- 630 RPM :- 2600 MM :- 4

PRESSURES
O.P.U PRESSURE DRAINAGE SYSTEM DEWATERING SYSTEM RATING OF COMPRESSORS VOLUME OF AIR H.P RECIEVER L.P RECIEVER = 25 KG/CM = 2 50 M/hr = 2 500 M/hr = 2 0.8 M/hr = 1.6 M = 1.0 M

SINGLE LINE DIAGRAM

JOGIPET FEEDER SADASIVPET FEEDER

1.3 WORKING PROCESS IN SINGUR POWER HOUSE:

The Main requirement for hydro-electric power plant is the availability of water in huge quantity at sufficient head and this requirement can be met by constructing a dam across a river. The schematic arrangement of a typical hydro-electric plant is shown in the following figure.

In Singur, an artificial storage reservoir is formed by constructing a dam across Manjeera River. Near the bottom of the dam, there is a water intake. Trash Racks of 38meters long are provided at the water intake to prevent the ingress of floating and other materials to the turbine. A Power tunnel of 720m long and diameter of 50 feet is taken off from the reservoir to the valve house at the start of Penstock. The valve house contains Bulk Head Gate for controlling water flow to the power station and automatic isolating valves for cutting off water supply in case the penstock bursts. A small storage reservoir called Surge tank (open at the top) is provided just before the valve house for better regulation of water pressure in the system to avoid the water hammer phenomenon.

From the reservoir the water is carried to valve house through power tunnel and from valve house to the water Turbine through pipes of large diameter 6.10m made of steel or reinforced concrete, called the Penstock. Gravity causes water to fall through the penstock inside the dam. At the end of the penstock there is a Kaplan reaction turbine which is turned by the moving water, converts Hydraulic Energy into Mechanical energy. The shaft from the turbine goes up into the 3-phase Alternator of capacity 7.5MW, which produces the power. The water after having done its useful work in the turbine is discharged to the tail race which may lead it to the river. Each 11 kV phase of Alternator is fed to the primary of single phase 11/132 kV Step-Up transformer. The secondary of the Transformers are connected to the 132 kV SWITCH YARD from where it is distributed as ten two 132 kV feeders and five 11 kV feeders.

Kaplan Turbine
The Kaplan Type Turbine and Propeller type Turbine all are belong to axial flow type turbines which are available for hydraulic power resources of medium and low heads. Our company supplies both the Propeller type (fixed blade type) and the Kaplan type (revolving blade type) turbines. The Propeller type turbines are suitable for hydro-power stations with small or medium capacities and heads, and relatively stable loads, The Kaplan type turbines are suitable for hydro-power stations with large capacities and heads, and relatively unstable loads. The Kaplan Type turbines supplied by our company are ranging from 3 to 65m in water head, 50KW to 50MW in capacity and 0.4 to 7m in runner diameter.

Kaplan Turbine Applicable Scope

Propeller type Runner

Medium Vertical Kaplan Turbine-Generator Unit with Digital Automatic Governor

Small Integral Vertical Kaplan TurbineGenerator Unit with Manual Revolving Runner Blade

KAPLAN TURBINE INTRODUCTION: Kaplan-type hydraulic turbine in which the positions of the runner blades and the wicket gates are adjustable for load change with sustained efficiency, it is a purely axial flow turbine with a vertical shaft disposition. Which was designed and developed by the Australian engineer Viktor Kaplan? Kaplan turbine has adjustable runner blades with less number of blades (i.e. 3 to 8 blades). Kaplan turbines are now widely used throughout the world in high-flow, low-head power production. Victor Kaplan obtained his first patent for an adjustable blade propeller turbine in 1912. But the development of a commercially successful machine would take another decade. Kaplan struggled with cavitations problems, and in 1922 abandoned his research for health reasons. DIAGRAM

CONSTRUCTION DETAILS OF KAPLAN TURBINE: Components of the Kaplan turbine: Scroll casing: It is the cashing in which we pass the water to the runner in the turbine. Guide vanes: It is the blade in which guides the water and control the water passage (i.e. how much the water flow goes in the turbine). Draft tube: After passing through the runner, the water is discharged to the tail race through a gradually expanding tube. Runner: It is an important part of the turbine which is connected to the shaft of the generator and consist movable vanes and hub (boss). Hub (Boss):- It is the part of the runner in which blades are mounted. WORKING OF KAPLAN TURBINE: The Kaplan turbine is an inward flow reaction turbine, which means that the working fluid changes pressure as it moves through the turbine and gives up its energy. The design combines radial and axial features.

The inlet is a scroll-shaped tube that wraps around the turbines wicket gate. Water is directed tangentially, through the wicket gate, and spirals on to a propeller shaped runner, causing it to spin. The outlet is a specially shaped draft tube that helps decelerate the water and recover kinetic energy. The turbine does not need to be at the lowest point of water flow, as long as the draft tube remains full of water. A higher turbine location, however, increases the suction that is imparted on the turbine blades by the draft tube. The resulting pressure drop may lead to capitation. Variable geometry of the wicket gate and turbine blades allows efficient operation for a range of flow conditions. Kaplan turbine efficiencies are typically over 90%, but may be lower in very low head applications. APPLICATIONS: Kaplan turbines are widely used throughout the world for electrical power production. They cover the lowest head hydro sites and are especially suited for high flow conditions. Inexpensive micro turbines are manufactured for individual power production with as little as two feet of head. Large Kaplan turbines are individually designed for each site to operate at the highest possible efficiency, typically over 90%. They are very expensive to design, manufacture and install, but operate for decades.

VARIATIONS: The Kaplan turbine is the most widely used of the propeller-type turbines, but several other variations exist: Propeller turbines have non-adjustable propeller vanes. They are used in low cost, small installations. Commercial products exist for producing several hundred watts from only a few feet of head.

Our Products - Kaplan Turbines

Pictured Above: Installation of 225KW Kaplan Invergarry Dam Compensation Set

Click Thumbnails To Enlarge The Kaplan turbine was developed by Austrian engineer Viktor Kaplan around 1915. Kaplans are generally considered for low head high flow applications. The Kaplan is an inward radial flow type reaction turbine similar to a Francis turbine. The turbine is usually placed in a spiral volute. Like a Francis turbine the Kaplan has a series of adjustable wicket gates. However the turbine runner (looking somewhat like a ships propeller) has adjustable blades. By changing the angle of the blades in tandem with the angle of the turbines the Kaplan can maintain a high efficiency even at very low flows.

Reaction Turbines like the Kaplan have a change in water pressure as the water passes through the turbine. There is pressure on the upstream side of the turbine runner and suction on the downstream side. On the downstream or outlet side of the turbine is the drafttube which slows the water as it exits the turbine. The draftube has a unique curved horn like shape. Because Kaplans have a very flat flow to efficiency curve they are particularly suited to sites on rivers where the amount of available water varies greatly.

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The Kaplan Turbine

The kaplan turbine is a great development of early 20th century. The Kaplan is of the propeller type, similar to an airplane propeller. The kaplan's blades are adjustable for pitch and will handle a great variation of flow very efficiently. They are 90% or better in efficiency.and are used in place of the old (but great) Francis types in a good many of installations. They are very expensive and are used principally in large installations. The kaplan turbine, unlike all other propeller turbines, the runner's blades were movable. The guide vanes could also be turned and were automatically adjusted to any angle suitable to that of the blades by a combiner, so the turbine was efficient at different work-loads. A circular stay collar absorbed the compressive forces acting on the flume casing. All low-head, high discharge propeller turbines had to be given amply dimensioned draft tubes since the efficiency of the turbine depended on a strong pressure. If the height of the draft tube was too great, the water pressure around the runner became so low that cavitation posed a serious problem, and it was necessary to mount the runner below tail-race level

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A Kaplan turbine is basically a propeller with adjustable blades inside a tube. It is an axial-flow turbine, which means that the flow direction does not change as it crosses the rotor. Figure 1 shows a simplified Kaplan turbine.

Figure 1 Basic layout of a Kaplan turbine. The inlet guide-vanes can be opened and closed to regulate the amount of flow that can pass through the turbine. When fully closed they will stop the water completely and bring the turbine to rest. Depending on the position of the inlet guide-vanes they introduce differing amounts of swirl to the flow, and ensure that the water hits the rotor at the most efficient angle for the highest efficiency. The rotor blade pitch is also adjustable, from a flat profile for very low flows to a heavily-pitched profile for high flows (see Figure 2). This adjustability of both inlet guidevanes and rotor blades means that the flow operating range is very wide (a characteristic from the inlet guide-vanes) and the turbine efficiency is high and the efficiency curve very flat (a characteristic from the adjustable rotor blades allowing optimum alignment of the blade to the oncoming flow).

Figure 2 Kaplan turbine rotor blade positions.

The nose cone on a Kaplan turbine is important hydro-dynamically to reduce losses and prevent the formation of a core rope vortex, and also provides the space for the complex blade pitching mechanism inside. The draft tube is also a critically important part. Although a static fabricated part, the geometry of the draft tube is carefully designed to extract any remaining kinetic energy from the flow by reducing the water pressure at the exit of the rotor. There are variants of Kaplan turbines that only have adjustable inlet guide-vanes or adjustable rotor blades, which are known as semi-Kaplans. Although the performance of semi-Kaplans is compromised when operating across a wide flow range, for applications where the flow does not vary much they can be a more cost-effective choice. Figure 3 below shows how the efficiency various across the operating flow range for a full-Kaplan (curve A), a semi-Kaplan with adjustable blades (curve B) and a semi-Kaplan with adjustable inlet guide-vanes (curve D). It also shows the efficiency curve for a propeller turbine (a Kaplan with fixed blades and fixed inlet guide-vanes (curve C).

Figure 3 Kaplan turbine efficiency curve comparison. Kaplan turbines could technically work across a wide range of heads and flow rates, but because of other turbine types being more effective on higher heads, and because Kaplans are relative expensive, they are the turbine of choice for lower head sites with high flow rates. Typically they are used on sites with net heads from 1.5 to 20 metres and peak flow rates from 3 m 3/s to 30 m3/s. In the UK this tends to be on lowland rivers with low heads (1.5 to 5 metres) and relatively high flow rates (up to 20 m3/s). Such systems would have power outputs ranging from 75 kW up to 5 MW.

The smallest good quality Kaplan turbines available have rotor diameters of 600 mm, though these tend to be prohibitively expensive, at least a very low heads, so generally speaking the smallest rotors are 800 mm. The largest rotors available have 3 to 5 metre diameters. For even larger sites multiple-turbines tend to be used rather than increasing the diameter further. Kaplan turbines are available in three basic configurations; vertical axis, horizontal axis (also called S-turbines) and bulb turbines. The commonest orientation currently being installed in the UK (at least by Renewables First) is vertical axis. Vertical-axis Kaplans have the advantage of requiring the smallest footprint or land-take. A typical layout is shown in Figure 4. The Kaplan turbine is built into the concrete structure, with the inlet volute (basically a snail shell shaped pipe that wraps around the inlet guide-vanes and distributes the water equally around the whole circumference) and draft tube cast into the concrete at the construction phase. So critical is the perfect geometry of the intake volute and draft tube that it is normal practice for the turbine manufacturer to supply the wooden formwork for these parts to be used by the civil engineering contractor.

Figure 4 Cross-section of a typical vertical-axis Kaplan turbine system.

Hydro Power - How it works

Internationally, about 20% of all electricity is generated by hydropower - the worlds most widely used source of renewable energy. In Nepal, 100% of electricity is generated from hydro sources. In countries such as Peru, Brazil and Norway, more than 85% of their electricity uses hydropower. In New Zealand, about 60% of electricity is generated from hydro sources. In China till 2009, about 22% of electricity is generated from hydro sources. Hydroelectric power stations capture the energy of falling water to generate electricity. Two factors are used to assess the generating capacity of a waterway. The first is the quantity of running water, or flow rate, measured in cubic metres per second. The second is the difference in vertical metres between the intake pipe and the turbine outlet, or head. Formula: Where Theoretical Qc = power flow available (kW) = 9.81 in metres3 per x Qc x second; H x Overall Efficiency H = net head

When considering other factors, such as the efficiency of machinery, pipeline friction and the need to keep residual water in the stream, the practical output is less than the theoretical output.

Hydropower works by converting the movement of falling water into electricity. Many forms of hydro power exist and have been used by humans throughout history, some examples of this are watermills powering machinery such as sawmills and farmers irrigating land using gravity.

Most often water is stored in dams or reservoirs. This water flows through an intake and into a large pipe called a penstock. The penstock then feeds water into a turbine which powers a generator. The turbine is powered by water flowing through the wicket gate. This gate can be controlled to determine the rate of flow through the turbine and therefore the amount of power generated. The turbine is attached by a shaft to an electric generator. Some common terms: * kWh Kilowatt hour. This is used to measure electric power use. A kWh is commonly referred to as a unit of electricity. A typical one bar electric heater running for one hour will consume one kilowatt of electrical energy. * GWh: Gigawatt hour one million kWhs or units. * Head: Difference in vertical metres between the intake pipe and the turbine outlet. * Penstock: A high-pressure pipe extending from the first upstream water surface to the turbine. * Wicket gates: Angularly adjustable streamlined elements that control the flow of water to a turbine. * Turbine: A machine that converts the energy of falling water to mechanical energy. * Generator: A machine that converts mechanical energy into electrical energy.

Kaplan Hydro (Propeller Turbines)

Turbines

Runner diameters: 0.6-3m Suitable water head: H=3-30m Capacity of the generator unit: 160-20000kw The speed range of the turbine: 60-750rpm Models and Parameters

The features of the Kaplan Hydro Turbines (Propeller Turbines): They operate in a head range of 3 meters to 30 meters and are primarily used for electrical power production. The power output ranges from 160KW to 20000KW, Runner diameters are between 0.6 and 3 meters. The speed range of the turbine is from 60 to 750 rpm.

* The propeller type is with a vertical axle and fixed runner, blade angle can not be changed during operation mode, the efficiency curve is steep and this type is generally suitable for power station that has water head with slight change or its operating units can be adjusted according to actual load change. * The Kaplan type is with adjustable runner controlled by oil servomotor and moved according to the load/head change to ensure higher average efficiency, the efficiency of some Kaplan turbine is higher than 94%. ADDNEW's Kaplan Hydro Turbines (Propeller Turbines) is widely used in hydro power stations for the small load and water head changing or low head. Models and Parameters for parts of Propeller Hydro Generating Sets

Models

and

Parameters

for

parts

of

Kaplan

Hydro

Generating

Sets

Cone Valves

Installed for flow regulation from 0 to 100% discharge and as pressure relief valve. Two types are used: Cone Valves and Ring Valves. An oil hydraulic or electromechanical operator controls the valves. Flow is in one direction only. Adjacent equipment of operator, control system ( hydraulic, electric, electronic ), discharge liner, connecting pipes is part of the valve supplier. Installed valves up to a diameter of 2,000 mm ( Aquamilpa / Mexico ) and maximum design heads of up to 216 m waterhead ( Guavio / Colombia ) are within the ANDRITZ HYDRO supply record. Upstream of the regulating valves in many cases a guard valve for maintenance and emergency shut down of butterfly or spherical type is installed.

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Gates

Dams for hydropower plants have to meet most stringent safety requirements. ANDRITZ HYDRO supplies any type of high pressure gates, such as fixed wheel gates, sliding gates, radial gates and caterpillar gates. These gates are used for power intakes, bottom outlets or river diversion works. As outstanding projects may be mentioned the bottom outlet gates for Mica Dam / Canada with 189 m operating head and the recently awarded sliding gates for a new bottom outlet for the Mauvoisin Dam / Switzerland, which are to be operated under 190 m waterhead. For controlled flood discharge ANDRITZ HYDRO also supplies spillway gates, normally as radial or fixed wheel gates. For low head or run-off-the-river power plants ANDRITZ HYDRO supplies all kinds of hydromechanical equipment for weirs and power house inlet and outlet structures.

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Centrifugal PumpHigh Pressure

Centrifugal Pump High Pressure

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Centrifugal Pump Vertical & Submerged

Centrifugal Pump Vertical & Submerged

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Bulb Turbines

Today low heads can be used for power generation very economic feasable. More than 300 units supplied by ANDRITZ HYDRO from heads up to 30 m, a maximum runner diameter of 7,700 mm and outputs up to 55 MW are the experience in this segment of hydro power generation. The total installed capacity amounts to 4,500 MW approximately. ANDRITZ HYDRO is the leader in Bulbturbine/Generator units with more than 50% marketshare in the last decades.

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Francis Pump Turbines

Pumpturbines are the necessary completion of the hydraulic turbine program for peak load - and storage power generation. The ANDRITZ HYDRO experience covers heads up to 600 m and outputs up to 350 MW. The total installed capacity is approx. 15,500 MW worldwide.

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Kaplan Turbines

With the invention of the Kaplan turbine by the Austrian Viktor Kaplan the base for a new turbine technology was founded, which is reputed as classic today. The concept is feasable within a head range of up to 80 m. Runners with 3 to 8 blades cover the whole range. ANDRITZ

HYDRO has experience in runner diameters up to 10,000 mm and outputs up to 200 MW. Semispiral concrete and full steel plate casing concepts can be utilized. The total installed capacity is approx. 23,000 MW and approx. 850 large units have been installed worldwide.

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Pit Turbines

For Hydropower Stations with very low heads it is sometimes more economic to use the pit turbine / generator concept. A step-up gearbox increases the speed of the generator to make this component more compact, smaller and therefore less expensive. This will increase the overall feasibility of these projects in the very low head range.

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Propeller Turbines

When Kaplan turbines are operating at full load or more or less constant flows it is mor feasible to save cost for the adjustment of the runner blades. In those cases the runnerblades are fixed at a certain blade position. ANDRITZ HYDRO has important installations of Propeller turbines in Africa and the USA.

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Hydro Generators

ANDRITZ HYDRO has been producing generators and other electrical equipment since 1892. Well known under the repudated brand name "ELIN", VA TECH HYDRO generators are in operation all over the world. Generators with a capacity of more than 40,000 MVA are in service. Our own welding and machining facilities secure high quality and short delivery time.

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Butterfly Valves

Based upon model tests, the lens type and lattice door ( through flow ) type valves are optimized and a minimum flow head loss coefficient of 0.07 can be guaranteed. This type of valve is mainly used as safety valve or as a turbine inlet valve and pump valve. They are operated by oil hydraulic systems for opening and closing or closing weight and hydraulic pressure for opening. For turbine inlet valves oil pressure can be taken also from the governor hydraulic oil system. The sealing system is of flexible adjustable type - rubber/metal or metal/metal. The lattice door type valves can be also equipped with a maintenance seal. The hydraulic and electric / electronic control system is part of the delivery. Auxiliary equipment like bypass, air and vacuum valve, pipe rupture device, connecting pipes are usually in the scope of supply. Water flow through the valve in both directions is principally possible.

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Spherical Valves

his type of valves has a minimum head loss due to a complete free through flow. They are usually installed as high pressure turbine inlet and pump valves and are equipped with controlled service and maintenance sealings. Flow in both directions is possible. The control system is of oil hydraulic pressure system or by water pressure system or mixed opening by oil pressure, closing by water pressure. The water for the valve control system is taken from the upstream side. Oil pressure for the control system can be also supplied from the hydraulic turbine governor oil system. The most important references for spherical valves are up to a diameter of 3,200 mm ( Thissavros / Greece ) and up to a maximum of 1,430 m design waterhead ( Oschenik / Austria ).

COMPONENTS Servo motors

When the turbine load changes during generating operation, the servo motor shall operate the guide vane smoothly coordinating with the speed governor .the operation shall be performed by oil pressure supplied from the pressure supplied from the pressure oil supply system .the servomotors shall be capable to close the guide vane from the fully opened position to the fully closed ones against maximum hydraulic pressure of 600m in water column due to water hammer after load rejection.

RUNNER :

GUIDE VANES :

SPIRAL CASING :

Stay ring :