PRESENTATION ON

PLANNING AND EXECUTION, OF

HYDRO POWER PLANTS

By

V.K. KANJLIA, DIRECTOR, CBIP

 STAGES OF PLANNING
RECONNAISSANCE
FEASIBILITY PRE-FEASIBILITY STUDIES

FEASIBILITY STUDIES

SITE INVESTIGATION
DETAILED PLANNING OF WORKS
DETAILED PROJECT REPORTS CIVIL
ELECTRICAL
COST ESTIMATE

TECHNOECONOMIC
ENVIRONMENTAL
EVALUATION & APPRAISAL STAGE CLEARANCES FROM
STATUTORY BODIES
INVESTMENT DECISION

CONSTRUCTION STAGE
 PLANNING
 STAGES OF PLANNING INCLUDE A THREE STAGE PROCESS:

 STAGE-I

 SURVEY INVESTIGATION & PREPARATION OF FEASIBILITY

REPORT

 STAGE-II

 PREPARATION OF DPR & DEVELOPMENT OF

INFRASTRUCTURAL FACILITIES

 STAGE-III

 INVESTMENT DECISION FOR PROJECT EXECUTION &

CONSTRUCTION OF PROJECT
 HYDRO ELECTRIC PROJECT
EXECUTION

 Infrastructure Works.

 Main Works:
 Civil Works.

 Electrical & Mechanical Equipment Works.

 Hydro-Mechanical Works
 List of E&M Equipment
1.0 TURBINE AND GOVERNING EQUIPMENTS
1.1 TURBINE
1.2 GOVERNING SYSTEM (DIGITAL TYPE) AND
ACCESSORIES
2.0 GENERATOR AND ASSOCIATED EQUIPMENTS
2.1 GENERATOR
2.2 EXCITATION SYSTEM
2.2 ISOLATED PHASE BUS DUCT
3.0 MECHANICAL SYSTEMS
3.1 EOT CRANE
3.2 COOLING WATER SYSTEM
3.3 DRAINAGE SYSTEM
3.4 DEWATERING SYSTEM
3.5 COMPRESSED AIR SYSTEM
3.6 HVAC SYSTEM
3.7 FIRE FIGHTING SYSTEM
3.8 OIL FILTRATION SYSTEM
3.9 D.G. SETS
3.10MECHANICAL WORKSHOP EQUIPMENTS
 List of E&M Equipment
4.0 ELECTRICAL SYSTEMS
4.1 GENERATOR STEP-UP TRANSFORMERS
4.2 CONTROL, MONITORING AND PROTECTION SYSTEM
4.3 220V AND 48V DC SYSTEM
4.4 220KV/400KV XLPE CABLES
4.5 POWER AND CONTROL CABLES (INCLUDING CABLE
TRAYS)
4.6 11 KV SWITCHGEAR SYSTEM
4.7 415V SWITCHGEAR SYSTEM
4.8 STATION SERVICE TRANSFORMERS
4.9 UNIT AUXILIARY TRANSFORMERS
4.10 POWER LINE CARRIER COMMUNICATION SYSTEM
4.11 ILLUMINATION SYSTEM
4.12 GROUNDING SYSTEM
4.13 PUBLIC ADDRESS SYSTEM
4.14 ELECTRICAL WORKSHOP EQUIPMENTS
5.0 GIS AND POTHEAD YARD EQUIPMENTS
5.1 GAS INSULATED SWITCHGEAR
 Erection Sequence
 Readiness of GIS location, transformer
bay location , Pothead yard location.
 Readiness of Crane beam.
 Placement of ground mat & Concreting.
 EOT Crane Erection.
 Readiness of foundation for erection of
Draft Tube(DT) assembly.
 Draft tube erection.
 Erection Sequence
 Draft tube concreting.
 Foundation plate erection, Spiral case stay
ring, bottom ring & runner chamber
erection.
 Concreting of above.
 Lowering & installation of runner.
 Shaft free.
 Erection Sequence
 Stator assembly in service Bay.
 Stator winding connection & HV test.
 Generator Rotor assembly in service Bay.
 Assembly of lower combined bearing
 Assembly of stator complete
 Assembly of brake lifting, brake dust exhaust
system, standstill heaters & air shield Drive
End(DE).
 Assembly of rotor and slip ring support.
 Assembly of upper bracket
 Erection Sequence.
 Assembly of brush holder bracket and air shield
Non Drive End(NDE)
 Assembly of slip ring complete and carbon dust
exhaust system
 Run out check of generator rotor.
 Coupling with turbine shaft
 Run out check with coupled turbine
 Adjusting magnetic center and air gap.
 Assembly of covers.
 Final assembly.
 Erection Sequence
 Parallel activity of the auxiliary equipment
like:
 Governing system erection & pre
commissioning.
 Static Excitation, AVR & Bus duct erection &
pre commissioning.
 Generator step up transformer erection & pre
commissioning.
 XLPE cables, GIS, Pothead yard, DC system,
control & monitoring, Protection system, UAT,
SST, cooling water & drainage systems, DG
sets, illumination, etc.
 Erection Sequence
 Unit axis alignment & box up.
 Testing & Pre-commissioning.
 Availability of water.
 Spinning, dry out & synchronization.
 Field tests & handover.
 SITE TESTING PHILOSPHY

THE PURPOSE OF SITE TEST IS TO

ENSURE THAT THE EQUIPMENT /
SYSTEM PERFORMS THE DESIRED
FUNCTIONS.
1. LOCAL TESTS / EQUIPMENT TEST.
TEST IN THIS CATEGORY,ARE THOSE
TESTS WHICH ARE PERFORMED ON THE
EQUIPMENT LOCALLY TO ENSURE ITS
HEALTHYNESS AND ITS ABILITY TO
FUNCTION AS PER SPECIFICATION.
 Continued---

2. REMOTE TEST/SYSTEM TEST

AFTER THE EQUIPMENT IS

INTERCONNECTED IN A SYSTEM,IT
SHOULD FUNCTION AS PER THE
SYSTEM REQUIREMENT.REMOTE
TEST/SYSTEM TESTS ARE
PERFORMED TO CHECK THAT ABOVE
REQUIREMENT IS MET.
 LOCAL TESTS:

1. Motors.
2. Control panels.
3. Pumps.
4. Compressors.
5. Relays.
6. CT/PT/CVT.
7. Circuit breaker.
8. Isolator
9. Generator.
 Continued---

10. Turbine.
11. Inlet valve.
12. GSU Transformer.
13. UAT/SST.
14. LT Panel/HT panel.
15. Excitation equipment.
16. Governor.
 REMOTE TESTS/SYSTEM
TESTS:
1. Unit control scheme including Inlet valve
control.
2. Unit Protection Scheme
 Mechanical protective Devices
 Electrical protection.
3. Feeder control.
4. Feeder Protection.
5. Alarm & Annunciation system including
Sequence Event Recorder.
 Continued---
6. Auxiliary System.
 Cooling Water system.
 Compressed Air system.
 O.P.U
 O.L.U.
7. A.C Supply system including 11KV.
8. D.C Supply system.
9. Drainage & Dewatering system.
10. Fire Protection System
 GSU TRANSFORMER:
1. I.R. Value of Transformer Winding.
2. Transformer oil test.
 B.D.V
 TAN DELTA
 P.P.M
3. Ratio test at Diff.Taps.
4. Resistance at Diff Taps.
5. Mag .Current at 415 V from both end.
 Continued---

6. Vector Group check.

7. Bushing C.T.Check.
8. Buchloz Relay test.
9. P.R Device & oil level gauge,flow
relay.
10. Winding temperature.
11. Oil temperature.
12. Functional check on pumps/Fans.
 Control Panels:
 Physical inspection
 Insulation resistance tests.
 Continuity test.
 Tests to prove correct operation of
interlocks,tripping and closing
circuits,indication etc.
 Meter calibration check.
 Protection relay test and setting.
 Sequential operation check.
 Protective gear timing tests as may be
applicable.
 Test operation of alarm devices.
 C.T./P.T.CHECK

 Polarity check.
 Ratio Test.
 Magnetising.

MOTORS:

 I.R Value.
 Direction of Rotation.
 CIRCUIT BREAKER:

1) Functional Check.
2) Open/close test.
3) Opening/closing time check.
4) Breaker duty cycle test.
5) Pole discrepancy check.
6) Pressure Relay test.
7) Contact Resistance check.
 L.T. PANEL/H.T. PANEL:

 Physical Inspection.
 I.R Value check.
 Disconnection of Ext. cable.
 Functional check.
 Opening/closing operation.
 Tripping through protection.
 Pre-commissioning
check/tests on generator
A. STATOR:
After completing the winding connection.
 The Stator is put on dry out with a
rectiformer.
 During dry out test,we take the megger
value of winding and P.I(Polarisation Index)
 After dry out each winding of stator is
subjected to high voltage test(I.e at 23KV
AC for 11 KV stator) for one minute
 B. ROTOR : Continued---

Before mounting the rotor pole,impedance

test for each pole is carried out by applying
AC voltage through variac.After mounting all
poles and doing inter connections of all poles,
following tests are performed
 Winding resistance is measured with the help
of micro ohm meter.
 Impedence of complete Rotor is measured by
AC voltage test.
 IR value is measured with Megar.
 High voltage test at 2KV with AC HV test kit.
 Continued---

C. GENERAL:

 Functional check for fire-protection

system inside generator barrels.
 Functional checks of brake system.
 Pressure/leakage test of jack/brake line
SYSTEM CHECK / REMOTE
TESTS UNIT CONTROL
SCHEME :

 Operation of Interlocks for starting.

 Starting sequence check.
>Stopping sequence check
SYSTEM CHECKS (contd.)

 >Trippingchecks through Electrical

Protection
>Tripping checks through Mechanical
Protection
>Emergency shutdown through
Emergency Shut Down Valve.
 CONTROL & RELAYING
SCHEME:

1) Current Injection through primary

injection upto the relays & meter.
2) Stability of various diff. Scheme.
3) Voltage Injection through primary circuit
upto relays & meter.
4) Remote checking of breakers & isolators.
 Continued---

5). Alarm & Annunciation checking.

6). Starting/Stopping of machines.
7). Tripping of C.B. & Machine through
protection.
8). Voltage Raise/Lower check.
9). Speed /Power Raise/Lower check.
10). Synchronization check
GOVERNING SYSTEM:

 Functional check of OPU system

 Tripping devices through OPU
 Low air pressure
 Low oil level in pressure tank.
 Functional check of Governor.
 Start command from UCP
 Speed lower/raise.
Stop command from UCP.
Operation speed relays.
Operation of master switches.
Remote meters check.
Gate Limiter position/Gate
position switch
Balance meter.
Speed Meter.
Signal from PMG/P.T./SSG
 Excitation system:

 Functional Check.
 Field breaker operation check-Closing ,
opening and tripping on fault
 Auto/Manual control of generation
voltage.
 Alarm & Annunciation check.
 Indication check.
 Metering check.
 Control Panels:
 Physical inspection.
 Insulation resistance tests.
 Continuity test.
 Tests to prove correct operation of interlocks,
tripping and closing circuits,indication etc.
 Meter calibration check.
 Protective relay test and setting.
 Sequential operation check.
 Protective gear timing tests as may be
applicable.
 Test operation of alarm devices.
 COMMISSIONING TESTS OF
RELAYS
1. GENERAL INSPECTION
2. INSULATION CHECK
3. AC CIRCUIT CHECK(CT/PT)
4. SECONDRY INJECTION OF RELAYS
5. PRIMARY INJECTION TEST OF CTs AND
STABILITY AND SENSITIVITY TEST OF
RELAYS.
6. D.C FUNCTIONAL CHECK.
7. CHARGING OF EQUIPMENT AND LOAD
CHECKS.
 TEMP. SENSING DEVICES
1. CALIBRATION OF TSD AT VARIOUS
TEMP. (OPERATION RANGE)
2. TEST FOR ALARM AND TRIP SETTINGS
AND CONTACT CHANGE OVER CHECK
 Continued---

 FOR COMMISSIONING OF FIRST UNIT

IN A POWER STATION , THE GENERAL
SERVICE REQUIRED SUCH AS WATER,
ELECTRICAL SERVICES,FIRE-
FIGHTING, DRAINAGE SYSTEM,
COMPRESSED AIR SYSTEM,D.C
SYSTEM AND COMMUNICATION
SYSTEM SHOULD BE AVAILABLE IN
ADVANCE.
 Continued---

COMMISIONING OF A UNIT CAN BE DIVIDED

INTO THREE OPERATIONAL PHASES. IN THE
FIRST PHASE THE OPERATION OF EACH
SYSTEM IS PROVIDED BY MANUAL
CONTROL.THE SECOND PHASE INVOLVES
OPERATIONS OF ALL THE SYSTEMS IN AN
INTEGRATED MANNER ON AUTOMATIC
CONTROL. IN THE THIRD PHASE AUTOMATIC
SEQUENCE CONTROL PHASE IS ESTABLISED
SEQUENCEWISE ACTIVITIES
FOR COMMISSIONING:
 FILLING OF WATER WAYS.
 INITIAL RUN IN MANUAL MODE.
 HIGH VOLTAGE TEST OF STATOR
WINDING
 BEARING RUN AT DIFFERENT SPEED
AND FINALLY AT RATED SPEED.
 SHORT CIRCUIT TEST OF GENERATOR
WINDING(SCC).
 Continued---

 PERFORMANCE TEST OF ALL

PROTECTION.
 STABILITY AND SENSITIVITY TEST
OF DIFFERENTIAL RELAYS.
 OPEN CIRCUIT CHARACTERISTIC TEST.
 PERFORMANCE TEST OF ALL
VOLTAGE RELAY.
 Continued---

 SYNCHRONISATION CHECKS.
 OVER SPEED TEST.
 OVER LOAD THROW OFF TEST AT
DIFFERENT LOADS.
 RECORDING AND MONITORING OF
VOLTAGE RISE AT THE TIME OF LOAD
REJECTION TEST.
TESTS PERFORMED ON
EACH MACHINE BEFORE
COMMERCIAL RUN:

 PRESSURE AND FUNCIONAL TESTS OF

BRAKE AND JACK SYSTEM,AND HIGH
PRESSURE OIL LUBRICATING SYSTEM.
 TEST FOR TIME REQUIRED FOR BRAKES TO
STOP THE MACHINE SAFELY WHEN THE
BRAKES ARE APPLIED AT THE SPECIFIED
SPEED WITH THE WICKET GATES CLOSED
AND FIELD CIRCUIT BREAKER OPEN.
 Continued---

 DETERMINATION OF THE
TEMPERATURE OF BEARINGS.
 PHASE SEQUENCE CHECK.
 Open Circuit Test (OCC).
 Short Circuit Test (SCC).
 MEASUREMENT OF AIR GAP.
 VIBRATION MEAUSREMENT OF
MACHINE PARTS .
 LOAD REJECTION TESTS.
 SHAFT VOLTAGE MEASUREMENT.
 P.H.
SECTION
SPIRAL CASING
SHOP ASSEMBLY OF SPIRAL
CASE AND STAY RING
BUTTERFLY VALVE
Thank You