experience of ahec on rmu of hydro power stations...
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INDIAN INSTITUTE OF TECHNOLOGY ROORKEE
Alternate Hydro Energy Centre,Indian Institute of Technology, Roorkee
Email : akumafah@iitr.ac.in, aheciitr.ak@gmail.com
Workshop on“Renovation, Modernization, Uprating & Life Extension
of Hydro Power Plant - Diverse Issues & Handling Strategies” Dec 16, 2016 at New Delhi
Experience of AHEC on RMU of Hydro Power Stations and RMU in Karnataka
AHEC IIT ROORKEE EXPERIENCE AND FACILITIES FOR RLA AND RMU STUDIES
• AHEC IIT Roorkee established in 1982 to impart education, training
and carry out research in the area of power generation through the
development of small hydro power
• AHEC is also working in the field of other renewable energy sources
as well environmental management of water bodies.
• AHEC has carried out RLA studies in Uttarakhand and Uttar Pradesh.
• Carried out RMU study and prepared DPRs of more than 100 hydro
projects of different capacities in Himachal Pradesh, Uttarakhand,
Punjab, Jammu & Kashmir, Arunachal Pradesh, West Bengal, Bihar,
Sikkim, Uttar Pradesh and Karnataka.
• AHEC also have testing and measurement facilities for carrying out
RLA test and investigations.
Measurement and Testing Instruments for RLA&LA and RMU studies
Portable Ultrasonic Transit Time Flow Meter For Pipes With Wet Type
(Transducers 8 Path)
Portable Ultrasonic Transit Flow Meter For Open Channels - 8 Paths
Portable Electro-Magnetic Type Current Meter
Portable Propeller Type Current Meter
DISCHARGE MEASUREMENT
Propeller Current Meters with Programmable Electronic Unit
Smart Pressure Gauges
Ultrasonic Transit Time Flow Meter
Acoustic Doppler Current Profiler (Vertical and Horizontal)
STRUCTURAL / HYDRAULIC TESTS
Ultrasonic Concrete Tester Concrete Hammer (M-Type) Concrete Hammer (N-Type)
Micro Cover Meter Water Level Indicator Total Station
Global Positioning System Hand Held Digital Altimeter
MECHANICAL TESTS
Ultra Sonic Flaw DetectorNon Contact ThermometerGauge Pressure Transducers
Smart Differential Pressure
Transducer
Ultrasonic Thickness Meter
Eddy Current Crack Detector
Non-Contact Ultrasonic Level
Measuring Systems
Noise Meter
ELECTRICAL TEST
Portable Relay Test Power Quality Analyzer
Portable Vibration
Tester
Megger
Hipot Tester3 phase Clamp
on Portable Power Energy
meter
Micro Processor Controlled Portable
5kV Insulation Tester
True Digital Multi meter
High Voltage Capacitance Test Set Partial Discharge DetectorELCID Tester
Residual Life Assessment and Life Extension Programmes
Cold survey: Noting of rating plate details and general description of themachine as well as inspection of equipment in stand still condition.
Hot survey: Hot survey covers observation in operating condition foridentifying the problem areas and recording of such deficiencies includinginteraction with operating staff.
NDT of hydro-mechanical parts (trash rack, gate, hoist, etc.), turbinerunner, rotor and casing through dye penetration and ultrasonic tests,Electrical tests: insulation resistances, polarisation index test, AC pole droptest, high potential tests, DC resistance test, partial resistance tests, DCresistance tests, rotor impedance tests, open circular test, calibration checksand secondary injection tests. Tan delta and capacitance test, partialdischarge test.
Vibration measurements
Noise measurements
Temperature measurements
Structural strength tests on hydraulic structure, power house building, floor,walls etc.
RENOVATION OF ELECTRO-MECHANICAL EQUIPMENTS
• Renovation of Turbines
• Renovation of Generator
• Renovation of Excitation System
• Renovation of Governor
Detailed Project Report
Prepared covering following features:
Salient features.
Need for the project.
Location and scheme of
development
Hydrological studies.
Water - Power study
Technical features of the project
Recommendation of RLA and Life
extension studies.
Details of civil works including
power channel, gates, trash racks,
power house building, spill
channel, tail race channel for
renovation.
Details of all components of
Electromechanical work viz.
Turbine, generator, auxiliaries,
controls, protection and metering
Power evacuation scheme
Construction programme
Possibility of Uprating of
Capacity
Modernisation for technology
benefits
Details for central automatic
operation of power stations
Cost estimates, Generation
Cost
Economic and Financial
analysis
Preliminary design and
drawings as detailed below
Relevant drawings
Power Scenario in Karnataka• The State of Karnataka, located on the Western part of the Deccan
Peninsular region of India, has seven river basins formed by theKrishna, Cauvery, Godavari, West flowing rivers, North Pennar,South Pennar and Palar which accounts for about 6% of the country’ssurface water resources of 17 Lakh MCM.
• Karnataka is endowed with hydropower potential of about 7750 MWof which only about 3667.35 MW have been harnessed.
• It has 16 hydro power stations commissioned during last 60 years atdifferent timing. Out of these 10 are demand driven based and 6 areirrigation based. These 10 projects are developed in 3 cascades andforms the backbone of generation in Karnataka.
• Karnataka Power Corporation Limited (KPCL) owns hydro, thermal,diesel, solar and wind plants with an installed capacity of 7,223 MWas given below.
Source Installed capacity (MW)
Thermal 3,528
Hydro 3,667
Solar 24
Wind 4
Total 7,223
Eight Hydro Power Stations in Karnataka planned for RMU
Sharavathy River Complex
Name of Plant Linganamakki Sharavahty Gerusoppa dam Mahatma gandhi
Year of commissioning 1979-80 1964-77 2001-2002 1947-52
Capacity (MW) 2 27.5 10 103.5 4 60 4 13.2 + 4 21.6
Power (kW) 55000 1035000 240000 139200
Net Rated Head (m) 29.5 439.634 47.5 356.402
Design Discharge (cumec/ unit) 103 28.5 4.67 and 7.64
Estimated Cost (Rs. Lacs) 11041 10749 3156 7702
Annual Energy (MU) 259 5115 530 259
Additional Cost (Rs./kWh) 0.75 0.04 0.11 0.52
Kalinadhi complex
Name of Plant Supa dam Nagjhari Kodasalli Kadra
Year of commissioning 1984-85 1979-84 1998-99 1998-99
Capacity (MW) 2 50 6 150 3 40 3 50
Power (kW) 100000 900000 120000 150000
Net Rated Head (m) 72 347 37 32
Design Discharge (cumec/ unit) 92.5 43.5 (135 MW);
47.5 (150 MW)
141.6 201.8
Estimated Cost (Rs. Lacs) 6838 9099 1075 1064
Annual Energy (MU) 429 2819 337.43 367
Additional Cost (Rs./kWh) 0.28 0.06 0.055 0.05
RECOMMENDATIONS FOR RMU WORKSGerusoppa Dam Hydro Electric Project
Civil Works• Reaming of form drains and flushing of foundation drains in drainage
gallery of Gerusoppa dam• Restoration of damaged right bank road to GPH, left and right bank flood
protection works with spillway guide walls• Up-gradation of roads at Gerusoppa dam, power house and colony• Modifications of Tail race exit invert level
Hydro Mechanical Works• Cleaning, inspection, repair and repainting of internal and accessible
external surfaces of penstocks
E & M Works• Turbines
o Hydraulic operated GV servomotor locko All instrumentation like pressure gauges, temperature indicating
devices, flow meters, auto operated cooling water supply & pressure oilsupply to governor valves, compatible to SCADA.
o Dynamic studies of generating unit to establish continuous safeoperation of machines at possible overload - vibration spectrumanalysis, pressure pulsation at various points, noise analysis, stabilizedtemperatures of bearings and windings and transformer characteristics.
o Inspection of underwater parts and removal of abnormalities observed.o Cleaning, inspection, repair and repainting of complete under water
surfaces of turbine components e.g. inlet pipe, butterfly valve, spiralcasing, stay ring, runner, runner chamber, draft tube etc.
o Cleaning and repainting of external visible surfaces of turbinecomponents and associated equipment including oil, water and air pipelines.
RECOMMENDATIONS FOR RMU WORKSGerusoppa Dam Hydro Electric Project
Generator 11 kV , 60 MW• Cleaning of stator winding, Cleaning stator and frame assembly,
tightening of wedges, rotor pole assembly• Cooling water system improvement with replacement / provision of
consisting of 1) Water booster pumps 2) Water flow and pressure switches4) Motorized or solenoid operated control valves .supply of an automatic,self-cleaning strainer.
• Replacement of air coolers/ tubes.
Main transformer 67 MVA• Residual life assessment study shall be done for the condition of winding,
core bolts, oil condition, and oil cooling system efficiency.• Oil drains Pit in plant.
Relay and Control Panels• Replacement of relays with Numerical relays, Electronic Meters and TNC
breaker. switches of Control panels, generator transformers panel.
220 kV Switchyard• Midlife replacement of 220 kV breaker parts operating mechanism main
contacts etc as per manufacturer
SCADA SYSTEM• provision of E&M equipment being planned or done earlier. (for RLDC
requirement)
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