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

Gerusoppa Dam

Supa Dam

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)