1.0 Introduction.In past and also at present every country is looking for energy either its electrical or non-electrical because it play a very important role in the growth of country because it is the one of the main industry in all over the world .This report is on the fact and figure concerning industrial process and industrial management operation of Sayano-Shushenskaya hydroelectric power station and also include the causes of incident in Russia on Shushenskaya hydroelectric power station and its effects on different areas of life like on health environment ecology and also explore the finance because of this disaster.

1.1 BackgroundSayano–Shushenskaya hydroelectric power station is located on the Yenisei River, near Sayanogorsk in Khakassia.It was the biggest hydroelectric power station in Russiabefore the accident and the sixth-largest hydroelectric power station in the world, by average power generation.(Enginering Failures, 2012) The plant is operated by RusHydro. On 2 July 2009, RusHydro proclaimed the station’s all-time highest electricity output per 24 hours.(Enginering Failures, 2012)

The idea of this dam was present in 1960 and work started in 1968 and in 1978. This power plant was ready to produce electricity from the year 1960 to 2009. This plant was working until the disaster in 2009 which had destroyed 85% of the total plant.

1.2 Explanation of the incidentAt 08:13 local time (00:13 GMT) on 17 August 2009, the station suffered a sudden catastrophic "pressure surge" in turbine known as a water hammer and resulted in the ejection of turbine 2 with all equipment of a total weight 900 tons, from its base.Turbines 7 and 9 also suffered evere damage, while the turbine room roof fell on and damaged turbines 3, 4 and 5. Turbine 6, received only minor damage as it was the only one of the station's 10 turbines that did not receive electrical damage due to shorting of transformers.Hence, this caused a transformer explosion and water flooded engine rooms. Experts said 69 people were found dead while 6 people are still listed as missing. (Euler, 2012)

1.3Purpose of writing the report.The purpose of writing this report is to have a better understanding on engineering failures besides analysing the significant effects and implications towards the health, environment, social and the technology key areas besides proposing prevention measures.

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2.0 The industrial process and Management operation2.1 Industrial process

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RusHydro is established as part of Russia’s privatization movement in December 2004, even though the Russian government owns most of its shares (about 60%). RusHydro still possess 55 hydro plants, is the leading power company in Russia by installed capacity estimated (25.4 GW) and the second-largest hydroelectric power company in the world. (Kevin, 2012)The Sayano-Shushenskaya power plant's turbine type is Francis which has 16 blades, each turbine rated power 650MW, estimated discharge per unit is 3585 m3/s and the estimated nominal speed is 14286 rpm.(Euler and Rafael,2009). Basically the Sayano-shushenskaya dam is concreted arch gravity dam which cylindrical form with radius on top plan 600m, the height of dam is 242m, base length of 10744m and the width is 25m. For the hydroelectric plant the shore spillway of dam is 189.6m long, it has 11 intakes and the cross section size of vents is 8.2 x 5.4m. This power plant uses the conventional hydropower plant concept. The industrial process of the hydro power plant as follows:

Intake - Gates on the dam open and gravity pulls the water through the penstock, a pipeline that leads to the turbine. Water builds up pressure as it flows through this pipe.

Turbine - The water strikes and turns the large blades of a turbine, which is attached to a generator above it by way of a shaft. The most common type of turbine for hydropower plants is the Francis Turbine, which looks like a big disc with curved blades.

Generators - As the turbine blades turn, so do a series of magnets inside the generator. Giant magnets rotate past copper coils, producing alternating current (AC) by moving electrons.

Transformer - The transformer inside the powerhouse takes the AC and converts it to higher-voltage current.

Power lines - Out of every power plant come four wires: the three phases of power being produced simultaneously plus a neutral or ground common to all three

Outflow - Used water is carried through pipelines, called tailraces, and re-enters the river downstream. (Kevin, 2012)

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The water in the reservoir is considered stored energy(Kevin, 2012). When the gates open, the water flowing through the penstock becomes kinetic energy because it's in motion. The amount of electricity that is generated is determined by several factors. Two of those factors are the volume of water flow and the amount of hydraulic head. The head refers to the distance between the water surface and the turbines. As the head and flow increase, so does the electricity generated. The design for the operation of function are characterised as below:

Number of Units: 10 Turbine Type: Francis (16 blades) Rated Power: 650 MW each Rated Discharge per Unit: 358,5 m³/s � Nominal Speed: 142,86 rpm � Net Head: 194 m � Operation Date: 1978 � Runner Weight: 156 ton � Runner Diameter: 6,77 m

2.2 Management and operationManagement structures appear in every type of organization including government departments, non-government organizations (NGOs), charities, and even the local sporting association. (Sebastion, 2010) Therefore selecting the proper management structure makes certain an organization has nonstop expansion, in other hand choosing the wrong structure produces tensions between employees and managers, which allows unproductive work practices to burgeon and reduces company profitability. In the worst case, a faulty management structure can lead to company finality. For that reason, there are a number of key components that strengthen a management structure and should be considered when put into practice a new structure. (Sebastion, 2010) Several of these key components are:• Complexity• Task definition• Co-ordination• Type of Influence• Vertical• Communication Style• Horizontal differentiation• Centralization• Spatial differentiation• Formalization

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3.0 Root factors that cause the disaster of Sayano Shushenskaya hydroelectric power station.

The root cause of the disaster started with sudden closing of the Unit 2 wicket gates which caused the heavy water hammer. Thus, the upward force was resulted from the water hammer destroying the structures and further causing the elevation of the turbine cover and shafts.

The main root cause of the sudden closing of turbines is when a large piece entered the turbine runner and jammed. This piece turned the runner and hit all the wicket gates in a split second causing the sudden closing.(Euler, 2012)

It could be further evaluated as the accident was the accident was mainlytriggered by vibrations of turbine № 2 which headed to fatigue damage of the mountings of the turbine, including its cover. The report initiated that at the second of the accident, the nuts on at least 6 bolts protecting the turbine cover in place were absent. After the accident, 49 found bolts were investigated and out of that, 41 had fatigue cracks. On 8 bolts, the fatigue-damaged area exceeded 90% of the total cross-sectional area.(Euler, 2012)

On the day of the mishap, turbine № 2 worked as the plant's power output regulator. At 8:12 the turbine № 2 output powers was reduced by an automatic turbine regulator, and it entered into a power band unrecommended for the head pressure that day. In a while after the bolts keeping the turbine № 2 cover in place were broken. Under water pressure (about 20 atmospheres) the spinning turbine with its cover, rotor and upper parts jumped out of the casing, destroying the machinery manor equipment and building.

Rushed water with a high intense pressure immediately flooded the rooms and continued damage to the plant. Simultaneously, an alarm was received at the power station's main control panel, and the power output fell to zero, causing in a local blackout. However, it took 25 minutes to physically close the water gates to the other turbines. Therefore, during that time they sustained to spin without load.(Documenting Reality, 2009)

Besides that, human factor is also one of the root causes. For example, unit 2 turbine was under maintenance and should have been shut down. However, no steps were taken at the time which had eventually leaded the vibration of turbine 2 to the maximum.

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4.0 Consequences of health, environment/ecology and damages cost that are caused by the disaster.

Subsequently after the disaster, there were numerouseffects towards human health, environment, ecology and damage costs. Sayano-Shushenskaya Power generation is disconnected instantly following to what RusHydro later stated to as a powerful hydro shock.

4.1 Consequences to health and environment

The damage of the turbines and support equipment at Russia’s Sayano-Shushenskaya Hydro Power Plant in August 2009 claimed the lives of 75 workers(Hub Pages, 2013). The explosion caused huge amounts of oil to spill into the Yenisei River, which runs into the Arctic Sea. Tonnes of oil spill from the transformer led to killing tons of trout fish in two fisheries, and also other severeeffects on flora and fauna. (Hub Pages, 2013)

Figure 2Workers contain an oil spill in the Yenisei River, near the settlement of Mayna, Russia on

August 19, 2009.

4.2 Damages cost/ Compensation costsSix out of ten turbines were wrecked in an Aug. 17, 2009, accident at the Sayano-Shushenskaya plant in southern Siberia. RusHydro approximate it will take US$1.23 billion (37 billion rubles) and four years to rebuild the facility.(Boston.com, 2009)The accident shut down the power station, which supplies numerousmainaluminum plants. The government said electricity supplies from other power plants were being re-routed to help cover the loss, but power cuts were reported. The flow of water caused electric and mechanical damage. Serious electric and mechanical damage and varying degrees of damage to the construction elements. Complete destruction of the construction elements, the generator and the turbine. Electric and mechanical damage and varying degrees of damage to the construction elements.(Boston.com, 2009)

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Compensation of 1 million rubbles ($31,600) was paid to each victim’s family, and 100,000 rubbles (US $3,100) to each survivor. The public where most of the workers were housed was flooded and destroyed it is being rebuilt.(Accident at Russia’s Biggest HydroelectricPlant, 2010)The families of those who died in the accident at the Sayano-Shushenskaya hydropower plant will be paid compensation money, with 75 million roubles allocated for the purpose form the Russian government reserve fund(Accident at Russia’s BiggestHydroelectric Plant, 2010):

Figure 3Russian workers at the damaged Sayano-Shushenskaya hydroelectric power plant. Plans are in place to disassemble and replace the three destroyed turbines, and to repair the remaining seven.

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5.0 Improvement and preventive actions5.1 Building hydroelectric power station and dams.When building the hydro power plant they must consider adding unit vibration monitoring systems are should be improve and issuing commands to stop the unit and close the inlet gate after some threshold. Suitable materials are the basis of every technical product. Availability and price are often decisive for the choice.(Guidelines for Public Safety at HydroPowerProjects, 2011) The selection of incorrect material can cause significant damages. Most importantly the operation of all the turbines should not be placed to full capacity.

5.2 Danger and Warning SignsEmergency procedures were not in place when this catastrophe happened. Emergency protocols must be in place along with routine drills. Emergency stop function the emergency stop control shall trigger or permit the triggering of certain safeguard movements where necessary. Each dam should have adequate danger and warning signs. Properly located and spaced signs can be an effective method of preventing persons from entering hazardous areas. It is important to locate signs so that persons entering an area from any direction can see one or more of the signs.

5.3 InspectionThese dams should be safely designed by considering all loads and stresses. Even after the construction is complete, it is very important to frequently inspect the dams. Often, it is the lack of inspection of dams which turns to be a factor leading to unfortunate incidents. Engineers in all fields need to recognize the need for routine and through maintenance. Machinery must be properly maintained.

5.4 Preventive measuresPreventative steps are needed for Sayano-Shushenskaya hydro power plant, to avoid this kind of accident in the future. All the necessary measures that need to be taken have to comply with safety standards. There are varieties of organizations which provide assessment in workplace safety standards and quality, namely Occupational Safety and Health Administration (OSHA), National Institute for Occupational Safety and Health (NIOSH), International Organization for Standardization (ISO). Each of these organizations is having separate functions covering different types of safety standards. Sayano-Shushenkaya should try to qualify themselves as a certified power generation facility by these reliable organizations. Besides, Sayano-Shushenskaya has to educate their employers regularly on safety procedures within the compound.

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6.0 ConclusionIn conclusion, a simple mistake done by the management end up with a disaster. The main cause of this disaster is the negligence of the management.This is a good lesson for the ‘Rushydro’, as this company gave more importance to the economic output rather than workers safety. In the end, about 75 lives were sacrificed. For improvement and running a safe hydro power plant, technology should always update and implement it. Whenever there is, a new safety factor found it should always put into practice to every hydro power plant. This catastrophe wouldn't happen if this money has been spent for proper and efficient maintenances.Hydro-electric power has always been an important part of the world's electricity supply, providing reliable, cost effective electricity, and will continue to do so in the future. Hence, as an engineering student, we should learn a lesson from this incident and we should be very committed to our job and handled it with responsibility. Engineers should think deliberately about the future generations and value of lives as mankind and give preference to safety as safety comes first in our job.

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References.Accident at Russia’s Biggest Hydroelectric Plant, 2010. Accident at Russia’s Biggest Hydroelectric Plant. [Online] Available at: http://homer.ornl.gov/sesa/analysis/oec/docs/LL_from_Accident_at_Russia's_Hydroelectric_Plant.pdf [Accessed 7 January 2013].

Boston.com, 2009. The Big Picture. [Online] Available at: http://www.boston.com/bigpicture/2009/09/the_sayanoshushenskaya_dam_acc.html[Accessed 5 January 2013].

Documenting Reality, 2009. Documenting Reality. [Online] Available at: http://www.documentingreality.com/forum/f240/sayano-shushenskaya-hydro-accident-russia-17-august-2009-a-53006/[Accessed 20 December 2013].

Enginering Failures, 2012. Enginering Case Studies. [Online] Available at: http://engineeringfailures.org/?p=703[Accessed 20 December 2013].

Euler, R., 2012. Accident at Russia’s Biggest Hydroelectric. [Online] Available at: http://www.ieeeghn.org/wiki/images/b/bf/Russia-hydro-accident.pdf[Accessed 23 December 2013].

Guidelines for Public Safety at HydroPower Projects, 2011. Guidelines for Public Safety at HydroPower Projects. [Online] Available at: http://www.ferc.gov/industries/hydropower/safety/guidelines/public-safety.pdf[Accessed 3 January 2013].

Hub Pages, 2013. The Sayano-Shushenskaya dam hydro-electric power station accident due to Turbine Failure. [Online] Available at: http://livingsta.hubpages.com/hub/The-Sayano-Shushenskaya-dam-hydro-electric-power-station-accident[Accessed 2 January 2013].

Kevin, 2012. How Stuffs Work. [Online] Available at: http://science.howstuffworks.com/environmental/energy/hydropower-plant1.htm[Accessed 3 December 2013].

Sebastion, 2010. Management Structures. [Online] Available at: http://www.hkiaat.org/images/uploads/articles/Management.pdf[Accessed 23 December 2013].

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