GUJARAT TECHNOLOGICAL UNIVERSITY Chandkheda, Ahmedabad Afflicted

BABARIA INTITUTE OF TECHNOLOGY

Project Report

On

UKAI HYDRO POWER PLANT

Submitted in accordance with the INDUSTRIAL VISIT

for

4TH semester of the BE course

In the branch of

ELECTRICAL ENGINEERING

YEAR 2015

SL NO. NAME ENROLLMENT NO.

1 SAURABH DAYAL SINGH 130050109106

2 DEORE MAULIK N. 130050109018

3 BHAVIN BARAD 130050109006

4 SAURABH PAKRASHI 130050109060

5 VIVEK PAGE 130050109057

6 HARSH AGRAWAL 130050109003

7 SHADMAN 130050109055

8 VISHAL CHAUDHARI 130050109013

9 VIPUL PATEL 120050109096

10 MILAN KOYANI 130050109045

11 ANKIT PAL 130050109047

12 DIVYESH 130050109043

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ACKNOWLEDGEMENT

Writing this industrial visit report happens to be one of the greatest achievements in this phase of my life.

Express my heartiest thanks to those who provided me tremendous support and making it a useful

firsthand experience. I am indebted to those who helped me in one way or the other in heavy indeed. I

take the opportunity to thank all of them. I am very thankful to our HOD Dr.D,M Patel sir and

Coordinator Mrs.Heli.A .Shah who gave us the excellent guidance and cooperation on Industrial Visit .I

am thankful to the UKAI HYDRO POWER PLANT, ukai where I able to prepare this project report.

I express great sense of gratitude to Chief Engineer of Ukai Hydro Power Plant who gave us the

opportunity to learn with his prestigious his valuable guidance, integrate support and perceptive criticism

helped me to conceptualize this research work his guidance is precious and unforgettable experience

which will help us in our future.

I Specially thanks to Mr Prashant Chaudhari , Mr Datesh Jhosi sir and Miss Dinal Panchal for paying

their kind support, guidance and cooperation for the successful completion of this study at UKAI

HYDRO POWER PLANT. They guided us at every point and place of UKAI hydro power plant .

Moreover ,thanks to all my collogues who were at the visit.

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CONTENT

1. INTRODUCTION OF UKAI HYDRO-ELECTRIC POWER PLANT…………….…04

2. HISTORY OF UKAI HYDRO-ELECTRIC POWER PLANT…………………..……05

3. BASIC PRINCIPLE OF HYDRO POWER PLANT…………………………….…….06

4. SITE SELECTION FOR HYDRO POWER PLANT……………………………….…07

5. CONSTRUCTION OF HYDRO POWER PLANT……………………………………08

6. WORKING OF HYDRO POWER PLANT………………………………………...…11

7. MAIN PARTS OF HYDRO POWER PLANT………………………………………..14

8. ADVANTAGES OF HYDRO POWER PLANT……………………………………..18

9. DISADVANTAGES OF HYDRO POWER PLANT…………………………………19

10. PURPOSE OF VISIT……………………………………………………………….…20

11. SELF EXPERIENCE……………………………………………………………….…21

12. MAIN FEATURES OF UKAI HYDRO POWER PLANT………………………...…23

13. CONCLUSION……………………………………………………………….………27

14. SNAPSHOTS OF INDUSTRIAL VISIT……………………………………………..28

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INTRODUCTION

UKAI HYDRO-ELECTRIC POWER PLANT:-

The Ukai Dam, constructed across the Tapti River, is the largest reservoir in Gujarat. It is also

known as Vallabh Sagar. Constructed in 1972, the dam is meant for irrigation, power generation

and flood control. Having a catchment area of about 62,255 km2 and a water spread of about

52,000 hectares, its capacity is almost same as that of the Bhakra Nangal Dam. The site is

located 94 km from Surat.

The storage capacity of Ukai dam is almost 46% of the total capacity of all the other existing

dams in Gujarat if put together. Thus it can be concluded that the rest of the dams have as little

as 0.1% average storage capacity. During the last 40 years, the actual irrigation potential is

attained through all the major and medium water resources projects in the State, which comprises

only 14 million hectares.

The dam is an earth-cum-masonry dam. Its embankment wall is 4,927 m long. Its earth dam is

80.77 meter high, whereas the masonry dam is 68.68 meter high. The dam's left bank canal feeds

water to an area of 1,522 km2. and its right canal provides water to 2,275 km2 of land.

There are four units of hydro turbine each of 75 MW with a total installed capacity of 300 MW.

All the above units are of BHEL make. Commissioning dates of unit no. 1 to 4 are 08.07.1974,

13.12.1974, 22.04.1975 and 04.03.1976 respectively.

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Gujarat has around 21 large dams, among 541 Indian Dams. Ukai Dam near Surat is one of the major projects including Sardar Sarovar Dam. Only 5 projects of Gujarat are considered to be the

prime sources of water across the state, namely the Dharoi, Dantiwada, Kadana, Ukai and Sardar Sarovar. These 5 Dams of Gujaratare also of national importance.

The storage capacity of Ukai dam is almost 46% of the total capacity of all the other existing dams in Gujarat if put together. Thus it can be concluded that the rest of the dams have as little

as 0.1% average storage capacity. Ukai Dam is thought to be the mega project in Gujarat. During last 40 years, the actual irrigation potential is attained through all the major and medium water resources projects in the State, which comprises of only 14 million hectares.

However, the Sardar Sarovar Dam would alone provide irrigation facilities to 19.24 million

hectares and it makes a lot of difference in tiding over famine conditions prevailing recurrently in Gujarat State.

The floods of among the worst Gujarat's Surat city has experienced in recent times. The sudden release of a huge amount of waterfrom the Ukai dam led to over 80 per cent of Surat, which

comprises of only 14 million hectares. However, the Sardar Sarovar Dam would alone provide irrigation facilities to 19.24 million hectares and it makes a lot of difference in tiding over famine conditions prevailing recurrently in Gujarat State.

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BASIC PRINCIPLE OF HYDRO POWER PLANT:-

In hydroelectric power plants the potential energy of water due to its high location is

converted into electrical energy. The total power generation capacity of the hydroelectric

power plants depends on the head of water and volume of water flowing towards the

water turbine.

The hydroelectric power plant, also called as Dam or Hydropower plant, is used for

generation of electricity from water on large scale basis. The dam is built across the large

river that has sufficient quantity of water throughout the river. In certain cases where the

river is very large, more than one dam can built across the river at different locations.

The water flowing in the river possesses two type of energy: The Kinetic energy due to flow of water and The Potential energy due to the height of water. In hydroelectric power

and potential energy of water is utilized to generate electricity.

The formula for total power that can be generated from water in hydroelectric power plant due to its height is given,

P = r*h*g

Where, P = Total power that can be produced in Watts.

r = Flow rate of water measured in Cubic meters per second.

h = It is difference in height between the source of water (from where water is taken)and the water’s outflow (where the water is used to generate electricity, it is

the place near the turbines).

g = Gravity Constant = 9.81 meter per second sq.

The formula clearly shows that the total power that can be generated from the

hydroelectric power plants depends on two major factors, the flow rate of water or volume of flow of water and height or head of water.

More the volume of water and more the head of water more is the power produced in the hydroelectric power plant. To obtain the high head of water the reservoir of water should

as high as possible and power generation unit should be as low as possible. The maximum height of reservoir of water is fixed by natural factors like the height

ofriverbed, the amount of water and other environmental factors.

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SITE SELECTION FOR HYDRO POWER PLANT:-

Some point that should be given importance while selecting a site for Hydro-electric

power station is given below.

Availability of Water:-

Since the primary requirement for a hydroelectric power station, is the availability of

huge amount of water such plants should be built at a place (e.g.river, canal) where adequate water is available at a good head.

Storage of Water:-

There are wide variations in water supply from a river or canal during the year. This

makes its necessary to store water by constructing a dam in order to ensure the generation of power throughout the year. The storage helps in equalizing the flow of water so that

any excess quantity of water at a certain period of the year can be made available during times of very low flow in the river.

Cost and Type of Land:-

The land for the construction of plant should be available at a reasonable price.Further, the bearing capacity of the soil should be adequate to withstand the installation of heavy

equipment.

Transportation Facilities:-

The site selected for the hydro-electric plant should be accessible by rail and road so that necessary equipment and machinery could be easily transported.

It is clear from the above mentioned factors that ideal choice of site for such a plant is

near a river in hilly areas where dam can be conveniently built and large reservoirs can be obtained.

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CONSTRUCTION OF HYDRO POWER PLANT:-

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Pumped-Storage Plants:-

There's another type of hydropower plant, called the pumped-storage plant. In a

conventional hydropower plant, the water from the reservoir flows through the plant,

exits and is carried downstream. A pumped-storage plant has two reservoirs:

Upper reservoir - Like a conventional hydropower plant, a dam creates a reservoir.

The water in this reservoir flows through the hydropower plant to create electricity.

Lower reservoir - Water exiting the hydropower plant flows into a lower reservoir

rather than re-entering the river and flowing downstream.

Using a reversible turbine, the plant can pump water back to the upper reservoir. This is

done in off-peak hours. Essentially, the second reservoir refills the upper reservoir. By

pumping water back to the upper reservoir, the plant has more water to generate

electricity during periods of peak consumption.

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The Generator:-

The heart of the hydroelectric power plant is the generator. Most hydropower plants have

several of these generators.

The generator, as you might have guessed, generates the electricity. The basic process of

generating electricity in this manner is to rotate a series of magnets inside coils of wire.

This process moves electrons, which produces electrical current.

Each generator is made of certain basic parts:

Shaft

Exciter

Rotor

Stator

As the turbine turns, the exciter sends an electrical current to the rotor. The rotor is a series of

large electromagnets that spins inside a tightly-wound coil of copper wire, called the stator. The

magnetic field between the coil and the magnets creates an electric current.

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WORKING OF HYDRO POWER PLANT:-

A hydroelectric dam converts potential energy (and/or kinetic energy) to electrical energy by means of a turbine and alternator.

A typical hydroelectric dam has the following main parts:

Water reservoir:A large quantity of water is stored in a reservoir (or dam). The height or depth of the stored water determines how much electricity can be generated.

As the depth increases, the generation of electricity also increases. Gate: A control gate is used for releasing/blocking water from the dam. Depending

upon the electricity requirements, the gate is opened. Penstock: The released water from the dam reaches the turbine blade through the

penstock. The proper slope and diameter of the penstock is important for the

efficiency of the dam. Turbine: The turbine consists of a number of large fan blades and a spindle. The

spindle rotates when water strikes the blades. Thus the power of flowing water is converted to the rotational power of the spindle.

Alternator:The spindle of the turbine is connected to the alternator, where rotational

power of the spindle is converted intoelectrical power.The produced electricity is then distributed to the grid.

River:The outflow of water from the turbine is released to a river.

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Working of Turbine:-

The theory is to build a dam on a large river that has a large drop in elevation (there are

not many hydroelectric plants in Kansas or Florida). The dam stores lots of water behind it in the reservoir. Near the bottom of the dam wall there is the water intake. Gravity

causes it to fall through the penstock inside the dam. At the end of the penstock there is a turbine propeller, which is turned by the moving water.

The shaft from the turbine goes up into the generator, which produces the power. Power

lines are connected to the generator that carries electricity to your home and mine. The water continues past the propeller through the tailrace into the river past the dam. By the

way, it is not a good idea to be playing in the water right below a dam when water is released!

Working of Turbine

As to how this generator works, the Corps of Engineers explains it this way:"A hydraulic

turbine converts the energy of flowing water into mechanical energy. A hydroelectric

generator converts this mechanical energy into electricity.” The operation of a generator

is based on the principles discovered by Faraday.

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Pumped storage: Reusing water for peak electricity demand

Pumped storage is a method of keeping water in reserve for peak period power demands by pumping water that has already flowed through the turbines back up a storage pool above the power plant at a time when customer demand for energy is low, such as during

the middle of the night.

The water is then allowed to flow back through the turbine-generators at times when

demand is high and a heavy load is placed on the system.

The reservoir acts much like a battery, storing power in the form of water when demands

are low and producing maximum power during daily and seasonal peak periods. An advantage of pumped storage is that hydroelectric generating units are able to start up

quickly and make rapid adjustments in output.

They operate efficiently when used for one hour or several hours. Because pumped storage reservoirs are relatively small, construction costs are generally low compared

with conventional hydropower facilities.

Run-of-the-river:

Run-of-the-river hydroelectric stations are those with small or no reservoir capacity, so

that the water coming from upstream must be used for generation at that moment, or must be allowed to bypass the dam.

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MAIN PARTS OF HYDRO POWER PLANT:-

Flow Chart of Hydro Power Plant

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1) Catchment area:-

The whole area behind the dam draining into

streak or river across which the dam is been

built at a suitable space is called catchment

area.

2) Reservoir: -

The reservoir is employed to stored water, which is further utilizes to

generate power. It may be generally of two types.

a) Natural (e.g. SARDAR SAROVAR DAM)

b) Artificial (Dam)

Water is held in upstream reservoir is called storage &behind a dam at a

plant is called pond age.

3) Dam: -

A dam is a barrier to confine or raise water for storage or diversion to

create a hydraulic head. Dams are generally built areconcrete for stone

masonry, earth or rock fill or timber.

4) Spillways: -

The rise of water level beyond the limit endangers the stability of dam

structure. To relieve reservoir of the excess of after contribution, a

structure is provided in the body of dam or near the dam or on the

periphery of basin .This safeguarding structure is called spillway.

Excess accumulation of water endangers the stability of dam construction.

Also in order to avoid the over flow of water out of the dam especially

during rainy seasons spillways are provided. This prevents the rise of

water level in the dam.

Spillways are passages which allows the excess water to flow to a storage

area away from the dam.

Gate:

A gate is used to regulate or control the flow of water from the dam.

Pressure tunnel:

It is a passage that carries water from the reservoir to the surge tank.

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5) Conduits: -

Conduits are just simple channels of water that is they carry water from

the turbine. They may be open like canals or closed like penstocks, tunnels

and pipelines.

6) Surge tanks: -

A surge tank is a small reservoir or tank in which water level rises or falls

to reduce the pressure swings so that they are not transmitted in full to a

closed circuits.

When there is a sudden close or decrease in pressure due to control valve

then there is a back flow of water. This creates a high pressure zone in the

penstock due to which it may burst . This effect is known as WATER

HAMMERING EFFECT .

To avoid this a tank is attached to the penstock which stores water in it .

This tank is called as Surge Tank.

7) Draft tubes: -

The draft tube is a conduit, which connects the runner exit to the tailrace.

Draft Tube is an empty structure made beneath the Turbine. It serves in

following purpose’s :

It allows the turbine to be set above tail water level without loss

of head, to facilitate inspection and maintenance.

It regains by diffuser action , the major portion of the kinetic

energy delivered to it from the runner.

It increases the output power.

It increases the efficiency of Hydro Power Plant.

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8) Penstock:-

From the intake work are fore bay water is taken to the turbine by a

conduit system is known as penstock. There are two type of penstock.

(a) Low Pressure

(b) High Pressure

High pressure penstock consists of channels or a pipe. Low penstock

consists of a steel pipe which can take water under pressure.

Penstock is the connecting pipe between the dam & the turbine house.

It helps to increase the kinetic energy of the water coming from the dam.

Penstock is made up of a very strong material which can sustain the high

pressure of water.

9)Power House:-

The power house is a building in which the turbines, alternators and the

auxiliary plant are housed. Some important items of equipment provided

in the power house are as follows:

Turbines

Generators

Governors

Relief valve for penstock setting

Gate valve

Transformer

Switch board equipment and instruments

Oil circuit breaker

Storage batteries

Outgoing connections

Cranes

Shops & offices

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ADVANTAGES OF HYDRO POWER PLANT:-

No fuel charges.

Running cost almost nil.

No stand by losses.

Highly reliable.

Efficiency does not decrease with time.

Construction and operation wise very simple.

Maintenance cost very less.

Starts quickly and synchronizes fast.

Minimum staff when plant is operational.

No ash problems thus pollution frees.

Also useful in flood control and irrigation and drinking water purpose.

Comparatively quiet long life.

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DISADVANTAGES OF HYDRO POWER PLANT:-

Higher initial cost.

Takes long time of erection.

Plants are setup at distant places so transmission losses increase.

Totally dependent on the availability of water.

Larger area required.

Period of installation time is high.

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PURPOSE OF VISIT

Our main purpose for this visit is familiar with industrial environment and to get practical

knowledge and learn where & how we apply our theoretical knowledge in real application.

To know how the power is generated in hydro power plant.

Electrical Engineering Dept. of BABARIA INSTITUTE OF TECHNOLOGY College,

VADODARA decided to arrange one day industrial visit for 4th Electrical Engineering students

to improve practical knowledge and get benefited their theoretical knowledge.

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SELF EXPERIENCE:-

On 28th Feb, Saturday at 10:45 am we reached at H.P.S, Ukai. We got entry in power station at 11:55 am.

Generation process:-

We entered in to the plant we shown that there was four unit for producing electricity and each have capacity of 75 MW. There was only one unit is working at that time. The information about plant which have been we got below,

The turbine was situated about 30 ft under the ground. The water was come force fully by sloping. About 6000 cusec water is required to rotate turbine at 150 rpm. Means if we want to

rotate turbine 150 rpm we have to required 28 liter water per second. At the starting time of unit which is shutdown more than 24 hours, free running was required and for these oil and water supply given to turbine with pressure 25 kg/cm2. When they require

stopping unit they used servo motor for locking purpose. There were two types of cooling system, one oil cooling system for the bearing of turbine and

other is air cooling system for generator.

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Control process: After that we where go to control room. In control room they control whole plant automatically

using SCADA system & control panels are used to control the system and also indicate the

system conditions.

Transmission process: In last at switch yard we learn transmission system. We also learn the equipment like lighting

arrester, CT & PT, transformer, insulator etc.

At last also we knew that ukai H.P.S break the 24 yrs old record by producing 221.2 MUS (1MUS

=1000MW) electricity in last month.

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MAIN FEATURES OF UKAI HYDRO POWER PLANT:-

Location Vill.: Ukai

Purpose Multi-purpose

River Tapi

Area of catchment 62225 km2

Mean annual rainfall 785 mm

Year of commencement of construction work 1964

Year of completion 1972.

Dam

Type Earthen & Masonry

Bed Rock Basalt (Dolerite Dyke )

Maximum height above the lowest point of foundation

80.772 m

Length at the top of the dam 4927 m.

Total Volume Content:

Concrete 0.21 Mm3

Masonry 1.51 Mm3

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Earthwork 23.67 Mm3

Reservoir

Area at full reservoir level 612 Km3

Gross storage capacity 7414.29 Mm3

Effective storage capacity 6729.896 Mm3

Area under submergence

a) Forest b) Waste land c) Culturable

a) 22258 ha b) 7485 ha c) 30350 ha

No. of villages under submergence 170

Spillway

Type Ogee

Length 425.195 m

Energy dissipater Ski-jump bucket

Maximum discharge 46269 m3/s

Type, Nos. and size of gate Radial, 22, 15.55 m X 14.783 m

Canal

Length of canal -

73+48=121 Km. (Left)

Capacity -

35.0 m3/Sec (Left)

Gross command area 1,21,410 Ha. (Left)

Culturable command area

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66,168 Ha. (Left)

Geology

Name of Scheme District Rock type encountered at the dam site

Ukai / Tapi Surat Besalt (Dolerite Dyke)

Power Plant

Type Under ground, River bed power house

Hydraulic Head 57 m to 34 m

Maximum discharge 213 m3/s

Installed Capacity 300 MW

Villages under command

a)District b)Taluka c) No. of villages

Surat

Mandvi 7

bardoli 11

Mahuva 29

Tapi

Songadh 20

Vyara 43

Valod 41

Navsari Chikhali 39

Vansda 9

Valsad Valsad 24

Navsari Dharampur 1

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Total 224

Cost

Estimated cost Rs 13896.15 lacs

Name of scheme

River Village Taluka Dist.

Catchment Area (Sq.Kms)

Yield (MCM) Maximum observed flood (Cumecs) Gujarat Other Maximum Average

Ukai Tapi Ukai Songadha Surat 917 KM2 61308.00 - 17220.00 42470.00

Date Crest R.L. (M.)

F.R.L. (M)

H.F.L. (M)

Top of Dam R.L.(M)

Gross Capacity at F.R.L. (MCM)

Dead storage (MCM)

Live storage (MCM)

Lenth of Spillway (M)

06/08/1968 91.135 105.156 106.99 111.25 7414.29 684.394 6729.896 425.195

Type of Spillway

Details of Gates Lenth of

Auxilary Spillway (M)

Left Bank Canal Right Bank Canal

Year of Completion

Types Nos. Lenth K.M.

Discharge Capacity (Cumecs)

Length K.M.

Discharge Capacity (Cumecs)

Ogee Radial 22 73.00 35.00 - - 1972

G.C.A. (Ha) C.C.A. (Ha) Maximum Irrigation

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Year Area

1,21,410 66,168 1999-2000 88,564

CONCLUSION:-

After visit at the UKAI Hydro Power Station I can say that one can visualize the complex study

of power generation using coal as a fuel, which will help me a lot in future in many field & I can

understand the function of each component in hydro power station, their importance, their

arrangement & precautions that to be used for the safety in the plant.

Hydro is a flexible source of electricity since plants can be ramped up and down very

quickly to adapt to changing energy demands.

The major advantage of hydroelectricity is elimination of the cost of fuel.

Hydroelectric power stations that use dams would submerge large areas of land due to the requirement of a reservoir.

At last I will only say that I really enjoyed my visit over here and I again want to thank all my

faculties, staff of UKAI Hydro Power Station to give me this great pleasure of the training.

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SNAPSHOT OF UKAI HYDRO POWER PLANT