INTRODUCTION TO SJVNL

LAYOUT PLAN

The Sutlej JaL Vidut Nigam Limited SJVNL (formally Nathpa Jhakri power
corporation limited - NJPC) was incorporated on 24th may 1988 as a joint
venture of Govt. of India and Govt. of state Himachal Pradesh to plan,
investigate, organize, execute, operate and maintain Hydro- electric power
project. It owns and operates India’s largest Hydro Power Station 6*250
MW Nathpa Jhakri Hydro Power Station. The present authorized share
capital of SJVN Ltd. is Rs. 4500 crores which is under revision to Rs. 7000
crores. Different states to which the balance power is allocated are
Himachal Pradesh, Haryana, Jammu & Kashmir, Punjab, Rajasthan, Utter
Pradesh, Chandigarh and Delhi.
The approved cost of the project was Rs. 7666.31 crores with completion
cost of 8058.34 crores. On completion the project had cost Rs. 9083 crore

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The main components of this project are:
1. A 67.5 m high diversion dam on the Sutlej River.
2. An underground desalting complex.
3. A 27.4 m long head race tunnel.
4. A 301 m deep surge shaft.

5. Steel lined pressure shaft.

6. Underground power house and transformer hall.

Nathpa jhakri project salient features:

 It has a 62.50 m high concrete gravity dam at Nathpa village of Kinnaur

district of Himachal Pradesh and it divert 486 Cumecs of water through 4
power Intakes
 Underground Desilting chamber 4 Nos. each of 525m long, 16.31 m wide
and 27.50 m deep which is the largest underground complex for
desiltation of water in the World.
 A head race tunnel of 10.15 m dia. And 27.39km long which is the
longest power tunnel in the world and terminates to 21.6m/ 10.2m
diameter
 It has the deepest surge shaft which is 301m deep.
 There are three circular steel lined pressure shafts each of 4.9 m dia. and 571
m to 622 m length which feed six generating units.

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 The six generating units with Francis turbine of 250 MW and utilize a
design discharge of 405 cumecs and a design head of 428 m.
 The discharge tubes to the collection gallery for discharging the water
back into the river through the 10.15 m dia and 982 m long tail race
tunnel.
 The project has an underground Transformer hall and Power house.
There is a Surface Switch Yard for evacuation of power through two no.
of transmission lines.
 The project also has an interesting feature of Sholding Works
Complex which enable diversion of water of Sholding Stream into the
HRT.
 Annual energy generation of 6750.85 million units in a 90% (MU)
dependable year.
 This project has also pro idea direct and indirect employment by
various national and international contract agencies working on the
project.

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Other main features of the project:
Human resource development:
The company is having well established strategy for imparting training to
the employees and involves other professional people to motivate the
employees for good working. The training imparted is two dimensional i.e.
in house training and through external professional institutions as well.

Safety concern:
SJVNL abides by its moral responsibility for maintaining a safer environment
for all its employee and also these of its contracting agencies .Due attention is
given to health and safety aspects in working areas. The safety measures
adopted encompass the best codes and practices, which are disseminated to
all the employees for ensuring compliance at all levels.
Future project:
Agreement for the execution for the Rampur Hydro Electrical project
between SJVNL and govt. of Himachal Pradesh was signed on 20th October
2004 of 412 MW utilizing the tail race water of ongoing 1500MW Nathpa
Jhakri Hydro Electric Project is a run of the river scheme works for which
Nave already been commenced by SJVNL and other project in the state
H.P.viz. Khab and Luhari projects and in Uttranchal and Sikkim shell be
taken for execution.

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Some Planning and Design Aspect:

Cable Anchors: It was found that a large number of cable anchors of 200
tones capacity shall be needed in the dam complex. 285 cable anchor have
been provided for the excavation in the intake area. Another 185 have been
installed in the left bank of dam and road to the top of dam. 131 cable
anchors are being installed for stabilization of both the banks in the plunge
pool area extending from 90 m downstream of dam axis to 150 m
downstream of dam axis.

Reservoir Flushing: Sutlej River carries heavy sediment load during

snowmelt and monsoon season. Provision of low level sluices in the dam
ensures outflow of sediments from the reservoir whenever the water
availability is more that the design discharge. Further flushing of reservoir
behind Nathpa dam is also envies gad once or twice every year when the
discharge in the river exceed 1500 cumecs.

Desilting Cavern: The four desilting chambers are required to function

under adverse conditions of both external and internal water pressure.
Complete analysis both for the rock support during excavation and long term
stability during maintenance condition was carried out through numerical
modeling which involved through investigation based on field and
laboratory testing of rock mass properties and geological details of joints,
major shear planes etc.

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Head Race Tunnel:

Tunnel Lining In Hot Water:

Hot water has been encountered in the HRT downstream of Wadhal Adit
junction for a length of about 3 km. the chemical test of water has revealed that
it can be aggressive to normal concrete. Special precaution in concrete mix
design with use of pozzolana were taken to counteract the aggressiveness.

Steel Liner In HRT: Steel liner with length of 710 m and 375 m
respectively have been provided at Mangled and Daj creek of the head race
tunnel where rock covers are inadequate against maximum internal water
pressure which ranges from2.8 to3.1 MPa. With a view to avoid stress
relieving and limit the plate thickness to 40 mm the diameter of the steel
liner has been reduced to 8.5 m with transition both upstream and
downstream to 10.15 m di meter. In the absence of information of water able
in the hill full external pressure up to the natural surface has been taken in
the design of steel liner for the external water pressure.

Maintenance Access: Being a very long HRT it would be difficult to

inspect the same in case of emergency / shutdown. Keeping this point in
view intermediate vehicular accesses have been planned through Nathpa and
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Wadhal construction adits here steel doors in an opening in the concrete
plugs has been provided.

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DAM:

The function of the dam is not only to raise the water surface to
create artificial head but also to pro ide the Poundage. Storage and facility
For diversion into conduit. The dam is straight gravity type dam having
the height 62.5 m on Sutlej River at Nathpa to divert 405 cumecs of
water through four Intakes. The dam is most important part of the
Hydroelectric project. It is built of concrete or stone masonry on a rock hill.
The length of the dam at the top is 170.2 m consisting of 63 m as non over
flow structure and 88.2 m as sluice block section with each having the size 7
x 7.35 m with crest 1458.0 m.
Catchment area of the dam 49820 sq.km.
Design Flood 5660 cumecs.
Maximum water level 1495.50 m.
Minimum water level 1474.00 m.
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1) Selection Of Dam:
Selection of dam to be constructed at a particular site depends upon
topography, Foundation survey , soil condition and other characteristic
of the Location. The foundation of the dam must Be Sufficiently
strong to withstand the weight of the structure, water pressure etc.
without crushing , sliding or permitting movement of the structure .The
Foundation of the dam should be sufficient impervious so that there will be
no objectionable passage of water.

2) Spill Way Gates:

There are two spill way gates on the dam situated at Nathpa on Sutlej
River. These act as a safety valve. It discharges the overflow water to
outside the dam when reservoir is full. This condition arises during flood.
These gates can be opened and shut automatically when water overflows of
the level and closes when water reaches in the level.

3) Radial Gates:
There are five radial gates in the dam located in the lowest point of the
dam. Radial gates are always closed. They can be opened only in condition
when trees come in dam or reservoir due to flood. All these things can be
discharged through these gates. So radial gates can be opened in these
conditions.

4) Intake Gates:
Intake structure comprises of four intakes of about 500 m long these
inlets of river has been designed to handle a discharge of 846 cumecs.

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Intake gates are trash racks type. The suitable opening of 19.26 m * 15.7 m
at the start of the base is reduced to 6m*5.2m through a suitable transition. A
continuous skimmer wall with top at EL. 1468.73 m is made in front of all
the four intake gates to restrict the entry of sediments into the intakes. An
opening provided in the skimmer at the downstream end through which the
bigger sediments are flushed out. Through four intake gates the water goes
to desilting chamber.

5) Desilting Chambers:
An underground desilting arrangement comprising f four chambers is
made on the left bank of the river Sutlej to excel de silt particles down to
0.2 mm size from water. Before it enter head race tunnel. Four intakes has
been made to feed four chambers through each tunnel respectively. The
flow to the chambers is regulated by the gates at the intake. There are four
desilting chambers each have three meter wide collection trench in the
centre running along its length. The sediments from the collection trench
will fall down to the flushing tunnel 5m in diameter horse sluice. The
flushing gates will be provided at the junction of flushing conduits and main
flushing tunnel. Top of each chamber is connected to the head race tunnel
through link tunnel of diameter 5.02m. It reduces the flow of water and also
prevents the particle of 0.2 mm to the turbine. Here the water flows with a
velocity of 33.4 cm/sec.

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6) Silt Flushing Gates:
There are four silt flushing gates they create a pressure in the desilting

chamber and Suck out salt and particles at the edge of the desilting chamber .

7) HRT Intake Gates:

After desilting chamber water goes through HRT intake gates. They
are also four in no. The water at the output of each HRT intake gates are
combined to main head race tunnel. About 90 m to about
.1480canvas4umalongitslengththe head race tunnel is provided with steel lining
where the rock support is not expected.

Head Race Tunnel

The head race tunnel is 27.3 km long & have diameter 10.15m. it is
one of the largest Head Race Tunnels in the world. The tunnel diameter is
based on the techno economic studies for Dischargeof 405 cumecs at
a flow velocity 5m/sec The rock cover of head race tunnel vary from

There are six audits in the head race tunnel :

a) Nathpa Adit EL. 1450.89m.
b) Sholding Adit EL. 876 m.
c) Nugalsari Adit EL 647 m.
d) Wadhal Adit EL. 842 m.
e) Manglad Adit EL.691 m.
f) Rattanpur Adit EL.1357 m

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Sholding Works:
In order to augment the flow during the lean months of water scarcity the
water of the sholding khad one of the cribularies of Satluj river is having a
26m long tunnel that divert a discharge of 8 cumecs through a tunnel having
a diameter of 2m. from here the water will enter the hooper and desilting
chamber.

Surge Shaft:

The main surge shaft is located at the intake f the penstock at 27.3 km
form head race tunnel. It is just like wall. Its function is to avoid the water
hummer effect. Three penstocks are taken from the surge shaft at the
bottom , two from side of surge shaft and one is taken from the center of
the surge shaft. A 12 m dia Horse shoe shaped 185m long lower gallery
at EL 1370m has also been provided. The minimum water level in the
surge shaft is about 30 m The surge shaft is concrete lined of adequate
thickness. It is the deepest surge shaft in the world.
Three drainage galleries at different elevations has been Provided
around the surge Shaft to relieve the external water pressure on the lining.
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 Pressure Shaft:
Three shafts of diameter 4.9m and length varying from 619m to 660m take off
from the surge to an angle of 45 degree to the horizontal. These are lined with
high tensile steel of thickness varying from 32mm to 60mm. Each pressure
shaft is bifurcated into the branch tunnel of dia 3.45 m. Each pressure shaft is
designed to carry a discharge of 315 cumecs . Butterfly valve housed in valve
chamber has been constructed in the horizontal reach of pressure shaft for its
repair and maintenance. A spherical valve has been provided in each penstock
branch tunnel inside the machine hall cavern to enable closing of penstocks
whenever required.

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Other features of surge shaft:
a) Pressure relief valves has been provided in the top 80 m of the

concrete lining to reduce the external pressure e as an additional

margin.

b) A 25 cm deep sill beam has been provided on the collar of the surge
shaft to prevent any trash lying on the pond floor.
c) The slopes of the top pond are well drained. The drainage water is
disposed of very far away from the pond.
d) Due to very high head difficulty in maintaining verticality of
guide rails, stop logs could not be provided in the surge shaft.
e) An inspection ladder has been provided in the connecting shaft
forming approach to the drainage galleries.

Valve Assembly:
The valve assembly consists of a top and bottom valve body and a
double lattice valve disc assembly with all necessary seals, bearings and
seats. A valve chamber 79.52 m long 9.5 m wide and 22.34 m high has been
excavated 106 m downstream of the surge shaft essentially in quartz mica
schist.

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Valve Body:
The valve body is manufactured in cast steel and are flanged on both
sides. The top and bottom sections are assembled with an ‘O’ ring seal
An
d locilite 574 between faces and located with stainless steel dowels.
The valve incorporate support feed fabricated with the valve body to
available the valve to secured to the foundation by the use of soleplates.

Valve Seat:
Two valve seats are fitted within the valve body to form seal with each
disc seal on the lattice blade with valve in the closed position. During
normal operation the Downstream forms the water seal. The downstream is
machined with the ‘O’ ring seal located groove. A Nitrile rubber ’O’ ring
seal is assembled in the groove and prevent leakage b/w the valve ring and
seat ring.

Maintenance Seal:
The purpose of the guard wall maintenance seal is to provide a double
isolation when used in conjunction the service seal. The principle of double
isolation is essential whenever personnel are required to enter the
downstream – dewatered penstock. The upstream and downstream chambers
formed between the seat ring and the valve body are connected by drilling to
a penstock pressure water control system.

Air Release Valve:

Fitted on the top of the valve body is a orifice air release valve, operated
by a float. The valve release air to atmosphere during fitting of

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the valve body and when full of water seals the orifice to prevent leakage.
Most of the air trapped during penstock filling will be released via the four
anti vacuum valves. When all four anti vacuum valves are closed all
remaining trapped air is released via these valves operated by a float.

Anti-Vacuum Valve Assembly:

Four Anti-Vacuum valves are fitted and two on each side of the
downstream pipe works. The 500mm nominal diameter float operated anti
vacuum valves sense the pressure drop downstream of the penstock guards
valve and open and allow air into the penstock preventing the formation of
vacuum. When the chamber is filled with water the float rises extending the
springs and contacts the Nitrile rubber sealing ring

POWER HOUSE:

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Nathpa Jhakri project has underground power house With

internal dimensions 222 m* 20 m and 29 m high located at 200 m

below the natural earth level . The main access tunnel to the power house
is 731.5 m long .The power house has an arched roof with concrete lining.
The main inlet valve has also been provided at An EL. 982.5

The power house has four floors:

The turbine floor is at an EL. 990 m . The main auxiliaries in this floor
are Governor , Oil cooler , Brake Dust Collector , Oil Vapour
Collector , Secondary water pump and the turbine pit . The turbine is
coupled with Generator with the help of the shaft.

The generator floor is at an EL. Of 995 m here we also have Unit

Auxiliary Board, Temperature measuring gauges, the Excitation
Transformer for providing the Starting torque to start the generator and the
220 V battery room.

Service Bay Floor at an EL. Of 1000.5m from he e the functioning of

generating units is controlled with the help of operating system .

MIV Floor is the lowermost floor of the power house. It contain six
individual MIVs, each weighing 92 tones and being controlled by the lifting
of a counter weight 76 tones by means of a servomotor which is operated
hydraulically.

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 The construction um downstream Surge gallery is provided to reach
the tail race and to facilitate the excavation of the machine hall , the tail race
and pressure shaft.

Block diagram of power station

Turbine: The Turbine used here is the “VERTICAL FRANCIS TURBINE”

means the rotating parts of the it have a vertical axis of rotation.
This turbine belongs to the reaction turbine family. The water is under
pressure as it enter the runner and completely fills all its channel as it

passes through . The head for the Francis turbine is usually between
that of Kaplan ( low head ) turbines and that of Pelton (high head)
turbines.

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TURBINE FUNCTION:
The water from the penstock enter the spiral casing. In the spiral casing , the
water is spread around the whole circumference by stay vanes , and is lead in
towards the guide apparatus. The guide apparatus has
movable vanes , which are controlled by the governor and can be set
independent of output After this impact the water continues in the Draft
Tube and out the tail race tunnel. The effect is transferred from the Runner
to the Generator, which is directly connected to the Turbine Shaft. The
turbine develops the power partly due to the velocity of the water and due
to difference in pressure acting on the front and back of Runner buckets such
a Turbine essentially consist of guide apparatus consisting of outer ring of
stationary guide blades fixed to the casing of turbine and an inner ring
consist of rotating blade forming a wheel or a Runner. As the water passes
over the rotating blades of the Runner both pressure and velocity of the
water reduced causing a reaction force on the turbine. The guide blades of
the turbine are pivoted about axis an parallel with turbine axis so that
quantity of the water entering in the turbine may be regulated by turning
them simultaneously in one direction or the other, their motion is
automatically controlled by Governor. Francis type turbines can be
constructed in vertical or horizontally but horizontal construction more
accessible and have higher speed, but for large machine vertical construction
is preferred to effect higher speed. As compare to Pelton wheel a Francis
turbine offer advantage of high efficiency at full load and at 75% of full load
. This turbine can be designed for higher speed than Pelton Wheel .The gross
head of the turbine is 488m and design head is 425m.

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TURBINE COMPONENTS:
1) Rotating parts.
2) Turbine guide bearings.
3) Turbine upper and lower cover.
4) Guide vanes
5) Governor (Regulating mechanism).
6) Spiral casing.
7) Draft tube.
8) Shaft seal.
9) Dewatering system.
1.) ROTATING PARTS:
There are mainly three rotating parts:
a) Runner.
b) Turbine shaft.
c) Oil slinger.

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a) Runner:
The Runner has been welded up from crown and band of stainless
cast steel to Vanes from stainless steel plates. The vanes have been
machine worked. The crown band have “Roots” towards the vanes. Air
for stabilizing purpose is allowed through the Runner center via the
shaft seal and drilled holes in the turbine shaft flange. The moment of
force on the runner is transferred to the turbine shaft through the
Shear pin connection. The coupling bolts between the turbine shaft
flange and the Runner are tensioned by means of Hydraulic
wrence.

b) Turbine Shaft:
The turbine shaft is made of SM steel with flanges hammered out
at both ends. The turbine shaft and generator shaft are connected by
flanges. The connection primarily transfer the moment of force through
the shear studs.

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 Francis Turbine Runner

c) Oil Slinger:
The Oil slinger is located below the turbine bearing and
connected to the turbine shaft. Its purpose is to collect the oil from turbine
bearing and during operation bring the oil into rotation inside the slinger
cylinder from here it is catches by the oil scraper and led to the oil cooler
and the bearing oil reservoir.

2.) Turbine Bearing:

Bearing Design:
The turbine bearing is radial vertical slide guide bearing. The
bearing has a strong construction and a simple manner of operation, which
require a minimum of maintenance. The bearing house is split and attached
to the upper turbine cover. It has two manhole hatches for access and

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inspection of shaft seal and pipe connections. The bearing shell consist of
two segments, which are bolted together and attached to the upper side
of the bearing house. The shell has four oil pockets and four babbit metal
Surfaces with machined wedge shaped entrances , which ensure a stable
centering of the turbine shaft. The bearing has been fitted with an
inspection hatch ,dip stuck for oil slinger, Fluid level gauge for bearing
house, thermometers and level switches for surveillance. The bearing has
been fitted with external oil cooler. This is automatically put into Operation
when the cooling water system is started.

Bearing Function:
When the unit starts the oil slinger start rotating , oil is slung up
into the cylinder section and cover the vertical with a layer of oil. The
thickness of this layer will be determined by the position of the oil scraper.
The amount of the oil in the oil slinger is regulated by means of the oil
scraper, which is attached to the bearing shell When there is a sufficient
rotating speed , the damming up pressure become strong enough to force the
oil up through the ascending pipe through the oil cooler and out into the
bearing house. From there the oil flows down through the four windows in
the bearing house cover and is spread out to the four oil pockets in the
bearing shell. A film of oil follow with the shaft in the wedge shaped
entrance on the bearing shell and builds up the guiding oil layer.

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3.) Turbine Covers:
Upper Cover: The upper cover is bolted to the spiral casing ring. It serves
as a bearing for the regulating ring and a support for the upper stationary
labyrinth seal, turbine inner cover with shaft seal as well for the longest
trunnion of the guide vanes. The interchangeable upper stationary labyrinth
seal is made of forged steel and is bolted to the cover. The seal surface on
the labyrinth seal faces the equivalent seal surface on the upper rotating
labyrinth seal bolted to the Runner.

Lower cover: The lower turbine cover is bolted to the spiral casing stay

ring. It serves as a support for the short tur nnion of the guide vanes, the
lower stationary labyrinth seal and the draft tube cover. Supporting
sleeves of Aluminum Bronze for guide bearing have been installed.
Corrosion resistant austenite steel has been welded into the wearing
Psurface of the lower turbine cover between the wear ring and the lower
labyrinth seal.

4.) Governor:
The Turbine has two servomotors. The connection between the
servomotor and the regulating ring consist of an adjustable connecting rod
and a spherical bearing. It sense the speed of the turbine rotation and
generate a signal proportional to the difference between the turbine speed
and the governor speed reference and therefore develop a hydraulic
control signal sufficient to control the turbine. The adjustable rod is used
for pre tensioning the guide apparatus.

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 When pre tensioning the guide apparatus the guide vanes
are given a Moment which produces a force toward closed
position. This compensate for slackening and deformation in the lever
and link connection and provides a closing force greater than or
approximately equal to hydraulic opening force on the openings
force on the vanes with full pressure in the spiral casing.

5.) Spiral Casing:

The spiral casing the waterway between the penstock and the guide
apparatus. It has been constructed to ensure constant water speed

around the whole Circumference of the guide apparatus. The spiral casing
is built from a stay ring and plate shell to an all welded construction of
fine grained sheet steel .The spiral ring is consisting of an upper and lower
ring connected to each other by welded stay. The stays has been shaped
in a hydraulically Favorable w y in order to lead the water in towards
the guide apparatus with the least possible loss.
Spiral casing Has been fitted with outlets for Index
measurements and a manhole for inspection. The outlets for pressure

measurements , watering & air escape are positioned on the expansion

box at the inlet of the spiral casing . The main part of the spiral casing has
been concreted in a solid slab being supported against the downstream
rock wall. The hydraulic force acting on the spiral casing inlet is thereby
balanced against the rock.

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 Spiral casing
6.) Draft Tube:
The outlet consist of a draft tube and a draft tube steel lining
continuing with a concrete lined tunnel and forms the water way from
the runner to the Race Channel. The draft tube cone is welded and
consist of two parts. The upper part is bolted to the lower fixed
labyrinth seal. It is made from stainless steel. The lower part is attached
to the draft tube steel lining with a flexible flange connection. It has One
manhole for access to the draft tube and it is fitted with four stub pipes
with cover for installation of an inspection platform. The draft tube
steel liner is completely set in concrete. It has been welded and fitted
with a flange toward the draft tube cone. The draft tube can be

26
emptied into the dewatering pit by slight extension of the cross section in the
direction of the flow from the runner outlet to the end of the plate covering.
The draft tube have 10 segments with a plate thickness of 30 mm and total
wt.34000kg.

7.) Shaft Seal :

Shaft seal is attached to the inner cover , which is attached
to the upper turbine cover. Due to the rotation f the water in the gap
between the runner and the upper turbine cover the gaps in the shaft seal

will be water free when the turbine is in operation. In order to prevent

the contaminated water downstream of the turbine to enter past the
upper labyrinth seals and up through the shaft seal during start and stop
of the unit. When the shaft has come to complete standstill the service
seal will be closed , valves in drainage and overflow pipes will be
automatically closed and flushing water pump stopped. At certain output the
turbine may need air to the outlet section of the runner. This ventilation take
place through a separate air pipe, which is connected to the shaft seal
support ring. The air pipe is fitted with a check value preventing the tail
water from leaking out during standstill.

8.) Shaft Seal Flushing Water:

In order to prevent the contaminated water from entering into the shaft
seal during start and stop sequence of the unit and when rotating speed is too
low to keep the shaft seal dry , the shaft seal flushing water system will
provide filtered water at sufficient water. The intake is

27
from the pressure equalizing piping between upper turbine cover and draft
tube. A centrifugal pump is increasing the pressure and flushing strainer
particles above 200 micron is removed. The system will automatically be put
into operation during start and stop of the unit.

9.) Penstock Dewatering System:

The dewatering system consists of one high pressure drainpipe for
each unit. The inlet is upstream the MIV and the system consist of a gate
valve and a hand manufactured needle valve. Dewate ing is made from the
penstock to the draft tube down to the tail water level. After setting the draft
tube gate the remaining water is drained through the draft tube to the
dewatering pit from where it is pumped to discharge outside the draft tube
gate by dewatering system.
The movement of MIV is shown in the fig. below:

MIV in Closed Position

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 MIV fully opened

10.) Guide Apparatus:

The Governors action on the Two main servomotors is
transferred via rod connections to the regulating ring . The actual
guide apparatus consists of 23 guide vanes, check plates on upper and
lower turbine cover as well as guide vane lever and links.
The guide vanes are made of forged stainless steel and had
been shaped to provide the best possible hydraulic conditions. The guide
vanes have bearings on upper and lower turbine covers . These are self
lubricating slide bearings with Teflon covering. The coupling between
guide vane and guide vane lever is a pure friction coupling, thus
allowing the guide vane to slide away in case of foreign object is

29
 preventing the guide vane from being closed. An alarm in that case will be
activated. The guide vane lever and regulating ring is connected by links.
The links are joined by self - lubricating bushing on stainless steel pins
attached to the regulating ring and the guide vane lever respectively.
The guide vane movement is shown in the fig.

0% OPEN

30
 100% OPEN

GENERATOR:
The vertically mounted synchronous generator converts The
hydraulic energy of H2O into electrical energy. The generator will be
vertical shaft type having salient poles with closed air circuit ventilation
and suitable for coupling to a machine turbine.
It will have static excitation system energizing the field coils. The
slip rings, Permanent magnet generator and mechanical over speed
device will be located suitably on a fabricated shaft, which in turn will be
fitted to a rotor spider. The speed of the turbine wheel must therefore
match the synchronous speed of the generator.
The generator will have a combined thrust and guide bearing below the rotor. The
generator will have the rating and characteristic as the components will be
designed to withstand seismic forces as applicable.

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Generator Components :
The generator consist of following components-
1. Foundation
2. Stator
3. Rotor
4. Air water cooling system
5. Slip ring system
6. Excitation
7. Bearing
8. Braking and lifting equipment

1) Stator : The rotor winding is excited by a direct current

and induces a voltage in the stator winding. This is taken by Bus bar to the
main current lines. The stator consist of the Frame , Laminated stator core
and the stator winding embedded in the slots of the laminated core.

HOUSING – Depending upon the operating condition of the machine, the

generator housing absorb the generated mechanical loading and transfer
these to the foundations.

32
 Generator components

STATOR FRAME – The stator frame will be build up of weld able steel
plates and will have adequate depth to prevent distortion during transport or
under any operating condition.

STATOR CORE -- The stator core will be built of stamping of high grade ,
non aging cold rolled silicon alloy with varnished insulation on both sides.
The segments will be secured to the frame by dovetail notches engaging
with corresponding dovetail key bars welded to stator frame.

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ANTI CONDENSATION HEATERS – Low temperature to prevent,
condensation on the winding during period of shut down will be mounted
below the winding located below lower air guide. They are of tubular or box
type construction consisting of a coiled resistant wire embedded in an
electrically insulting and heat conducting compound and protected with a
metal sheath.

Air-Water Cooling:
The mechanical and electrical losses arising in the course of
operation of the and the temperature rise of this part cause
must be reduced by cooling. generator rotor and stator are air cooled ,
while the bearings are water cooled.
The generator has a closed cooling circuit and is therefore sealed off on
all sides against the surrounding surface. The foundation walls from the
enclosure from the machine house, and the outer cover separates the
generator from the turbine room. The enclosure at the circumference is
provided by the generator pit. The cooling air enters tangentially through the
rotor and enters the stator through the gaps. The air water coolers arranged
after the stator removes the heat that the air has absorbed.

2) Rotor :
The rotor and rotor winding are excited with the direct current,
and generate a constant magnetic field. The rotational movement at the
specified synchronous speed induces a sinusoidal alternating current voltage
in all phases of the stator winding. The rotor will be designed to safety
withstand all mechanical stresses imposed by the maximum runway speed.
The static and dynamic balancing of the rotor will be carried

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out , as a part of precommissioning test at site and values of rotor vibrations
will be kept with in allowable limits according to satnderds.

The rotor consist of following components;

1) Shaft NDE
2) Pole wheel
3) Slip ring
4) Hub
5) Yoke ring
6) Long pole
7) Brake ring
8) Current feed
9) Pole body
10) Pole and plate
11) Pole winding
12) Damper winding
13) Pole body insulator
14) Shaft DE

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4) Slip Ring And Brush Gear :
The collector will be of mild steel and mounted on the top of

the generator tube shaft.The brush gear for the collector will be
mounted on insulated studs supported on the top bracket and will be
arranged to permit convenient access for maintenance and inspection.
The insulation for slip rings and their connections will be non-
hygroscopic and oil resistant. The slip ring system transfer the Direct
current necessary for excitation of the rotor from the fixed brushes to the
slip ring and thus to the rotor poles.

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5) Bearings :
The two different bearings are attached to the rotor i.e. Guide
bearing and Thrust bearing. The thrust bearing must take up the entire
weight of the rotating components of the machine set (rotor and turbine) and
axial thrust of the hydraulic machine. Both journal bearing together with
turbine journal bearing ensure a centered machine run from the standstill up
to the runway speed of the turbine.

Thrust Bearing : Thrust bearing is of pivoted segmental pad type in which

the stationary parts consist of a set of Babbit segmental pad supported on
circular pad supports made of alloy steel forgings. The bearing is self
lubricated and immersed in oil bath in which plugged n type of water cooled
oil coolers are placed to remove the bearing losses. Radial and
circumferential movement of the pads is prevented by means of stoppers.

Thrust bearing

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 Guide Bearing : The guide bearing will be of the pivoted pad type
consists of arrow of white metal pads arranged in a support ring to bear
on a journal surface. A pivot bar will be bolted to the back of each Guide
pad to enable the pad to rock slightly to take up a suitable position and
facilitate formation of oil film when running. The air surface above the
oil surface will be vented to the atmosphere by vapor pipes and air
pressurized oil vapor seal will be fitted to prevent the escape of oil vapor
into the generator air circuit.

MAIN ELECTRICAL EQUIPMENTS :

1) Synchronous Machine (Gener ator) :

It is a three phase double excited machine because its field winding
is energized form a dc source d its armature winding is connected to an
ac source. Its working as generator delivers or exports ac power. A

synchronous generator is canvas4universallyemployedufor the generation of three-

phase power at all generating stations. Most of the synchronous motors are
of silent pole type as it is most suitable for the slow speed water turbine
generators and are called Hydrogenates. There are six generators in the
power house each having 250 MW capacity and driven by speed of 300 rpm.
Each generator is having 96 brushes in which 48 are positive and 48 are
negative. There are two slip rings one is positive and other is negative. The
slip ring give excitation Current to rotor through brushes according to load.

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Generator specification:
Rated speed 300 rpm
Turbine Rated Head 428 m
Rated output 250 MW
Rated Output (Generator) 278 MVA
Power Factor 0.9
Terminal Voltage 15.75 KV
Manufactured By ALSTOM / GERMANY

2) Excitation System:
In large synchronous machinecanvas4uthefieldwindingis always provided

on the rotor. Some important excitation systems are :

DC Exciters : This is old conventional method of exciting the

field winding of synchronous generator. Here three machines pilot exciter,
main exciter and three phase alternator are mechanically coupled and
therefore driven by the same shaft. The pilot exciter feed the field winding
of the main exciter. The dc output from the main exciter is given to the
An
field winding of the main alternator through brushes d slip rings. The
conventional method of excitation suffers From cooling and
maintenance problem as associated with the slip ring, brushes and
commutators as the alternator rating rise. This trend led to the
development of the static excitation and brushes excitation system.

Static Excitation: Here the excitation voltage for the main alternator
field is drawn from output terminal of the main 3- phase alternator. For this
purpose a three phase transformer TR step down the alternator voltage to the
desired value. This three phase voltage is fed to the

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3-phase full converter bridge using thyristors. The power output from the
thyristor is delivered to the field winding of the main alternator through
brushes and slip rings. For initiating the process of static excitation first of
all field winding is switched on to the station battery bank to establish the
field current in alternator. The alternator aped is adjusted to the rated speed.

3) Braking and Jacking System :

The generator brakes will consist of a number of steel shoes

mounted on a vertical piston moving in cylinder and will operate against

a polished circular steel brake track located on underside of rotor. Brakes
will be automatically applied when the peed of the rotor reduce to a
preset value and will remain applied continuously so that the unit stops
completely.
The brakes will also serve convenient means For jacking the
rotor for maintenance purpose for this complete hydraulic rotor jacking
unit will be provided. Limit switch is provided Which shows the
indication that the Rotor is raised to maximum permissible limit. The
arrangement of piping will be such that after jacking system has been in use
air under pressure can be applied to the system to clear the pipes of oil.

4) Brake Dust Collector :

The brake dust collector consists of an extraction unit, hoppers around
brake assembly for trapping the brake dust and flexible hoses for connecting
hoppers to the extraction unit. The extraction unit will have a

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motor driven exhaust fan and will be fitted with an easily removable sheet
steel bin for collecting heavy dust. The lighter air born particles will be
collected by a suitable fabric based filter. The starter panel for motor having
provision for automatic start and stop of the motor will also be provided.

5) Oil Vapor System:

The oil vapor extraction system sucks of the vapor of generator
bearing. This oil vapor is generated during operation and led to the filters
outside the generator room. The pollution of the machine is this way
avoided.

General:
As soon as the generator starts running with the operating
temperature , the oily fog I developed in the bearing oil container by
very finally Distributed oil drops . “Breathing” the oil in bearing or
pressure differences inside and outside the bearing cause the oil vapor, a

mixture of air and oil that produces a different wetting of the parts and
surfaces at the outside. These damp places result in providing an ideal
background for dirt beginnings . During high speed of rotor or high
load the differential pressure increases also between the bearing
chambers and the environment. In this case the bearing seal and shaft oil
separators cannot hold back the oil mist any longer. To prevent this then
generator was equipped with a special oil vapor suction system.

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Design And Function:
Two pipelines are attached parallel above at the upper and lower
bearing chamber. The two pipes are led outward to the two suction filters.
The particles separated by the filter run off on the inside of the separation
pipe. The ventilator for the production of suction flow is inserted above the
separation pipe within the clean air side. An activated Carbon filter is
mounted behind the electrostatic unit to absorb smells and gases. Cleaned air
is blown by the activated carbon filter into the open air.

TRANSFORMERS
The Transformers used are manufactured by BHEL.The various
specifications of the transformers are given below:

TRANSFORMER SPECIFICATIONS

Make Bharat Heavy Electrical Limited

Types of cooling ODWF(oil drift water force)
Rating HV & IV (MVA) 102
Rating LV (MVA) 102
No load voltage HV (KV) 420/√3
No load voltage LV (KV) 15.75
Line current HV (AMPS) 421
Line current LV (AMPS) 6476
Temperature Rise oil (OC) 55(deg)
Temperature Rise windings 65(deg)

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Phase 1(single)
Frequency HZ 50 Hz
Connection Symbol YNd 11

PARTS OF TRANSFORMER:

1) CONSERVATOR
It is used generally to conserve the insulating property of the oil from
deterioration and protect the transformer against failure on account of bad
quality of oil. It is a small tank mounted on main tank and the two are
connected by a pipe. The main tank is completely filled with oil but
conservator tank is partially filled with oil. Its function is to allow space for
expansion of oil due to heating and contraction due to cooling of oil

2) SILICA GEL DEHYDERATING BREATHER

The breather is used to prevent entry of moisture inside the
transformer tank. The breather consists of silicagel. When air is taken in or
out of the transformer due to contraction or expansion of oil in the tank,the
silicagel absorbs moisture and allows the air free from moisture and allows
the air free from moisture to enter the transformer.

3) BUCHHOLZ RELAY
It is a gas-actuated relay used for protecting oil immersed transformers
against all types of faults. It indicates presence of gases in case of some
minor fault and takes out the transformer out of circuit in case of serious
fault.

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 4) BUSHINGS
Bushings are made from highly insulating material to insulate and to
bringout the terminals of the transformer from the container.

5) OIL GAUGE
Every transformer is provided with an oil gauge to indicate the oil
level.

6) TAPPINGS
The transformers are usually provided with few tapings on secondary
side so that output voltage be varied for constant input voltage.

7) RADIATORS: The radiators increase the surface area of the tank and more
heat is thus radiated in less time. It is generally used in large capacity
transformer.

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 8) NON RETURNING VALVE (NRV)
It is used here air is produced and is stored in compressor. It is
between compressor and air producer. It means that air is not returned back
when it reaches in the NVR.

9) OLTC
It is known as On Load Tap Changer. If the supply from the previous
sub-station is coming according to the requirement and less than the required
supply OLTC is used to increase the supply to level of load.

10) WINDING TEMPERATURE INDICATOR:

It is a device which indicate the temperature of winding of transformer
and possible damage to the transformer due to overload can be prevented.
The sensing bulb of dial thermometer is inserted inside the heating coil the
terminal of heating coil are connected to temperature gauge.

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 REFERANCES

 Technical Diary of SJVN Limited.

 Bansal, RK(2010). A textbook of fluid mechanics and hydraulic
mechanics(Revised ninth ed.)
 Chapman, Stephen J.2005. Electric Machinery Fundamentals. 4th Ed. New
York: McGraw Hill.

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