SALAL POWER STATION

SUMMER TRAINING REPORT POWER STATION

Submitted by:

AKASH KUMAR

SALAL POWER STATION (A UNIT OF NHPC)

B.TECH (ELECTRICAL ENGINEERING) JAIPUR NATIONAL UNIVERSITY , JAIPUR

INTRODUCTION
1.1 Salal Power Station A Profile
Salal Power Station located across the river Chenab in the State of Jammu and Kashmir is having an installed capacity of 690 MW with six generating units each of 115 MW. It is a run of the river scheme commissioned in two stages. Stage-I with 3 x 115 MW was commissioned in 1987, and stage-II with 3 x 115 MW was added later on during 1993-95 to utilize the surplus inflow available during the months from April to Sept. All the 6 units came into operation as follows: Unit I,II,III Unit IV Unit V Unit VI Nov.87 March93 May94 Feb.95

One rock fill dam, 118 meter high and 630 meter long and one concrete dam 113 meter high and 486 meter long have been constructed around a loop of the river at Dhyangarh. The spill portion consists of 12 nos. of radial gates of size 9.322m x 15.240m.The water is fed to the hydro turbine through six penstock of diameter 5.23 m (One for each machine) and 279 m long. After generation, water is discharge to the river through two nos. tail race tunnels of length 2.43 Km and 2.53 Km. The voltage level of generated power is 11 KV which is further stepped up to 220KV through 11/220KV, 43.33MVA bank of 3nos. single phase transformers. 220 KV switchyard is located adjacent to the power house on a filled platform and linked with generator transformer through lines supported on suitable tower structure. To evacuate power , 6nos. 220 KV feeders ( two nos. 220KV, single circuit Salal-Jammu lines, and 2nos. 220KV, double circuit salal - Kishenpur lines have been constructed from switchyard.

SALIENT FEATURES OF THE PROJECT

2.1

Location of project
Site Tehsil District State River Design Energy Dhyangarh Reasi Reasi Jammu & Kashmir Chenab 3100 MU

2.2

Date of commissioning
Stage-I Unit-I Unit-II Unit-III Stage-II Unit-IV Unit-V Unit-VI 09/11/1987 14/11/1987 20 /11/1987 31/3/1993 29/9/1994 23/2/1995 21497 sq Km. 11895 Cumecs 91 Cumecs 22427 cumecs

2.3

Hydrology
Catchment area Observed Max. Flood Observed Min winter flow Mean annual runoff at dam site

2.4

Diversion Tunnel
Length Upto outlet portal Upto Outfall point Diameter Discharge capacity 180.44 M 198.732 M 9.144 M 1400 Cumecs

2.5

Dam
Rockfill Dam Top width Max. height Length at top Normal reservoir level Deepest foundation level 10 M 118 M 630 M 487.68 M 378.78 M

Submerged area at EL 487.68 M Top elevation

9.35 Sq. Km 496.83m 113 m 450 m 487.68 m 494.08 m 220 m 105 m 125 m 22500 cumecs 12 Radial 491.91 m 383.0 m 6 3.35 m x 4.57 m Radial 12 sets 15.24m*9.33 m 90 MT 9.322 m 478.358 m 478.68m 487.680m 490.080 m Under unbalanced condition 12 sets multiple rope drums driven by an electric motor 12.39m 500 mm/min. M/s TEXMACO

2.6

Concrete Dam
Max. height Length at top Full reservoir level Max. water level Length of spillway Length of power section Length of non overflow section Spillway design discharge No. of spillway bays Type of gate Top elevation Deepest foundation level No. of river sluices Size of river sluices

2.7

Spillway radial gate

Type No. of gates Size Gate weight Design head Sill elevation Crest elevation Full reservoir level MWL Gate operation Type of hoist/capacity Height of lift Raising/lowering speed Make

2.8

Spillway stop log & lifting beam

Type Clear opening Clear height * For 5 Nos. interchangeable units * For 1 Nos. interchangeable units Weight of stop logs * For interchangeable units Wheeled stop-log 15.24 m 1.73 m 1.684 m 17 MT(approx.)

* For Non-Interchangeable Control method

20 MT(approx.) By gantry crane and lifting beam Main-85 Tonne Auxiliary-20 Tonne 27.5m 84.5m 3 m/min. 4 m/min. 5 m/min. 270 Meters (approx.) 3.352m*4.572m 416.052m 420.624m 426.11m Teflon cladded stem type 75 T Double acting hydraulic cylinder type 0.475 m/min 10 min. 100 kg/cm2 426.11 m 5592m*7620 m Vertical sliding type 6392 mm 6 5792

2.9

Spillway gantry crane

Hoist capacity Span Lift * Main * Auxiliary Speed * Main hoist * Auxiliary hoist * Cross traverse Crane travel

2.10

Sluice gates and hoist

Size Gate sill elevation Top seal Bonnet cover Seal Hoist capacity Type Lifting speed * Lower speed Lifting/Lowering time Working pressure Floor level of hoist chamber

2.11

Sluice stop log

Size of gate/vent Type of gate Slide track c/c No. of elements Side seal c/c

Sill to top seal centre Head over sill

7898 mm 80 m

2.12

Silt excluder gates and hoists

Service gate * No of gates. * Size of gates * Type * Sill elevation * Top seal level * Bonnet cover level * No of gates. * Size of gates * Type * Sill elevation * Top seal level * Bonnet cover level Hoist * Capacity * Type Lifting speed * Lower speed * Stroke * Working pressure * Test pressure * Operating fluid * Max. gate travel Power pack 6 2.0m*3.0m Fixed wheel 462 465 469 6 2.0m x 3.0m Fixed wheel 462 465 469 35 T double acting hydraulic hoist 0.5m/min. 0.5m/min. 3.6m 100 kg/cm2 240 Kg/cm2 20 c servo system 32 3.6m

* Make * Type * Motor * Manual pump

Hoerbiger hydraulic, Germany H-400 7.5kw, 1450rpm,3*415v, 50Hhz PM 50 6 5.23 m 279 m each

2.13

Penstocks
* No. * Diameter * Length * Intake level Penstock intake gates * Type * Vent size * No. of gates * Central height from gate sill * Wt. Of complete gate assembly * Design head * Initial seal compression Hoist * Make * Type * Lift/Gross stroke * Hoist capacity * Design pressure * Normal lifting speed & lowering speed * Emergency lowering speed * Operating oil Vertical(Lift fixed wheel type) 4.188m*5.358m(clear opening) 6 5.408m 17000 Kg 17.459m 4mm Riva calzoni, Italy Telescopic single acting 6500mm 53 Tones 100 kg/cm2
1m/min

8.25 m/min (adjustable) 10 c's servo system 32 2 2.463 Km

2.14

Tail race tunnel

Number Length Stage-1

Stage-2 Shape Diameter Design discharge Velocity

2.523 Km Horse shoe 11m 412 cumecs 4.2 m/s

TURBINE
3.1 Introduction
The vertical Francis type hydro turbine with its center line located at EL 380.00m is directly coupled with three phase, 50Hz, 127.8 MVA suspension type hydro generator. The Hydro turbine equipment is automatic controlled but provision has been made for manual control as well. The turbine comprises of following parts: 1) Embedded parts 2) Spiral casing and stay rings and pit liner. 3) Draft tube 4) Runner with 14 blades 5) Guide apparatus with 24 guide vanes and 2 servomotors. 6) Turbine shaft 7) Guide bearing with babbit segments and oil lubrication. 8) Governor 9) Shaft sealing system 10) Oil pressure unit 11) Oil cooler 12) Measuring instruments 13) Pressure relief valve. 3.1.1 FOUNDATION PARTS OF THE TURBINE: Stay ring: The stay ring is of cast welded construction, consisting of upper and lower rims fabricated from mild steel and connected together with eleven streamlined cast low alloy steel stay vanes and one mild steel fabricated tooth of the spiral casing. Suitable holes in the upper flange of the staying have been provided for draining the trapped water between pit liner and top cover. The stay ring has been made in two parts joined together at site with nuts and bolts. Suitable wedges, foundation bolts, and anchors have been provided in the stay ring for leveling and proper securing in concrete. Spiral Casing: This has been designed to provide uniform flow to the runner .It consists of several round and elliptical segments of different thickness provided in accordance with the water path and strength requirements. A manhole is provided in the reducer piece through which guide vanes can be taken out. Felt packing is provided on the top surface of the spiral casing to prevent transfer of load from the concrete above.

Pit Liner: This starts from above the spiral casing to the turbine floor. Vertical and horizontal rings have been provided for rigidity. Pit Liner includes CGL distributors fixed on to it.

3.1.2 Embedded Parts:

Draft tube knee lining: The DT lining is in 5 Parts. These parts were welded together during installation after clamping with bolts. Anchor plates and tie rods have been provided for rigid holding to the concrete, leveling bolts have also been provided at the base for leveling during erection. Outer surface of the knee is ribbed for rigidity. Foundation ring assembly: This forms the upper part of the conical portion of the DT. It consists of the foundation ring and conjugating belt in parts. The upper part of foundation is made of mild steel and portion after the runner exit is fabricated from Stainless steel plates to minimize the effect of cavitations in this portion of the DT. It is supported on the lower belt of the stay ring. The segments of the conjugating belt are welded on one side to foundation ring and on the other side to the DT cone. Draft tube cone: This forms the lower part of the conical portion of the draft tube, has been fabricated from mild steel plates. The cone is welded to the knee lining .two rectangular holes have been provided in the cone for facilitating erection of the platform in the DT for repairs and inspection. An inspection plug has been provided in the manhole cover to ensure that before opening the cover that the water level in the DT is below the level of the manhole. The external surface of the cone is provided with vertical and horizontal ribs for rigidity. Anchors have been provided for its proper bondage with the concrete. Drainage valve: This valve is located in the block out provided in the concrete portion of the of the DT. The bottom of the block out has been provided at a lower level than the bottom level of the DT for its complete dewatering. The valve is operated manually with the help of a hand wheel and spindle arrangement. The valve allows the water from DT to flow through an embedded pipe (dia 273 mm) to DT drainage gallery. 3.1.3 GUIDE APPARATUS: Guide apparatus regulates the flow of water through turbine for various conditions of load and head. It also serves as a closing device for turbine during normal and emergency conditions. It consists of guide vanes, turning mechanism of GVs, cover of turbine, guide vane bearing bodies.

The guide vanes are cast solid from stainless steel. The profile selected is optimum for the flow formed by spiral casing and stay vanes and suits the runner. Stainless steel replaceable liners have been provided on the faces of the turbine cover and the lower ring coming in the water path to prevent erosion. Each GV has three supports, one at lower journal and two for the upper journals. The bushes are made of bronze and are grease lubricated. Feeding of grease to the upper bush is done through a hole drilled in the flange of the bearing body while the lower bearing is supplied by a separate pipe connected to the hole through a guide vane. The lower and central bushes have been provided with rubber cap sealing to prevent the leakage of water. Leakages from the cup sealing of the central bush are collected in the turbine cover. The turning mechanism of GVs is designed to ensure the simultaneous turning of guide vanes during opening and closing of guide apparatus and is located inside the pitch circle diameter of guide vanes. It consists of regulating ring, link assembly strap, lever and shear pins. The regulating ring is made of welded construction from mild steel plates and is supported on the turbine cover. Bronze pads have been provided at the rubbing faces between regulating ring and its support, which is kept, submerged in oil to minimize friction. It is operated with the help of two servomotors installed in servomotor pits. The link assembly is made in the form of turnbuckle, which allows adjusting its length during assembly. The bearing bushes for the pins are made of a special synthetic material with inherent self lubricating properties. The connection of the strap to the lever is made through a safety shear pin which gets sheared off when the GVs are jammed, thus protecting the turning mechanism from damage. To prevent the lift of the GVs under water pressure the levers are held by stoppers fixed to the bearing bodies. The turbine cover is fabricated in two parts from mild steel plates and joined together with bolts. It is rigidly connected to the upper half of stay ring with studs. Holes have been provided at the bottom of its outer vertical cylinder to allow water drainage under gravity. In its internal vertical cylinder six windows have been provided to have access to the turbine sealing for repairs. The lower ring of guide apparatus is a forge-fabricated construction. The lower ring is fastened with the foundation ring with the help of bolts. A rubber ring has been provided between foundation ring and lower ring. For carrying out repair work of GVs, a permanent arrangement for lifting the top cover in turbine pit by 1.4m is provided. The turbine cover has four plugged holes, which are connected with the embedded header for supply of air under the turbine cover. Stationary labyrinth sealings are provided in the lower ring. Servomotors of Guide apparatus: Two servomotors are provided for turning the regulating ring. One servomotor is provided with a manually operated stopper for retaining the turbine in a closed position without oil pressure in it for long period. The stopper is provided with contact switches, which indicate its closed or open position on the control panel. It is not designed for hydraulic load, which may

occur in closed position. No oil pressure is allowed inside the servomotors s when the stopper is in position. The servomotors are connected with the regulating ring with piston rods. In the servomotors the piston rods are encircled by sleeves provided with gland type sealings for preventing oil leakage. The leakage passes on to the OLU from where it is pumped to oil tank of OPU. Emptying of servomotors is also carried out through the leakage unit. A high-pressure needle valve is provided in the drain line of the servomotor. For cushioning effect near the end of the stroke during closing of the guide apparatus, the piston is decelerated by throttling the oil through a special valve, which protects the system from the impact. Piston and its rings are made of cast iron. The piston rod of the servomotor without stopper is connected with the master controller by a wire rope for feedback connection. On the servomotor with stopper a scale has been provided to indicate the stroke in any position of the piston. 3.1.4 RUNNER ASSEMBLY: Runner converts the energy of flow of water into rotational energy, which is transmitted to the generator through shaft. The Francis runner has high hydraulic and cavitational properties and is made of 13:4 Stainless steel in one-piece casting. It consists of upper and lower rims joined together by 14 blades. On the upper and lower rims the labyrinth sealings are fixed by welding. Labyrinth are straight slit type and can be replaced after wear. The sealings are made of stainless steel. Cone of runner is welded construction from mild steel which is fixed in position with the help of bolts. For unloading the runner crown and top Cover, from water pressure, 16 holes have been provided in the upper rim of the runner which connects the zone above the runner to that below it. The cover plate of welded construction on the runner crown is fully welded with the runner. The runner is connected to the shaft by 20 fitted bolts, which transmit the torque and take axial load. The size of the bolts is 3.1.5 TURBINE SHAFT: The turbine shaft of dia 1000/700 mm is forged from high quality carbon steel. The shaft has flanges on both ends. The upper flange is connected to the flange of generator shaft. The lower flange is connected with the runner. On either ends the connection is made with the help of fitted bolts. The shaft is machined throughout its length. The shaft is provided with a bearing belt called skirt. One non-return air valve is provided on top of the generator shaft. 3.1.6 GUIDE BEARING: Self-lubricating TGB of segmented type is provided. It consists of 8 babbit-lined segments arranged along the outer circumference of the bearing belt of the shaft.

The segments rest on the ring fixed to the horizontal flange of the bearing body and are pivoted against the spherical end of the bolts in the bearing body. The bearing body is made in two parts of mild steel plates, fixed to the cover of turbine with the help of studs. A machined surface is provided in the body for the purpose of centering of the turbine shaft. The inner tank is fixed from below, is made in 4 parts to permit easy assembly and dismantling through the windows in the top cover the outer tank is fixed on the turbine cover with bolts. The cooler is located in the circumferential space between the bearing body and outer tank. They are fixed to the body from the sides. The cooler tubes casing is finally welded after cleaning the tubes. Under stationary conditions, the babbit lined segments are immersed in oil bath up to the C/L of pivoting bolts when the skirt rotates, the oil flows through the holes in the skirt due to centrifugal force and rises along the periphery of bearing body and segments. The oil flows over the cylinder falls on the oil cooler tubes. The oil after passing through the cooler flows into the inner tank through the radial holes in the bearing body. Thus the complete circulation of oil is achieved. Oil drainage arrangement is made from both the inner and the outer tanks. Oil grade IOC Turbine oil Servo prime -57 of IOC is used in TGB. The float level relays with electrical contacts have been provided for indicating the oil level in the guide bearing outer tank. There is also a provision for alarm in case oil rises above the max mark. or falls below the min mark. For thermal control, resistance thermometers, thermosignalisers are provided in bearing segments. For controlling the flow of cooling water through the guidebearing cooler, a flow failure relay is provided. TSDs are mounted on generator panel for measuring TGB temperature. TURBINE SHAFT SEALING: This sealing serves to prevent the water leaking through labyrinth sealings from flooding the top cover. Clean water is fed through radial holes in the bath formed in the body between the two rubber rings. This water under pressure does not permit the silted water to pass through the sealing and also presses the upper ring against the shaft. The upper ring is cooled by water supply from another pipe. These rings can be replaced without dismantling the guide bearings. A pressure gauge is installed to measure the pressure of clean water supply. Just below the base plate of the turbine sealing a rubber ring is fixed on the shaft flange. This ring presses against the tapper surface specially provided in the turbine cover when the rotor is lifter up by jacks. In this position of the turbine sealing can be repaired without the danger of flooding of the turbine cover. Water pipe lines: The system supplies water to the guide bearing cooling and clean water to the turbine sealing. One pump motor set is provided for the drainage of turbine top cover as a standby system. For top cover, drainage, ejector has been provided. An isolating valve before the sieve of ejector is provided to facilitate cleaning without draining of penstock. The outlet pipe from the bearing

oil cooler has a flow failure relay, and it discharges water into the drainage channel. Platform in turbine pit: Chequered plates inside the turbine pit is provided for facilitating movement and inspection of the bearing, servomotors, etc.

GOVERNING SYSTEM: (PID type)

Electro hydraulic Governor: The electro hydraulic governor is designed for automatic control of turbine. The governor provides for automatic and manual performance of the following operation.a) Turbine starting up. b) Routine and automatic shutting down of the unit at all operation duties c) Hydro unit governing both when it operates separately and in a group. d) Transferring the unit from separate to joint governing and vice versa. e) Tuning of the generator frequency to that of the mains by means of the auto synchronizer or non automatic synchronization means. f) Transferring the unit from generator duty to that of synchronous compensator and vice versa. In automatic governing, the governor duty provides for steady operation of the unit when operating: a) At idle run. b) At isolated load. c) At parallel operation for the mains both with separate and group governing. d) At load rejection or picking up. For manual hydro turbine control, the gate limiting gear is used. The governor set comprises of: 1) The electronic cabinet comprising electronic element, which serve for measuring the unit rotation speed, dashpot feedback, speed-droop etc. 2) Hydro mechanical control cabinet of the governor comprising hydro mechanical elements, which transform electric governing signals into corresponding motions of the main slide valve body, start and shutdown devices, elements of unit protection against over speed, generator overload at excess head, and other devices. The hydro mechanical control cabinet comprises the following gears and devices: a) Magnetoelectric transducer with hydro amplifier of nozzle baffle type. b) Main slide valve c) Gear for limiting gate opening according to head. d) Gate limiter. e) Speed changer.

f) Over speed protection device. g) Oil filter The above listed gears and devices are mounted on a frame and covered with a light weight metal shell. The face wall of the shell carries the following meters and indicators which are necessary for controlling the unit and governor operation. a) Main indicator for indicating the gate opening and the gate Limiter position. b) Electric tachometer which indicates the turbine rotation speed. c) Balance indicator which measures the amount and direction of the governing current flowing through the magneto electric transducer coil. d) Signal lamps, indicating the position of the gate servomotor lock. Beside these the face side of the shell carries the control hand wheel of the gate limiter and knob of the speed changer. A pressure gauge, which indicates the pressure of oil fed to the hydro amplifier of the magneto electric transducer and head indicator are arranged inside the control cabinet. For duplicating the readings on the unit panel of main control room in addition to meters and devices which are mounted on it, a gate opening indicator-receiver, electric tachometer and balance indicator are arranged. The hydro mechanical control cabinet is connected by cables to electronic cabinet by piping with oil pressure unit, gate servomotors and by mechanical feedback with turbine control elements. Oil pressure for control cabinet should be within 25 to 40 kg per sq cm. Principles of operation: The governor is designed for speed control, along with operation under steady state conditions, small transient conditions, large transient conditions, and blocked gate. It is also designed to allow power frequency control. The speed measuring unit along with other circuits together with the slide valve controls the movement of the pilot servomotor. The return motion makes it possible to obtain steady state position of main gate governor displacement, by resetting of the main slide valve. Temporary speed drop circuits, receiving an electrical input from the main servomotor, give a feedback signal for controlling the movement of the servomotors without hunting. Parameters- Temporary droop percent (bt) and decay time constant (Td) are set to allow stable operation of the hydro set. The stability-speed and output oscillations are influenced by the above parameters and also by the turbine, generator, grid and pipeline characteristics. The feedback device influences the response of the hydroset to any frequency or command signal. This response can be improved by the addition of phase advance unit. This unit adds a rate of change of speed error in addition to the speed error. this signs improves the performance of the machine. The derivative time constant (Tn) can be sent to achieve the desired performance.

Permanent speed droop circuits, deriving input from the main servomotor helps in the regulation. Frequency vs. gate servomotor relationship can be can be altered by changing the permanent speed droop setting to achieve desired regulation, manual load control and frequency control. Equipment: Consists of the electronic cubicle and the hydro mechanical cubicle. Inside the Electronic Cubicle: This cubicle is not required to be handled by the staff during usual operation of the set. It has a motorized potentiometer unit, a switch fuse unit, a regulating rack, power supply rack, speed relay unit, control relay unit, a limit adjustment rack. Motorized Potentiometer unit contains speed setting potentiometer and gate setting potentiometer. Speed sensing potentiometer is connected across +/- 15Vdc and provides speed adjustment command signal to the summing amplifier for the purpose of synchronizing. The speed adjustment range is 50+-5 Hz. Gate setting potentiometer is connected across +13V Dc and OV lines feed gate adjustment command signal to the summing amplifier through the feed back unit and the permanent speed droop potentiometer for the purpose of loading of the machine. The potentiometer is calibrated from 0 to 100 % and this holds good when the speed setting is the same as the frequency of the system. A common switch in the hydro mechanical cabinet controls the above potentiometers. After synchronizing the control automatically transfers to the gate setting potentiometer. The switch fuse unit contains: Governor supply switch, Limit adjustment switch, Cubicle lamp switch, cubicle Heater switch and fuses associated with the above switches. The Regulating rack is the heart of the Governor and comprises of : a single phase transformer, speed measuring unit, a phase advance amplifier, dead band unit, summing amplifier, Feed back unit, No load gate limit potentiometer, Power amplifier, Speed trim potentiometer, Closing damping limit potentiometer, Opening damping limit potentiometer, Governor sensitivity potentiometer, Temporary speed droop off line percentage potentiometer, Temporary speed droop off line time constant potentiometer, Temporary speed droop on line percentage potentiometer, Temporary speed droop on line time constant potentiometer, phase advance time constant selector switch, Dead band adjusting potentiometer. The Speed Measuring Unit: The speed / frequency signal is derived from the permanent magnet generator coupled to the turbine generator shaft. This is fed to the speed-measuring unit through a step down transformer. At the rated speed (50 Hz), an output of the measuring unit is 0 V and varies by +-0.8 V/Hz depending upon whether the speed is above or below the rated value. Phase advance unit: The speed measuring unit output is fed to the phase advance unit, which provides accelerometer signal using resistance capacitance feed forward and feed back network. The time constant of the derivative signal is adjustable from 0 to 1 sec. The modified speed error signal (signal + its rate of change) from the unit is passed on to the dead band unit and summing amplifier.

Dead band unit: This unit provides a dead band on the frequency error, preventing any control action over a small band of frequency around the rated value. It is adjustable from 0 to +-0.5 Hz. Feed Back Unit: This unit receives signals from the gate setting and the Governor feed back potentiometers (located in the hydro mechanical cabinet). The command and feedback signals are compared and the difference is fed to the permanent speed droop potentiometer. This unit also provides transient signal to the temporary speed droop time constant and percentage setting potentiometers. The components associated with speed trim, no load gate limit and damping limit potentiometer are also located in this unit. Permanent speed Droop: The Permanent speed Droop potentiometer derives its input from the feed back unit and supplies negative feedback to the summing amplifier. The potentiometer is calibrated from 0 to 10%. At 10% droop and gate setting at 0%, the gate shall open 100%, only if the freq drops by 10%. If the system frequency remains constant at 50 Hz, The gate setting has to be raised to 100% for 100% gate opening irrespective of the droop setting. The permanent droop contributes gate vs. freq. characteristic and helps in the regulation of frequency. Temporary Speed Droop (Damping): To achieve stability, the temporary speed droop signal to the summing amplifier is derived by differentiation of the signal obtained by comparison of gate setting and gate feedback signals in the feedback unit. The differentiating capacitors are located in the feedback unit. Two sets of identical potentiometers are available for on line and off line temporary droop time constant and percentage adjustments. Time constant adjustment 0 to 25 sec, Percentage bt 0 to 100%. The changeover from off line to online settings is carried out automatically with the synchronizing of the unit. The arrangement of the damping circuit is such that initially, output of the circuit supports the gate setting signal, thereby allowing faster loading and unloading of the machine. Opening and Closing of the damping Limits : these are provided to limit the damping signal for large transients where quick governor response is desired, limits adjustable from 0 to 100%. No Load Gate Limit: Gate position is compared to a set position on the no load gate limit potentiometer. Should the gate tend to open beyond the set value, a closing signal is fed to the summing amplifier. This circuit is automatically disengaged on synchronization of the machine. Summing amplifier: this sums up the signals from the following sources in the desired proportions: Phase advance unit, Dead band unit, Permanent Speed droop potentiometer, Temporary speed droop potentiometer, Speed setting potentiometer, no load gate limit circuit. Under steady state the output is 0 V. Phase advance dead band and summing Amplifier Units are located on one card control amplifier.

Power Amplifier: Resultant signal from the summing amplifier is fed to the power amplifier. This raises the power level of the summing amplifier output to a value sufficient to operate the electromechanical transducer, which in turn controls the main slide valve movement. Sensitivity of the amplifier is adjustable from 10 m-amp/Hz to 100 m-amp/Hz. Under steady state the output current is 0 mA. Max current swing is +-60 m-amp. Power Supply: The electronic circuits operate on +-15 V DC, 1 amp stabilized power supply. The AC input is derived from the PMG. The power supply is designed to withstand 30% to 100% variation on the input side- this takes care of m/c runaway speed. The output ripple is 1 mV peak to peak and regulation better than 1%. The basis for power supplies is two identical series regulators one for positive and the other for negative supply. The series regulators have built in protection against short circuit. An o/v card disconnects input to the series regulators in the event of output voltages exceeding 17 V DC. Speed Relays: The relays fed from the PMG: a) Governor Control Relay: Brings in governor control at 80% speed. b) Programmed Closure Relay: This relay picks up for speeds above 112%. It disengages he damping signal thereby closing through the transducer. c) Over speed protection relay (115% speed)- This relay picks up at turbine speeds exceeding permissible value and in case of failure of hydro mechanical devices, energizes an electromagnetic emergency slide valve, which stops the m/c after bypassing the governor. d) Over speed protection relay (145%) - This relay picks up for speed rise above 140 %( to 165%) in case of failure of governor and emergency slide valve. It gives signal for closure of inlet valve, quick falling of gates. e) Speed relay for pneumatic braking: This relay will pickup at 30-35% speed and will operate the control circuit for applying pneumatic brakes. f) Zero percent speed relay: this operates at 0.1% speed and will disengage the pneumatic brakes. Control Relays: The control relays are used for the following sequence controls: Auto Start: When starting the turbine under Auto control, starting relay raises the gate limiter to the starting opening. When the gate limiter begins to move in the direction of opening, another relay picks up through a micro switch and feeds opening signal derived from the station DC supply to the electro hydraulic transducer. This results in Gate servomotor displacement of the position permitted by the gate limiter. At 80% speed, governor control relay picks up and brings in automatic control.

Manual Start: Under manual start the gate limiter has to be manually controlled throughout the operation- before and after synchronization. Load Throw Off: In case of load throw off i.e. tripping of Gen circuit. Breaker, motor of 65G gets energized through the contacts of 52 relay and brings it to no load position.81, 81X relay affects on line to off line damping changeover. Limit Adjusting Rack: This rack contains devices that enable the gate limit mechanism adjustment according to the head, thereby preventing overloading of the generator. Outputs from the head transducer and gate limit potentiometer are compared in a comparator cum follow-up circuit, which controls gate limit raise and lower switch. Thus the gate limit follows the head such that the gate limit decreases for rising head and increases for falling head. Hydro Mechanical Cubicle: It consists of the following equipments: Electromagnetic Transducer with hydraulic amplifier, gate opening limiter, feed back shaft, lever transmission, feed back gear, main slide valve, contact device of gate limiter, gate limiter according to the head, feedback gear for adjustment according to the head, Control and Measuring instruments, double oil filter. The above units are housed in a cubicle. On the face panel of the cubicle the following control and measuring instruments and indicators are located which are necessary for the operation of the turbine and governor: Electro tachometer for speed of turbine, balance indicator, speed setting indicator, gate setting indicator, Gate limiter and Gate opening indicator, pressure gauge for oil pressure in the transducer, Servomotor stopper position indicator, gate limiter raise and lower hand wheel, speed / output raise / lower switch. Instruments mounted inside the hydro mechanical cubicle: scale for indicating the head, and gate limiter and gate-opening indicator with adequate transmitter to duplicate indications on the main control desk in control room. Electromagnetic Transducer and Hydraulic Amplifier: The electromagnetic transducer is the linking device between the electronic and hydraulic part of the governor. It consists of a coil (68) held in a magnetic field provided by a ring shaped permanent magnet (67) between leaf springs (70 and 82). To this coil is attached a flapper (65) held between nozzles (64). In normal conditions with the flapper in mid position the pressure on both sides of the piston (61) is equal and the needle (78) is held in mid-position. On passing of current through the coil, electromagnetic forces displace 68 up or down, depending upon the direction of flow of current. The displacement of the coil moves flapper nearer to one of the nozzles. When the needle moves lower chamber (77) of piston (58) will be connected either to the pressure in upper chamber (76) or to the drain. Thus, the piston follows the needle (78).Effectively

the direction and amount of movement of the piston is proportional to the direction and amount of the current flowing through the coil. Hydraulic amplifier operates at oil pressure of 18-20 kg/cm2. This pressure is controlled by the number of orifices in the throttling device (54). In case of manual control of the unit, turning the handle 66 into manual position cuts off the electro hydraulic transducer. Piston 61 will then be raised to the top most position under action of the hydraulic pressure in bottom chamber 77, thus giving an opening signal to pilot slide valve 46; the opening of main servomotor can be controlled by the gate limiter. Sensitivity o the transducer can be varied by moving fulcrum 56 of lever 57 with the help of hand screw. Main Slide Valve: Pressurized oil from the OPU is distributed to the opening chamber 80 and closing chamber 81 of the guide vane servomotor by means of slide valve pool (40). Needle 47 and spool 4 are made differential and under the constant action of hydraulics forces locks lever 45 against thrust reo 28 in case of automatic governing or limiter level 42 in case of manual control. Moving needle 47 up or down, decreases or increases the pressure above auxiliary piston 39, thereby moving main slide valve spool 40 up or down bringing needle back to its mid position with initiator and subsequently fulcrum being thrust rod 38 in case of automatic governing or limiter lever 42 in case of manual control. The time of closing or opening of gate servomotor are set by limiting travel of main slide valve spool 40 by means of nut 38 for closing, and nut 37 for opening. Gate Limiter: This allows the Guide Vanes to open under normal control and prevents the gates opening further. The limiter can be operated by a hand wheel. In case of manual control or by electrical motor in case of remote control. Operating the motor 8 or the hand wheel 10 raises or lowers the rod 31 which in turn actuates needle 47, for opening or closing of gate servomotor via lever 42. Movement of gate servomotor rotates feed back shaft 32 through a cable feed back thereby moving lever 42 till needle again comes to the mid-position and the gate servomotor stops. Gate limiter according to the head: This device prevents operation of turbine at nonrated duties restricting extra gate openings at higher heads. Cam 18 can be rotated by motor 17 or hand wheel 16, this cam through levers 23 and 25 actuates rod 31 similar to the actuation by gate limiter, thereby limiting gate opening. Over speed Protection Device: This consists of a level switch 35, mounted on main slide valve, which is connected to the emergency protection circuit in series with contacts of the over speed relay. When the speed of the unit reaches 115120% of the rated value and the main slide valve is in the opening direction, emergency closing of the gate is performed by the emergency slide valve, bypassing the governor. Oil filter: A Duplex oil filter is provided in the hydro mechanical cubicle for the electro hydraulic transducer to give trouble free operation. Degree of filtration of 70 micron has options for service and flushing.

Indicators available for main control desk: gate opening with limiter indicator, Electro tachometer, balance Indicator. The Governing equipment also includes the Joint Control desk, Emergency slide valve, oil pressure system, oil sump tank, oil pump- motor sets, Oil pressure accumulator, Oil leakage unit, and feedback connections. The joint control desk: This is common for all the three machines. It is provided to enable all the three generating units to be controlled as a single unit. Emergency slide valve and valve with Electromagnet: The emergency slide valve is intended for closing the turbine servomotors under all emergency conditions by passing the governor. The emergency signal is received by the valve with electromagnet and actuates and this actuates the emergency slide valve for direct admission of oil from the oil pressure vessel to the turbine servomotors. The emergency slide valve can also be actuated locally by pulling down the handle provided in the valve with the electro magnet. The switch for resetting the emergency slide valve is provided in the UCB. Oil Pressure System: Each turbine is provided with an independent oil pressure system of normal pressure 40 kg/cm2 for operation of governor and is common for guide vane servomotors. This system consists of oil sump tank, oil pump motor sets, and oil pressure accumulators. The system is designed to operate on continuous mode, where one pump is selected as a main & it operates continuously & the other standby pump operates intermittently when the oil pressure is lower than the preset value. Pumping of oil into receiver is carried out by the main pump motor under the control of the idler valve. This valve closes around the minimum working pressure to allow pumping of oil into the receiver & opens at maximum normal working pressure to discharge the oil back into the tank. Oil Sump Tank: It has sufficient capacity to hold all the oil in the governing system. The tank is totally enclosed, semi buried type, provided with manhole, oil level gauge, switches for high and low oil level alarm, a return oil strainer, suction and return connection for oil centrifuge equipments, a filter cum air breather, a thermometer with contact for high oil temperature alarm, etc. Oil Pump - Motor Set: These sets are mounted on the sump tank and have sufficient capacity to supply all the oil requirement of the governor and the servomotors, one for normal and other for standby. It consists of a screw pump silently running with accurately made steel rotor and cast iron casing., an electric motor of 415+-10% V, 3 phase, ac squirrel cage type direct on line starting, set of NRV, isolating valve, safety valve for governor oil pressure system, selector switch for changing over from main to standby pump-motor set.

Oil Pressure Accumulator: It is designed to withstand maximum working pressure and is of sufficient capacity to supply oil to perform three full operations of the guide vane servomotors .the receiver has a manually operated air release valve, oil level gauge with automatic valve for preventing air and oil loss in case of breakage of glass. Oil level switch for low oil level tripping is also provided. A manually operated drain valve, a pressure gauge, manhole, etc is also present. Oil Leakage Unit: This is intended for the collection of oil leakage from servomotors, draining of oil from servomotors, controlling valves and oil pipe lines, and periodic pumping from the tank of OLU into sump tank of OPU. The OLU consists of a tank mounted by a pump motor set. In the tank, a capacitance type level signalliser is installed for automatic operation of the pump, controlling of oil level alarm in case of higher oil level. Feedback Connections: The feedback gear is intended for the restoration of the governor main slide valve to the mean position during the process of governing. It consists of rope drive, which transmits the movements of the servomotor through the system of rollers to the main slide valve. On the feedback gear a master switch is also installed. Its contacts are set to close or open at definite position of the servomotor to actuate the automation elements of the hydro set. The feedback rope is protected by pipes.

Main Specification of the Turbine: Type of Turbine Nominal Dia of Runner Speed of Rotation Runway speed Maximum Head Design Head Minimum Head Rated output of turbine at design Head Optimum efficiency of the turbine At 90% part load Direction of rotation Max. Axial load transferred on generator Thrust bearing from turbine Type of spiral casing No. of runner blades Turbine shaft outer dia. Turbine shaft inner dia. Height of runner : Vertical Francis, : 3600mm : 187.5rpm : 375 rpm : 102M : 94.5m : 94.5M : 117.5MW : 92.5% : Clock-wise : 382T : Metallic : 14 : 1000mm : 700mm : 1952mm

II.GENERATOR Technical Particulars of the generator

Name of Manufacturer Type Rated line voltage Frequency Guarantee rated output at 11KV Rated Power Factor Rated Speed Runaway Speed Generator overall Efficiency at rated load : BHEL : Suspension, Vertical. : 11KV : 50Hz : 127800KVA : 0.9(lag.) : 184.7 RPM : 375.0 RPM : 98%

The generator is of the suspended type with the thrust bearing located above the rotor and has two Guide Bearings. One is mounted in the upper bracket and the other in the lower bracket. Air operated brakes are fitted on the lower bracket arms, which are also used for lifting the rotor. The air coolers are mounted on the outer steel casing of the stator. Circular pipeline for CO2 fire extinguishing system is located inside the concrete barrel. A turbine pit cover is mounted below the generator to prevent leakage of cooling air. It also serves as a platform for servicing the brakes and LGB. The PMG is mounted on the extension shaft directly coupled to the generator shaft. Thrust Bearing pads, rotor poles, and other parts that may be required to be taken out after long operation can be removed without dismantling the system. Stator: Stator windings: This winding is double layer bar type wave winding with six main and six neutral terminals brought out. The bars are made of large number of insulated rectangular conductors of small section, transposed to reduce eddy and circulating currents. The insulation is F, resiflex type. The bar ends are joined by brazing with special devices. The bars are coated with semi conducting varnish to avoid corona and flash over. The end part of the winding is braced with the bandage rings and the insulating spacers are put in-between them to make the part rigid enough to withstand all possible mechanical forces arising due to short circuit. Rotor: Poles: The poles are fixed to the rotor rim by T heads and tapered keys. Poles are made of steel stampings assembled between two forged end plates. Contour of the pole shoe is designed to give sinusoidal distribution of flux. Pole coils are made of special profile copper strips wound on edges. This special profile increases cooling surface area of coil and ensures better cooling. Pole coils are insulated between turns and to earth with class F insulating material. The pole coils are pressed to assemble rotor by means of spring s to prevent vibration of the pole coils. A low

resistance connected cage type damper winding made of copper is provided in the pole shoe. Slip rings: The slip rings of easy mounted type are fitted on the shaft at suitable position for easy inspection and maintenance. Lower Bracket: It is of welded construction, consisting of a central part and radial arms. The spider is secured to the foundation by foundation plates and bolts. The lower bracket can be taken out through the generator stator bore. Thrust Bearing: this is of pivoted segmental pad type, self lubricated and immersed in oil bath. Plug in type water-cooled oil coolers are inserted in the oil bath to remove the bearing losses. These coolers are provided with drain valves in case of longer shut down. Pads can be removed for repairs and replaced through the windows for oil coolers. The bearing runner has a mirror surface and is fixed to the thrust collar .It rotates over the babitted surface of the thrust pads. Thrust pads rest over the pad supports, which are supported on the pivot supports, screwed to the thrust-bearing frame. Pad supports work like springs and provides a cushioning effect to the whole assembly. Radial and circumferential movements of the pad are prevented by means of the locking plates. Insulation is provided between the runner and the thrust-bearing collar to prevent the flow of bearing currents. Resistance thermometers are provided for temperature indication. Thermo signaling devices 4 nos. each with two adjustable contacts and capillary length of 25 m is also provided in the alternate pads for alarm and tripping in case of overheating of pads. These TSDs are mounted on the panel placed on generator floor near UCB. Guide Bearings: Two guide bearings are provided in the machine, one in the upper bracket and the other in the lower bracket. They are of the self-oriented adjustable segmental pad type. Pads are insulated from the rest of the assembly to prevent bearing currents. The friction between the moving and stationary parts is reduced due to the babbited surface of the segments. Bearing pads are always immersed in oil. Plug in type water-cooled oil coolers are inserted in the oil bath to remove the bearing losses. RTDs and TSDs are provided for temperature indication and alarm. Thrust and guide bearings are easily accessible for inspection and maintenance. Seals are provided to prevent leakage of vapors. Pads can be taken out for repairs without disturbing other assemblies. III. Hydrostatic Lubrication System: Each generator has a separate HS system for creating a hydrostatic high-pressure oil film between the static and rotating parts of the thrust bearing system before starting and stopping of machines. This system consists of pump motor set high pressure, low pressure filters relief valve, pressure switch with electrical contacts for starting interlock of the machine, pressure gauge and shut off valves. Oil at predetermined pressure is fed through flexible hoses to allow movement of pads in operation. The system is set to come into operation automatically on starting and stopping of the unit. IV. Permanent Magnet Generator: This is mounted on the same shaft to provide supply to the governing system.

V. Static Excitation Equipment: Technical Specification: Manufacture Type Nominal field voltage Nominal field current No load excitation voltage No load field current Max. Continuous excitation current Ceiling voltage Ceiling Current Ceiling duration Excitation Transformer : BHEL : SEE : 243V : 1365Amp : 114V : 754 A : 1500A : 446 V : 2730 Amp : 5 Sec : 910 KVA

The Excitation equipment derives its excitation power from the generator terminal through the step-down transformer or the Rectifier / Excitation transformer. The AC input supply of all the electronic power supplies are given from the secondary transformer through intermediate transformers. The secondary of the transformer feeds the Thyristor Bridge, which consists of parallel-connected bridges to meet the field current requirement of the machine. The field discharge resistance in the field circuit, enables faster suppression of stored energy in the field. The DC output of the Thyristor Bridge is fed to the generator field to the generator field through field breaker. Redundancy is important for operational reliability. It is achieved splitting the converter into 3 independent blocks. Each of the blocks comprises of its own pulse output stage, its own cooling and monitoring of the components. Failure of one block results in only an alarm; operation is maintained. The second block failure however leads to disconnection. Voltage Build Up: As we know that the residual voltage of the generator is very low. Field flashing required for enhancing the voltage build up process. Once the generator voltage buildup up to 70% of the rated value of field flashing is terminated by the voltage relay unit which monitors the voltage. Automatic mode: The automatic mode excitation is regulated by AVR. The actual value of generated voltage which is sensed by through CT and PT after suitably stepping down and converting it to DC. Manual Mode: In the manual mode the gate control unit of the manual channel is directly controlled by the manual reference potentiometer. Limiters: Limiters are provided in the excitation scheme in order to avoid tripping during the dynamic and transient condition. Rotor Current Limiter: During certain operating region machine may loose its synchronism and get under excitation, to avoid this, rotor current limiters are provided. With the intervention of the rotor limiter the excitation is limited to thermal value. Rotor Angle Limiter: During certain operating region machine may loose its synchronism, to prevent this rotor angle limiters are provided. Stator Current Limiter: This limiter is provided to prevent the stator overheating in case of overload to thermal limits.

Excitation Transformer: The excitation transformer provided is provided with relays for protection from over current (instantaneous/delayed) and from over temperature. Rotor Earth Fault: A single stage rotor earth fault relay is provided for rotor earth fault protection. VI. Power Transformer: Technical specification Manufacture : Compton Greaves and BHEL Rating :Single Phase,43.33MVA,11KV/220KV Type : OFWF HV winding : Star LV winding : Delta VII. Station Service Transformer: two numbers GEC make 3 Phase 1000 KVA, 11/0.415 KV ONAN cooled transformers are installed at EL.408.5 M in the space available in the power house between the wall adjacent to U#3 and the power house retaining wall. The 11KV supply is fed from the available grid supply and the LT supply is fed to the station auxiliaries. The transformers are of the DY11 connection with OFF load tap change provision on HV side for voltage variation of +- 5% insteps of 2.5%. VIII. Unit Auxiliary Transformer: One number 500KVA, 11/0.415 KV 3 phase dry type transformer for each generating unit has been provided in the D/S gallery inside the powerhouse at El.396.95m. It has Dy11 connection with off load tap changer on HV side, voltage variation +-5% in steps of 2.5%. When the unit is running, the auxiliary loads are transferred to the unit aux transformer. IX.415V AC System: For starting the generating unit, the unit auxiliary boards draw power from 415V station service board through the respective breakers and unit LV breakers are kept open. When the unit runs up and obtains the normal voltage, the corresponding LV breaker is switched on manually to cater to the auxiliary load of the unit. The closing of LV breaker shall ensure through interlock circuits that the corresponding service board breaker is tripped before closing the LV breaker. In case the supply from the unit auxiliary transformer fails, the unit LV breaker trips and the corresponding service board breaker closes automatically. This happens due to the under voltage relay on the unit board after ensuring that the LV breaker has not tripped due to overload. Tripping of any of the 11KV breakers shall cause tripping of corresponding station LV breaker and closing of the sectionalizing breaker automatically, thus restoring power to that section of station bus. In cases when there is total failure o0f supply on the station board through the station service transformer, or when there is a total grid failure, the DG set is started and put on the station bus manually. Sectionalizing breaker is then closed so that the entire station service load and the auxiliary load of the unit to be started is transferred to the DG set. After start of the unit the auxiliary board supplies the auxiliary load. The switchyard board receives power from one of the station service boards through corresponding breaker. Theses breakers are interlocked and arranged for automatic transfer in case of failure of supply on either of the sections of station board.

X. DC System: One number 220V battery bank- one for both the stages consisting of 110nos. lead acid cells each of 2 volts connected in series is installed at El. 416 above control room. This caters to the need of DC supply to control panel and protection system, MOCBs and isolator opening/closing coils, emergency lighting for powerhouse and switchyard, and field flashing of the units during starting. The capacity of the battery bank is 1000 amp-hour based on 10-hour discharge at 27 degree C. The battery bank is connected to the charger. When the cells are fully charged, the specific gravity of the sulphuric acid is 1280. The battery room is well ventilated. The selector switch of the batter charger is kept in float position during normal condition. When the battery demands a quick charging current, the Boost charge circuit is switched on automatically. In case of emergency, when the boost charging of the battery bank is required by the operator, the boost charger can be switched on forcibly with a switch.

XI. Foundation Parts of the Turbine:

Stay Ring: The stay ring is of cast welded construction, consisting of upper and lower rims fabricated from mild steel and connected together with eleven streamlined cast low alloy steel stay vanes and one mild steel fabricated tooth of the spiral casing. Suitable holes in the upper flange of the staying have been provided for draining the trapped water between pit liner and top cover. The stay ring has been made in two parts joined together at site with nuts and bolts. Suitable wedges, foundation bolts, and anchors have been provided in the stay ring for leveling and proper securing in concrete. Spiral Casing: This has been designed to provide uniform flow to the runner. It consists of several round and elliptical segments of different thickness provided in accordance with the water path and strength requirements. A manhole is provided in the reducer piece through which guide vanes can be taken out. Felt packing is provided on the top surface of the spiral casing to prevent transfer of load from the concrete above.. Pit Liner: This starts from above the spiral casing to the turbine floor. Vertical and horizontal rings have been provided for rigidity. Pit Liner includes CGL distributors fixed on to it. Guide Apparatus: This regulates the flow of water through turbine for various conditions of load and head. It also serves as a closing device for turbine during normal and emergency conditions. It consists of guide vanes; turning mechanism of GVs, cover of turbine, guide vane bearing bodies. The guide vanes are cast solid from stainless steel. The profile selected is optimum for the flow formed by spiral casing and stay vanes and suits the runner. Stainless steel replaceable liners have been provided on the faces of the turbine cover and the lower ring coming in the water path to prevent erosion. Each GV has three supports, one at lower journal and two for the upper journals. The bushes are made of bronze and are grease lubricated. Feeding of grease to the upper bush is done through a hole drilled in the flange of the bearing body while the lower bearing is supplied by a separate pipe connected to the hole through a guide vane The lower and

central bushes have been provided with rubber cap sealing to prevent the leakage of water. Leakages from the cup sealing of the central bush are collected in the turbine cover. The turning mechanism of GVs is designed to ensure the simultaneous turning of guide vanes during opening and closing of guide apparatus and is located inside the pitch circle diameter of guide vanes It consists of regulating ring, link assembly strap, lever and shear pins. The regulating ring is made of welded construction from mild steel plates and is supported on the turbine cover. Bronze pads have been provided at the rubbing faces between regulating ring and its support, which is kept, submerged in oil to minimize friction. It is operated with the help of 2 servomotors installed ion servomotor pits. The link assembly is made in the form of turnbuckle, which allows adjusting its length during assembly. The bearing bushes for the pins are made of a special synthetic material with inherent self lubricating properties. The connection of the strap to the lever is made through a safety shear pin which gets sheared off when the GVs are jammed, thus protecting the turning mechanism from damage. To prevent the lift of the GVs under water pressure the levers are held by stoppers fixed to the bearing bodies. The turbine cover is fabricated in two parts from mild steel plates and joined together with bolts. It is rigidly connected to the upper half of stay ring with studs. Holes have been provided at the bottom of its outer vertical cylinder to allow water drainage under gravity. In its internal vertical cylinder six windows have been provided to have access to the turbine sealing for repairs. The lower ring of guide apparatus is a forge-fabricated construction. The lower ring is fastened with the foundation ring with the help of bolts. A rubber ring has been provided between foundation ring and lower ring. For carrying out repair work of GVs, a permanent arrangement for lifting the top cover in turbine pit by 1.4m is provided. The turbine cover has four plugged holes, which are connected with the embedded header for supply of air under the turbine cover. Stationary labyrinth sealings are provided in the lower ring. Servomotors of Guide Apparatus: two servomotors are provided for turning the regulating ring. One servomotor is provided with a manually operated stopper for retaining the turbine in a closed position without oil pressure in it for long period. The stopper is provided with contact switches, which indicate its closed or open position on the control panel. It is not designed for hydraulic load, which may occur in closed position. No oil pressure is allowed inside the servomotors s when the stopper is in position. The servomotors are connected with the regulating ring with piston rods. In the servomotors the piston rods are encircled by sleeves provided with gland type sealings for preventing oil leakage. The leakage passes on to the OLU from where it is pumped to oil tank of OPU. Emptying of servomotors is also carried out through the leakage unit. A high-pressure needle valve is provided in the drain line of the servomotor. For cushioning effect near the end of the stroke during closing of the guide apparatus, the piston is decelerated by throttling the oil through a special valve, which protects the system from the impact. Piston and its rings are made of cast iron. The piston rod of the

servomotor without stopper is connected with the master controller by a wire rope for feedback connection. On the servomotor with stopper a scale has been provided to indicate the stroke in any position of the piston. Runner Assembly: Runner converts the energy of flow of water into rotational energy, which is transmitted to the generator through shaft. The Francis runner has high hydraulic and cavitational properties and is made of 13:4 Stainless steel in one-piece casting. It consists of upper and lower rims joined together by 14 blades. On the upper and lower rims the labyrinth sealings are fixed by welding. Labyrinth are straight slit type and can be replaced after wear. The sealings are made of stainless steel. Cone of runner is welded construction from mild steel which is fixed in position with the help of bolts. For unloading the runner crown and top Cover, from water pressure, 16 holes have been provided in the upper rim of the runner which connects the zone above the runner to that below it. The cover plate of welded construction on the runner crown is fully welded with the runner. The runner is connected to the shaft by 20 fitted bolts, which transmit the torque and take axial load. Turbine Shaft: The shaft of dia 1000/700 mm is forged from high quality carbon steel. The shaft has flanges on both ends. The upper flange is connected to the flange of generator shaft. The lower flange is connected with the runner. On either ends the connection is made with the help of fitted bolts. The shaft is provided with a bearing belt called skirt. One non-return air valve is provided on top of the generator shaft. Guide Bearing: Self-lubricating TGB of segment type is provided; it consists of 8 babbit-lined segments arranged along the outer circumference of the bearing belt of the shaft. The segments rest on the ring fixed to the horizontal flange of the bearing body and are pivoted against the spherical end of the bolts in the bearing body. The bearing body is made in two parts of mild steel plates, fixed to the cover of turbine with the help of studs. A machined surface is provided in the body for the purpose of centering of the turbine shaft. The inner tank is fixed from below, is made in 4 parts to permit easy assembly and dismantling through the windows in the top cover the outer tank is fixed on the turbine cover with bolts. The cooler is located in the circumferential space between the bearing body and outer tank. They are fixed to the body from the sides. The cooler tubes casing is finally welded after cleaning the tubes. Under stationary conditions, the babbit lined segments are immersed in oil bath up to the C/L of pivoting bolts when the skirt rotates, the oil flows through the holes in the skirt due to centrifugal force and rises along the periphery of bearing body and segments. The oil flows over the cylinder falls on the oil cooler tubes. The oil after passing through the cooler flows into the inner tank through the radial holes in the bearing body. Thus the complete circulation of oil is achieved. Oil drainage arrangement is made from both the inner and the outer tanks. Oil grade IOC Turbine oil 57 of IOC is used in TGB. The float level relays with electrical contacts have been provided for indicating the oil level in the guide bearing outer tank. There is also a provision for alarm in case oil rises above the max mark. or falls below the min mark.

For thermal control, resistance thermometers, thermosignalisers are provided in bearing segments. For controlling the flow of cooling water through the guide-bearing cooler, a flow failure relay is provided. TSDs are mounted on generator panel. XII.Governing System: (PID type) Electro Hydraulic Governor: Features: Regulating circuit: Monolithic Integrated Circuit Operational amplifiers have been used. Hydraulic circuit: Fast response of distributing valves due to optimization of overlaps, running clearances, etc Fast response of electrical circuits due to fast acting solid state regulating circuit to ensure high governor sensitivity. Wide adjustment of characteristics operating parameters. The electro hydraulic transducer draws low current-max 60mamp. Zero transducer balance current at 50 Hz Limit adjustment can be carried out according to the head. Built in protection device for safe operation of turbine Can be tested even if the hydroset is at standstill Principles of operation: The governor is designed for speed control, along with operation under steady state conditions, small transient conditions, large transient conditions, and blocked gate. It is also designed to allow power frequency control. The speed measuring unit along with other circuits together with the slide valve controls the movement of the pilot servomotor. The return motion makes it possible to obtain steady state position of main gate governor displacement, by resetting of the main slide valve. Temporary speed drop circuits, receiving an electrical input from the main servomotor, give a feedback signal for controlling the movement of the servomotors without hunting. Parameters- Temporary droop percent (bt) and decay time constant (Td) are set to allow stable operation of the hydro set. The stability-speed and output oscillations are influenced by the above parameters and also by the turbine, generator, grid and pipeline characteristics. The feedback device influences the response of the hydroset to any frequency or command signal. This response can be improved by the addition of phase advance unit. This unit adds a rate of change of speed error in addition to the speed error. This signs improves the performance of the machine. The derivative time constant (TN) can be sent to achieve the desired performance. Permanent speed droop circuits, deriving input from the main servomotor helps in the regulation. Frequency vs. gate servomotor relationship can be can be altered by changing the permanent speed droop setting to achieve desired regulation, manual load control and frequency control. Equipment: Consists of the electronic cubicle and the hydro mechanical cubicle. Inside the Electronic Cubicle: This cubicle is not required to be handled by the staff during usual operation of the set. It has a motorized potentiometer unit, switch fuse, regulating rack, power supply rack, speed relay; control relay and adjustment limit rack.

Motorized Potentiometer until contains speed setting potentiometer and gate setting potentiometer. Speed sensing potentiometer is connected across +/- 15Vdc and provides speed adjustment command signal to the summing amplifier for the purpose of synchronizing. The speed adjustment range is 50+-5 Hz. Gate setting potentiometer is connected across +13V Dc and OV lines feed gate adjustment command signal to the summing amplifier through the feed back unit and the permanent speed droop potentiometer for the purpose of loading of the machine. The potentiometer is calibrated from 0 to 100 % and this holds good when the speed setting is the same as the frequency of the system. A common switch in the hydro mechanical cabinet controls the above potentiometers. After synchronizing the control automatically transfers to the gate setting potentiometer. The switch fuse unit contains: Governor Supply switch, Limit adjustment switch, Cubicle lamp switch, cubicle Heater switch and fuses associated with the above switches. The Regulating rack is the heart of the Governor and comprises of: a single phase transformer, speed measuring unit, a phase advance amplifier, dead band unit, summing amplifier, Feed back unit, No load gate limit potentiometer, Power amplifier, Speed trim potentiometer, Closing damping limit potentiometer, Opening damping limit potentiometer, Governor sensitivity potentiometer, Temporary speed droop off line percentage potentiometer, Temporary speed droop off line time constant potentiometer, Temporary speed droop on line percentage potentiometer, Temporary speed droop on line time constant potentiometer, phase advance time constant selector switch, Dead band adjusting potentiometer. The Speed Measuring Unit: The speed / frequency signal is derived from the permanent magnet generator coupled to the turbine generator shaft. This is fed to the speedmeasuring unit through a step down transformer. At the rated speed (50 Hz), an output of the measuring unit is 0 V and varies by +-0.8 V/Hz depending upon whether the speed is above or below the rated value. Phase advance unit: The speed measuring unit output is fed to the phase advance unit, which provides accelerometric signal using resistance capacitance feed forward and feed back network. The time constant of the derivative signal is adjustable from 0 to 1 sec. The modified speed error signal (signal + its rate of change) from the unit is passed on to the dead band unit and summing amplifier. Dead band unit: This unit provides a dead band on the frequency error, preventing any control action over a small band of frequency around the rated value. It is adjustable from 0 to +-0.5 Hz. Feed Back Unit: This unit receives signals from the gate setting and the Governor feed back potentiometers (located in the hydro mechanical cabinet). The command and feedback signals are compared and the difference is fed to the permanent speed droop potentiometer. This unit also provides transient signal to the temporary speed droop time constant and percentage setting potentiometers. The components associated with speed trim, no load gate limit and damping limit potentiometer are also located in this unit. Control Relays: The control relays are used for the following sequence controls:

Auto Start: When starting the turbine under Auto control, starting relay raises the gate limiter to the starting opening. When the gate limiter begins to move in the direction of opening, another relay picks up through a micro switch and feeds opening signal derived from the station DC supply to the electro hydraulic transducer. This results in Gate servomotor displacement of the position permitted by the gate limiter. At 80% speed, governor control relay picks up and brings in automatic control. Manual Start: Under manual start the gate limiter has to be manually controlled throughout the operation- before and after synchronization. Load Throw Off: In case of load throw off i.e. tripping of Gen circuit. Breaker, motor of 65G gets energized through the contacts of 52 relay and brings it to no load position.81, 81X relay affects on line to off line damping changeover. Limit Adjusting Rack: This rack contains devices that enable the gate limit mechanism adjustment according to the head, thereby preventing overloading of the generator. Outputs from the head transducer and gate limit potentiometer are compared in a comparator cum follow-up circuit, which controls gate limit raise and lower switch. Thus the gate limit follows the head such that the gate limit decreases for rising head and increases for falling head. Hydro Mechanical Cubicle: It consists of the following equipments: Electromagnetic Transducer with hydraulic amplifier, gate opening limiter, feed back shaft, lever transmission, feed back gear, main slide valve, contact device of gate limiter, gate limiter according to the head, feedback gear for adjustment according to the head, Control and Measuring instruments, double oil filter. The above units are housed in a cubicle. On the face panel of the cubicle the following control and measuring instruments and indicators are located which are necessary for the operation of the turbine and governor: Electro tachometer for speed of turbine, balance indicator, speed setting indicator, gate setting indicator, Gate limiter and Gate opening indicator, pressure gauge for oil pressure in the transducer, Servomotor stopper position indicator, gate limiter raise and lower hand wheel, speed / output raise / lower switch. Instruments mounted inside the hydro mechanical cubicle: scale for indicating the head, and gate limiter and gate-opening indicator with adequate transmitter to duplicate indications on the main control desk in control room. Electromagnetic Transducer and Hydraulic Amplifier: The electromagnetic transducer is the linking device between the electronic and hydraulic part of the governor. It consists of a coil (68) held in a magnetic field provided by a ring shaped permanent magnet (67) between leaf springs (70 and 82). To this coil is attached a flapper (65) held between nozzles (64). In normal conditions with the flapper in mid position the pressure on both sides of the piston (61) is equal and the needle (78) is held in mid-position. On passing of current through the coil, electromagnetic forces displace 68 up or down, depending upon the direction of flow of current. The displacement of the coil moves

flapper nearer to one of the nozzles. When the needle moves lower chamber (77) of piston (58) will be connected either to the pressure in upper chamber (76) or to the drain. Thus, the piston follows the needle (78).Effectively the direction and amount of movement of the piston is proportional to the direction and amount of the current flowing through the coil. Hydraulic amplifier operates at oil pressure of 18-20 kg/cm2. This pressure is controlled by the number of orifices in the throttling device (54). In case of manual control of the unit, turning the handle 66 into manual position cuts off the electro hydraulic transducer. Piston 61 will then be raised to the top most position under action of the hydraulic pressure in bottom chamber 77, thus giving an opening signal to pilot slide valve 46; the opening of main servomotor can be controlled by the gate limiter. Sensitivity o the transducer can be varied by moving fulcrum 56 of lever 57 with the help of hand screw. XIII. Centralized Grease Lubrication System: Semi automatic grease lubrication unit has been provided for lubrication, which provides grease to all the points. The backpressure switches off the unit automatically. It is used for lubrication of upper, middle, and lower bearings of guide apparatus. Filters are installed on the lines, which filter the grease before feeding to the main line. Feeders have been used to distribute the required amount of grease to different points through high-pressure reinforced hose. XIV.High-Pressure Compressed Air System: It is common to all the 3 units. One pressure accumulator with two pumps and compressor provides compressed air to pressure accumulator of OPU system of turbine. One compressor works as main and the other as standby. Technical Specification of HP Compressor: Manufacture :KG Khosla Number of Unit :2 Nominal Discharge pressure : 7Kg/cm2 Motor rating/RPM :36KW Unit discharge arte : 7&8 Kg/Cm2 Technical Specification of LP Compressor : Manufacture : Crompton Greaves Type : HY No. of Units :1 Nominal discharge pressure : 7 Kg/cm2 Unit discharge rate : 3.4 m3/min

XV. Fire Protection System:

Consists of fire protection of main generators. Protection of P/H equipment, main step-up transformers, SSTs, oil storage tanks, 220 KV switchyard, cable galleries, and control system of Stage I Fire protection for Salal I comprises of: i) Hydrant service for general fire protection

ii) iii) iv) v) vi)

Automatic water sprinkler and emulsification system for main transformers and oil storage tanks Automatic fire protection system for cable galleries and cable tunnels to switchyard. Automatic high speed halon 1301 system for control room, and station service boardroom in powerhouse. Portable chemical fire extinguishing apparatus for quenching small fires. Suitable fire detection systems for alarm and annunciation purposes and automatic operation of fire protection system.

XVI.11 KV Switchgear:
Stage I Station Service Supply for Salal is obtained from 2 nos. 11/0.415 KV station service transformer installed outdoor. H.V. supply (11KV) to these transformers is obtained from 11 KV switchgear. The incoming supply to 11 KV switchgear is taken from 2 nos. 11 KV lines coming from the grid. This switchgear controls the 11 KV supply to two 1 MVA each 11/0.415 KV station Transformers and one 11 KV spare feeder. The switchgear is installed indoor . the circuit breakers installed have nominal voltages of 11 KV. 11 KV side of the 33/11 KV transformer is star connected and the neutral is solidly earthed. Type of circuit breakers is low oil content circuit breaker, rated voltage 12 KV. The current transformers have 11 KV nominal system voltage, 3-phase and solidly earthed. 3P.Secondary winding is used both for relaying and metering. Lighting arrestors: Nominal system voltage 11 KV, rated voltage of arrestor is9 KV. Voltage transformers also have nominal voltage as 11 KV, 3 phase and solidly earthed. Accuracy class 11 KV switchgear is steel enclosed indoor type, complete with CBs, Bus bars, earthing arrangements, instrument transformers, Protective relays, cable end boxes, etc. All instruments, control switches, indicating devices, relays are mounted on the front panel. 11KV circuit breakers are floor mounted and horizontal draw out type. Safety interlocks and automatic shutters are provided to ensure that: The breaker cannot be plugged in unless in OFF position The breaker cannot be isolated in ON position and the moveable unit cannot be withdrawn when the CB contacts are not in open position. The breaker cannot be closed when the moveable unit is not plugged home or is not at full withdrawn position. Access to the breaker chamber is not possible unless the breaker is withdrawn. The LAs are of valve type distribution class of valve type distribution class of non-linear resistor construction and mounted in double cubicle. LAs are provided for the 11 KV bus.

XVII. Low-Pressure Compressed Air System:

Stage I: It consists of: i) Station service air system ii) Brake air system

There are two nos. of LP compressors installed in the compressor room at El. 399.2m. There is one common panel for both the units. The outlet pipe of each compressor is connected to the air receivers. The two air receivers are interconnected. One supplies air at the pressure of 7Kg/cm2 to all the generator brakes and turbine shaft seal. The other supplies dry air to station service, which has been provided on each floor of the powerhouse. Any one of the compressors can be set to work as main and the other as reserve during auto operation. The compressor of main will start as soon as the pressure in the air receiver drops from 7 to 6 Kg/cm2. Both automatically stop at 7 Kg/cm2. In case compressor fails to stop at 7 Kg/cm2 and the pressure rises further, the air will be released through a safety valve installed on air receivers.

XVIII. High Pressure Compressed Air System: The high pressure compressor
is meant for feeding air under pressure 40 Kg/cm 2 to the pressure accumulator from which oil is fed to the hydraulic components of the governing system of the turbine. The compressor plant consists of two nos. of compressor coupled with electric motors, two nos. of oil and water separators, one air receiver, control panel and measuring instrument. Any one compressor can be set to work as main and the other as standby. The compressor shuts off at 42 Kg/cm2 and picks up at 40 Kg/cm2. In case of malfunctioning of the set, the standby picks up when the pressure falls down to 38 Kg/cm2. Setting of the safety valve of the compressor is 45 Kg/cm2.

XIX. Drainage and Dewatering System: the dewatering system is designed for
dewatering of the penstock, scroll case and the draft tube. The water from the penstock and draft tube is drained by means of draft tube drainpipes. The water from the dewatering gallery is drained in to the dewatering sump.

XX. Air Conditioning System: The control room is provided with air conditioning
system for maintaining uniform temperature and humidity for the comfort of the personnel and satisfactory operation of sophisticated instruments and relays. The reception room adjacent to the control room is also air-conditioned. The equipment for air conditioning includes condensers, air handling unit, located at El. 416.0mtr. The air conditioning system consists of two condensing units each of 50T capacity. One unit is used at a time and the other acts as a standby.

Ventilation System:
Stage I: Forced ventilation system is provided for adequate air supply to all the areas of the powerhouse, by means of 4 nos. blowers each of 1200 m3/min capacity for both the stages. Three blowers in operation meet the requirement and the fourth acts as standby. These blowers discharge into a common duct system, the main duct running along the Eline at EL 416mtr. The air after ventilating the areas below the main m/c hall floor

escapes through the staircases/ hatch covers at different floors, exhausted out of the powerhouse by exhaust fans. Separate fan for the battery room is provided to divert the exhaust in the direction away from the inlet section. The air supply fans (4nos) are of centrifugal type. The exhaust fans are of the propeller type. The exhaust fans of the battery room are two nos. of tube axial type. Higher air pressure than the outside air is maintained inside the powerhouse by forcing in 10% more air than is exhausted from the building.

XXI 220 KV Switchyard Equipment: The switchyard is located at El. 417 meter
adjacent to the power station on a filled platform. There are total 13 bays in the switchyard. i) Six incoming feeder bays from six generators via generator transformers ii) Six outgoing feeder bays Jammu I, Jammu II, Kishenpur I, II, III, and IV iii) One bus coupler bay Power from generating units after stepping up to 220KV is transmitted to the switchyard by 220 KV link line. The circuit breakers and isolators are remotely operated from the control room in addition top provision for local control. A double bus arrangement and bypass isolator facility has been provided in the switchyard for easy maintenance of circuit breakers without interruption of power. XXII. Power Line Carrier Protection: PLCC system is used for speech communications between Salal powerhouse and Jammu and also between Salal powerhouse and Kishenpur s/s. The system is also used for carrier protection purposes.

XXIII. Control system: The control room of the power station is located at El.
419mtr. It houses the following equipment of control and protection system. i) Control desk for turbine and generating units ii) Simplex type control panel for generating units and generator circuit breakers iii) Annunciation panel iv) Control panels for outgoing feeders and bus coupler v) Synchronizing panel vi) Relay panel for generating units vii) Relay panels for outgoing feeders and bus coupler viii) AC Station service board ix) DC distribution board x) PLCC panels

XXIV.UCB: UCB of each unit comprises of the following panels:

i) Electrical measurement panel ii) Temperature measurement panel iii) Annunciation panel iv) Automation panel Theses panels have been installed on the machine hall floor of the powerhouse and are interconnected. It houses indicating meters for indicating machine parameters,

control switches, push buttons and indicating lamps for start/stop of the unit from the machine floor. The temperature measurement panel consists of one logo meter with selector switch and one temperature recorder. The RTDs installed at various locations in generator are connected to the above logo meter and recorder. Indication of temperature measured by individual RTD can be displayed by selecting the selector switch position. Annunciation panel consists of multi-channel fascia for indication of various faults in the machines, sensed through the various detectors. Automation panel contains all relays of automation circuit required for start/stop of generating unit. Relays for mechanical faults including some auxiliaries have also been provided. The rear side of the above four panels houses different AC and DC control supply switches and fuses of different circuits, which can be checked during fault tracing.

XXV. Protection system:

To prevent the different equipments like generating units, main transformer, unit auxiliary transformer, different outgoing feeders, from any kind of major problem that may develop during operation; protection in the form of different types of relaying has been used. The entire scheme of protection can be divided into the following zones: i) Generator protection ii) Gen Transformer protection including excitation transformer and UAT iii) 220KV BB protection iv) 220KV feeder protection Generator protection: The protections provided are a) Split phase differential protection in the stator winding b) Differential protection against phase to phase faults c) Over voltage protection d) Loss of excitation protection e) Stator earth fault protection f) Rotor earth fault protection g) Under impedance/ backup protection h) Negative phase sequence protection i) PT fuse failure protection a) Split Phase Protection: This scheme protects against turn-to-turn fault in the generator stator winding. Triple pole, instantaneous high stability circulating current relay, CAG34 has been used. This is a high impedance relay. The generator stator has been wound with two identical 3-phase windings connected in parallel. A balanced current arrangement between the two CTs (ratio 4000/5) connected in the line ends of the two windings has been made.

To prevent instability at a high level of fault current, stabilizing resistors in the relay circuit have been used in series with the relay coils. To shunt each relay and stabilizing resistor, a nonlinear metro sill resistor has been used in order to limit the over voltage. The plug setting of the relay is at 10% so that it operates at an unbalancing current value exceeding 10% of the set value. Interturn faults are uncommon but not unknown. A large portion of the insulating material is inflammable and in case of an air-cooled machine, the forced ventilation causes flames arising from an arc to spread around the winding. So the relay will also operate for the release of CO2 to extinguish fire. Thus the relay is arranged to i) Operate emergency shut down relay ii) Release CO2 iii) Trip unit Breaker iv) Trip UAT breaker b) Generator Differential Relay: This is also a high impedance type relay CAG34 similar to the above. It is used for generator winding protection against any phase to earth fault or phase-to-phase fault. Each relay coil gets its feed from two CTs of ratio 7500/5 amps placed one at the phase side and other at the neutral side. It is arranged to i) Operate emergency shut down ii) Release of CO2 iii) Trip unit breaker iv) Trip UAT breaker c) Generator Over Voltage Protection: This relay is VDG 11, inverse time over voltage relay used for over voltage protection of the generator. It has a setting range of 110-170%. This relay gets its feed from 11 KV/110 V PT placed on the phase side of the generator. Over voltages may occur due to: Defective operation of the voltage regulator A sudden variation of load, especially the VAR component Sudden loss of load due to line tripping, which causes a speed rise of the generator because of as relatively slow operation of the governor. This speed rise causes the voltage to increase. This relay is used to: i) Operate emergency shut down ii) Initiate trip alarm in the control room iii) Trip unit breaker iv) Trip UAT breaker d) Loss of Excitation Relay: Loss of field supply to the synchronous generator can be caused by a fault in the excitation system or by the incorrect opening of the field circuit breaker. Also during abnormal decrease of excitation or loss of

excitation, the generator draws the required magnetizing current from the system and operates as an induction generator. The machine in such a case will continue to generate power as per the setting of the governor. This operation as an induction generator results in the in the flow of slip frequency in the rotor. Since the generator is not designed as an induction machine, the damper windings are not adequate to carry the rotor slip current, so abnormal heating of the rotor takes place. Moreover, if the capacity of the machine is significant in relation to the system, the system voltage will drop and instability will occur. To protect against this, relay type YCGF11 has been used. This relay has a four pole induction cup movement which provides a single phase off set MHO characteristics with its center on the negative X axis. This offset is adjustable to avoid undesirable operation of the relay of power swings or loss of synchronism not accompanied by loss of field. The offset value is usually kept within 50-70% of Xd. The relay gets its feed from PT 11KV/110V, and CT 7500/5. It is arranged to I i) Initiate non-trip alarm in control room ii) Operates emergency shut down relay in the event of danger of system stability iii) Trip unit breaker v) Trip field breaker vi) Trip UAT breaker e) Stator Earth Fault Relay: The neutral point of the generator is usually earthed to facilitate protection of the stator winding and associated system. It is essential to insert impedance in the earthing circuit to limit the magnitude of the earth fault current. The neutral earthing has been done through a grounding transformer of capacity 80 KVA, 11KV/220V. Loading resistor of 0.328 ohms is connected in the secondary of this transformer and the relay is connected parallel to this resistor. The relay type is PVMM61. It is an induction disc relay with an adjustable inverse time voltage characteristic. The relay is arranged to i) Operate emergency shut down relay ii) Release of CO2 iii) Initiate trip alarm in the control room v) Trip unit breaker vi) Trip field breaker vii) Trip UAT breaker f) Rotor Earth Fault Protection: VAEM21 type rotor earth fault relay has been used here to detect earth fault in the generator field winding and associated circuits. The field circuit of the generator comprises of the winding and the armature of the exciter and the field circuit breaker. This forms an isolated DC circuit, not earthed, which means that single earth fault occurring in this circuit will not be able to result in the flow of fault current. Danger arises on the occurrence of a second earth fault at a separate point, which diverts the currents in part from the

intervening turns. The field current of a large machine is considerable and when so diverted can burn the conductor, causing serious damage rapidly. If a large portion of the field winding is short circuited, a magnetic imbalance is caused resulting in violent vibration which may damage bearing surfaces and displace the rotor to an extent that starts fouling the stator. The VAEM21 type rotor earth fault relay consists of a transductor, a transformer and a rectifier for providing bias voltage. This bias voltage is obtained after rectification of a 50 cps single phase auxiliary AC supply. This single-phase AC supply is used for negatively biasing the field circuit. The AC winding of the transductor is connected to the same auxiliary supply. When the field circuit is healthy, there is no flow of DC current and AC winding presents high impedance compared to the AC rectified relay. The AC rectified relay therefore remains uncharged. In case of a fault, DC current flows through the transductor DC winding, thus saturating the core and reducing the impedance of AC winding. g) Generator Back-up Protection: This is a YCG15A type relay. The relay is a distance measuring type having an offset mho characteristic. The balanced 3 phase external faults can be detected by impedance type relay set to reach just beyond the bus and given sufficient time delay for a chance to clear the fault. This relay provides for 3-phase single step definite time protection against all types of system phase faults. Provision is available in the relay to avoid maloperation during recoverable swings. This relay on picking up, trips the generator breaker, thus isolating the generator from the bus, if the fault has not been cleared after the time delay. h) Negative Phase Sequence Relay: Negative phase sequence current is developed when there is unbalancing of load in the system. The resulting reaction field is produced by negative phase sequence component, which rotates in the opposite direction to the DC field system. Hence it produces a flux, which cuts the rotor at twice the rotational velocity, inducing double frequency currents in the field system and the rotor body. The resulting eddy currents are very large and cause severe heating of the rotor. The duration of the unbalanced short circuit is such that the I 22t <= 40 in case of a normal air cooled machine. I2 is the rms value of negative phase sequence component of rated stator current. In Salal, a CTN 31 relay for negative phase sequence has been used. On energisation of this relay, alarm will be provided then after a time delay command will be given to trip the generator breaker only. i) Fuse Failure Relay: this is VAPM 31 type relay. This relay is for protection of PTs. Provision is made for prevention of incorrect tripping of circuit breaker by distance relays, others, on the failure or inadvertent removal of the PT secondary circuit fuse. This relay consists of a rectified AC voltage operated hinged armature unit. Theses coils for three phases are wound over a single core producing into effect a common relay for three phases. Each coil is connected across one of the PT secondary fuses and under healthy conditions this coil is

short-circuited by the fuse and cannot be energized. When one or more fuses blow out or are removed, the appropriate coil is energized and the relay operates immediately to open the circuit. The relay is arranged to: i) Initiate non-trip alarm ii) Interrupt tripping circuit of loss of field protection iii) Interrupt tripping circuit of the voltage controlled o/c back up protection Generator Transformer, UAT and Link Line Protection: The following protection has been provided for the generator transformer and associated equipment. i) Overall differential protection ii) REF protection for GT iii) Auxiliary relay for tripping and annunciation in GT iv) O/c protection for UAT v) REF protection on UAT low voltage winding vi) Auxiliary relay for tripping and annunciation functions in UAT protection vii) Link line protection i) Overall Differential Protection: The generator transformer is protected against internal fault by differential relays, which work on the merz-price system. Although the Buchholz relay detects all electrical faults that occur inside the transformer, it is possible to have a flashover outside the transformer at the windings. The differential protection detects all such faults and also clears other heavy faults faster than the Buchholz. When a transformer is energized, the inrush currents may attain peak values according to several times the transformer full load current. These currents also decay relatively slowly. This current generally flows in one side of the differentially connected relay only; hence it tends to operate it. A DTH32 type differential relay has been used as an overall differential relay covering the generator, main transformer, and the T-off to the UAT. This is high-speed biased differential relay and designed to provide stability during heavy through currents. The relay utilizes second harmonic restraint to prevent operation by normal magnetizing inrush currents produced when the transformer is energized. An instantaneous high set circuit overrides the biased differential circuit to clear heavy internal faults in about one cycle. Provision is made to ensure the secondary currents flowing in the interconnecting pilots are balanced and matched with relay rating. This relay is arranged to: i) Operate emergency shut down relay ii) Initiate trip alarm in control room iii) Trip circuit breaker iv) Trip UAT breaker v) Trip field breaker ii) Restricted Earth Fault Relay: The restricted earth fault relay works on the residual currents and protects the 220 KV secondary winding of the generator

transformer against earth fault. Any fault occurring outside the zone will have no effect on the relay. Relay used is CAG14 instantaneous circulating current relay type. It is provided with standard attracted armature relay in series with a circuit to system frequency, which rejects harmonics caused by CT saturation. A tapped internal autotransformer provides adjustable settings on a plug board. An external series stabilizing resistor allows continuous adjustment of voltage setting over a wide range. As soon as there is some earth fault in the 220 KV winding, this relay operates instantaneously. It is arranged to: i) Operate emergency shut down ii) Initiate trip alarm in the control room iii) Trip unit breaker iv) Trip UAT breaker iv) Over Current Protection in UAT: This is a CDG31 triple pole IDMT over current relay. This protects 500KVA, 11KV/415V UAT against o/c faults. This relay has a current setting range of 50% to 200%. It is provided with an induction disc relay, which has a high torque movement with low burden and low overshot. After time delay, the relay trips the generator through electrical lock out relay. It is arranged to: i) Operate emergency shut down ii) Initiate trip alarm in the control room iii) Trip unit breaker iv) Trip field breaker v) Trip UAT breaker v) REF for UAT: This is also a CAG14 type relay as used in main transformer. It protects the LV-415 V winding of the UAT. This relay is arranged to: i) Operate emergency shut down ii) Initiate trip alarm in the control room iii) Trip unit breaker iv) Trip field breaker v) Trip UAT breaker v) Link Line Protection: If a fault occurs between the CTs on the generator transformer secondary 220KV and the circuit breaker, the fault will be sensed by Bus protection and breaker will trip. But, the fault will still be fed by the generator and shall only be cleared after some time when the generator back up protection shuts it down. To safeguard the generator and the transformer against such faults and to clear them quickly, the link line differential scheme has been used with the CAG34 type relay. Bus Bar Protection: The protection scheme for a power system is meant to cover the whole system against all types of fault. Unrestricted forms of line protection such as O/C

and distance scheme meet this requirement although faults in the BB zone are cleared by these protections only after a time delay, the result may not be tolerable. The following BB protection has been used. i) BB differential protection: The CAG34 type for instantaneous high stability circulating current relay has been used for differential protection. ii) BB supervision relay: VTX31 relay has been used for continuous supervision of secondary connections of the BB zone protection scheme. It is a static definite time over voltage relay, connected across the bus bar and across the coil and stabilizing resistor of the main protective relay. When the voltage across the BB exceeds the relay settings voltage, the static circuits energize the attracted armature output unit. iii) BB shorting relay: This is an auxiliary relay to BB supervision relay. This is a VAJH13 high-speed tripping relay used for protection against BB shorting. It is a fast acting multi contact attracted armature type with a high degree of mechanical stability. This has hand reset contact and an operating coil cut off contact. As soon as shorting occurs in the BB, the relay operates. iv) Under voltage relay for auxiliary circuit DC fail annunciation: This is a VAG11 instantaneous voltage relay used for auxiliary circuit DC fail annunciation circuit. This is standard attracted armature relay of simple and robust construction. v) DC fail scheme relay: This is a VAG21 instantaneous voltage relay for control of DC fail scheme. vi) Bus coupler protection: The bus coupler has been provided with the following relays for its protection: a) CTIG LBB protection relay with time delay feature. b) VTT 11 pole c) VAG 11 under voltage relay a) Two zone BB protection scheme with separate check zone feature comprisingCAG34 bus differential relay, VTX131 bus wire supervision relay, VAJH 13 bus wire shorting relay, CDG 31 triple pole IDMT O/C relay for SST, VAG14 REF for SST, VAG 21 under voltage relay for standby DG set. Feeder Protection: The following protections are provided in the feeders: i) Phase comparison carrier protection: This has the following features High-speed operation High sensitivity for unbalanced faults HF range 50 KHz to 700 KHz Operational range of 36 DB Low CT burdens This scheme includes the following assemblies: Sequence network Starters HF transmitter and receiver Stability/ trip angle discrimination Meters, lamps, switches, coaxial cable, etc. ii) Distance Protection: The secondary or back up protection for feeders comprises of high speed directional distance relays for phase faults and separate directional distance

relay for detection of ground faults. For this purpose MM3V type relay scheme is used. The distance protection scheme is having stepped characteristic with three zones of protection a) First zone having instantaneous operation and the relay is set to protect 8090%of the protected line b) Second zone will protect the left out 20% of the first line and 50% of the next line section with time delay. c) Third zone will operate with time delay larger than zone2 and reach is set at least 1.2 times with impedance presented to the relay for a fault at the remote end of the second line section. iii) Protection against power swings: Power swings are variations in power flow which occur when the voltage of generators at different points of the power system slip relative to each other to cater for changes of load magnitude and direction or as a result of faults and their subsequent clearance. The result of a power swing may cause the impedance presented to a distance relay to move away from the normal load area and into the relay characteristic. In case of a transient power swing , it is important that a distance relay does not trip and should allow for the power system to return to a stable condition. This protection is provided in the distance protection type MM3V. There is a provision in the scheme for allowing the breakers to trip if the disturbance lasts for an interval equal or longer than the third zone tripping time. iv) Auto Re-closing of Lines: Most of the faults (80-90%) on transmission lines are transient in nature. This may result from lightning, temporary contact of the live conductor with foreign objects, insulator flashover, etc. If the faulty line is immediately tripped out due to the above-mentioned transient faults, and time is allowed for the fault to de-ionize, re-closure of the breakers will result in the successful energizing of the line. Autoreclosure schemes are used to carry this duty, thereby causing improvement in the continuity of supply. A further benefit is maintenance of system stability and synchronism. In Salal, single phase and 3-phase auto re-closing for the breakers of six outgoing lines and bus coupler breaker is provided in the auto-reclosing scheme, consisting of the following relays: 1. VARM 111 single and 3-phase auto-reclose system 2. OBS type auto-reclose selector switch Provision is available in the scheme to prohibit the operation in following circumstances: a) Tripping due to operation of BB protection b) Tripping due to operation of LBB c) Tripping just after manual close of line breaker d) Tripping for faults cleared by backup, second and third zone distance relays e) Failure of carrier of distance protection scheme This scheme is suitable for a) Single phase re-close and lockout b) Single phase and 3-phases re-close and lockout c) Three phases re-close and lockout

d)

Lockout

The auto re-closing scheme is suitable to work in conjunction with synchronizing check relays and dead line charging facility. v) 220KV- Breaker Protection: The following protection is provided. LBB: For this protection a CTIG39 relay is provided. This scheme is provided for failure of any 220KV circuit breaker to open after the action of the associated protection. This breaker protection shall trip all the other circuit breakers feeding the fault after a time delay. This protection scheme will be started by he relay of the respective circuit breaker and shall incorporate relays to monitor the continuing flow of fault current after the action of trip relay, which will be the indication of the failure of the circuit breaker. Necessary provision has been made to prevent mal-operation of the scheme for failure in the control circuits. Breaker Pole Discrepancy: A VTT 11 type relay is provided for this purpose. This relay with timer is provided to trip all the three poles of breaker in case of pole discrepancy arising due to mal-operation of the breaker poles. Provisions are made for alarm/ annunciation to indicate the breaker pole discrepancy. Interlocked Over Current Protection: Interlocked over current relay CDG31 type has been used to protect the dead zone between CT and Circuit Breaker. Protective tripping devices: Theses are grouped under three main groups: a) Electrical lockout circuit b) Non electrical lockout circuit c) Non lockout circuits a) Electrical L/O Circuit: The generators during electrical faults are tripped through the master relay 30Y on the relay panel in the control room. The tripping of this relay causes the tripping of the main breaker, field breaker, and UAT breaker. The tripping of this relay is accompanied by the tripping of any one or more of the following protection relay: Generator differential Generator split phase differential relay Gen Transformer differential relay Gen over voltage relay Stator earth fault relay Loss of excitation relay] Fire in the generator barrel Rotor earth fault protection Interlocked over current protection LBB AVR PT fuse failure Metering and protection fuse failure relay

Main transformer REF Main transformer buchholz relay Main transformer winding temperature high Main transformer oil temperature high Main transformer on fire Operation of REF of UAT UAT winding temperature high UAT o/c protection Excitation system trouble third stage b) Non-Electrical Lockout Trip: This tripping is due to mechanical faults causing non-electrical lockout master relay 30X to trip. This tripping causes opening of main circuit breaker, field breaker, and LT of UAT. The machine is stopped. The causes for this type of tripping are TGB temperature high TGB oil level low LGB temperature high LGB oil level low UGB temperature high UGB oil level low Thrust bearing temperature high Thrust bearing oil level low Generator air ventilation system temperature high Unit over speed Electrical lockout operated Governor faulty Emergency/ accidental closure of head gates OPU oil pressure low Over speed of unit Shear pin failure b) Non-Lock out Trip: This tripping is caused through the master relay 30Z. In this tripping, the generator circuit breaker trips and the machine keeps on spinning. The tripping is caused due to: Negative phase sequence protection trip Distance relay for generator backup protection trip Gen. Transformer winding temperature high Generator over voltage relay (59) Mo.No. VDG11AF1151B5 in three phases. Over voltage relay (instantaneous): Type: 159A,B, C Mo. No.: VTIG12AFB (N) 8001A in three phases. Under voltage relay: Mo No.: VAGM22AF74G

Volt Balance relay: Mo No.: VAGM61BF64 for three phases. Mo No.: VAGM61BF6A for three phases Generator over voltage relay: Mo. No.: VTIG12AFB (N) 8001A Restricted earth fault relay (64GTR): Mo no.: CAG14AF15A Restricted earth fault relay (64VTR): Mo.no.: CAG14AF15A Interturn differential protection: Mo No.: CAG34AF8001A (M) for all three phases Overall differential protection: 87GT Mo. No.: CAG34AF59A (M) for all three phases Generator differential protection (87G) Mo. No.: CAG34AF8001A (M) at all three phases Over current relay(51ABC) Mo. No.: CDG31FF9003A (M) for all three phases For Udhampur feeder 2: E/F relay (Over current and earth fault) Mo. No.: CAG52BF8012 (M) in R and B phase and 1 for e/f Distance protection at Salal Type: MM3V Distance protection at Udhampur end: SSRR3V scheme For Udhampur feeder-1: E/F relay and over current Mo. No.: CAG52BF8012B (M) in R and B phase and 1 for e/f Field failure relay YCGF (40G): Back up mho impedance relay (YCG15): Mo.no. YCG15PF8001ACM For Jammu feeder: E/F relay and over current relay Mo.No. CAG52BF8012B (M) in R and B phases and 1 for e/f

For Jammu feeder: Distance protection scheme Type: MM3V Over current relay (51A), 51(B) Mo. No.: CDG31FF5003A (M) Restricted earth fault relay for station transformer (64RA, 64RB) Mo. No.: CAG14AF12A Differential relay (87A) Mo. No.: CAG34AF59A Differential relay (87B) Mo no.: CAG34AF59A Differential relay for BB protection (87CH) Mo. No.: CAG34AF59A Negative phase sequence CTN Mo.no. CTN31D8FA68 LBB protection relay on Generator panel Mo.no. GTI539BF8012A (M) LBB Protection relay for all four feeders Mo.no. CTIG39BF8002A (M), 4 units on Udhampur 1, Udhampur2, Jammu and one on bus coupler Station earth fault relay on generator panel Mo.no. 64GIPVMM-161 Generator transformer overall differential relay Mo.no. DTH-32-MG8018A (M) 100% stator earth fault relay PVMM unit- II and III Mo.no. PVMM161 Negative sequence relay for Unit II and III Mo. No.: CTN31D8FA6B Voltage balance scheme for unit II and III Mo. No.: VAGM61BF6A

4. Starting and Stopping of Turbine Generator

Check List before stating the machine. A Checks in Control Room: . Check that there is no shut down against the machine which is going to be started. It may be insured that the machine is free from fault. The work permit register/maintenance register should be seen before running the machine. The AC and DC supply should be available in UCB. Check that no alarm is appearing on the alarm facia in control room, UCB or excitation panel. All relays and lockout relays should be reset. Check that alarm bells and trip hooters are operative. Test the annunciation window lamps through lamp test push button. Check that the pressure gauges provided for the penstock, spiral, draft tube are in working order. Guide vane should be fully closed Servomotor lock should be off. Brake air pressure should be normal. Turbine Guide bearing oil level should be normal. Governor OPU pressure and oil level should be normal. OPU pump should be on auto. Shaft maintenance seal should be off Transformer fire protection should be available. Generator breaker should be opened. Isolator should be closed. Cooling valve should be opened. Ensure that all the cooling water valves of the concerned unit supplying water to the stator air cooler, Turbine guide bearings, thrust bearings, Main transformers, shaft seal are open. Also ensure that the outlet valves of the respective cooling water circuits are open. Check that the pressure of 3-4Kg/cm2 is available. In case of reduction in pressure at any of the supply points the cause should be investigated and corrective measures taken so as to avoid rise in temperature.

Starting procedures can be carried out both from the control room or from the UCB depending upon the position of the selector switch on the control desk in the control room. Confirm following points before giving the start order. 1. Readiness of machine from respective floors. 2. Governor in auto mode. 3. Selector switch kept in Control Room position 4. The excitation selector switch kept in Control Room position. 5. Selector switch has been kept for Separate Governing. After the above checks, the following instructions are to be followed: 1. Filling up operation of Penstock Operate filling in valve of stop log by gantry crane through lifting beam if the stop log and penstock gate both are in lowered position. When water level in between the penstock gate and stop log rises to the normal reservoir level of 487.6 meter, lift the stop log completely. Now allow the water to enter into the penstock by crack opening of the penstock gate and monitor the penstock water pressure through the pressure gauge installed at EL-389(Turbine floor).When the penstock pressure shows around 10Kg/cm2,the operating staff at penstock intake gate be asked to raise the gate in full open position. 2. Give the start command to the start stop switch provided on the control desk to start position. Following sequence appears automatically. i) Start relay under automation circuit is energized ii) Electric motor of the gate limiter switched on and moves the limiter to starting position. iii) Gate apparatus opens and machine starts rolling to build up speed. iv) Turbine picks up speed and at 80% speed, governor relay is switched on. v) Governor takes control of machine vi) Field breaker closed and terminal voltage builds up to 70% through field flashing system. vii) After 70% of machine voltage, field flashing is switched off, blocking of gate control is cancelled and regulator takes function of regulating the rated voltage. In case the excitation control switch is put on manual mode and the field breaker is closed manually, then utmost care should be taken while closing the field breaker. Field breaker should not be closed before machine picks up 80-90% speed. If while closing FB the speed of the machine is low, then the UAT will be subjected to over fluxing stresses.

3.

Synchronizing Procedure: For putting the machine on bar, machine and system voltage, frequency and phase should be matched through a synchroscope installed on the control panel in the Control Room. The synchronization can be done on Manual or Auto mode depending upon the selection of control switch. Manual synchronization: 1. Check that the machine has attained 100% speed. 2. Check that generator voltage is 11 KV. 3. Now put the key into the synchronizing switch on the control desk and turn this to ON position. 4. Switch on the synchronizing panel and watch for the incoming as well as the machine voltage, frequency and synchroscope needle movement. 5. Adjust speed of the machine by flipping the switch Load / speed adjuster in the increase direction if the machine frequency is lower than the system frequency. If machine speed is higher than the system frequency flips the switch in the reverse direction. The machine frequency is thus matched to the system frequency. 6. Also adjust the voltage of the machine with help of the excitation Control switch to match with the system voltage. 7. Close the generator breaker by flipping the Breaker Control switch in Close position when the synchroscope needle is having a slow and smooth movement in clockwise direction and is just at 12 O clock or very near to the 12 O clock position. After synchronizing the machine, load is gradually built up Load/ Speed adjuster flip switch. Switch off the synchronizing switch and replace keys in the keyboard. Cautions during manual synchronizing: 1. Never try to close breaker when synchroscope needle is moving very fast 2. Dont try to close breaker when needle is moving in the anticlockwise direction, even if near the 12 O clock position. 3. Dont close breaker in a hurry. Wait for next rotation. Every bad synchronisation gives a big jerk which is harmful to machine. 4. As soon as the breaker is closed, quickly transfer some load by giving short flips of the Load/ speed adjuster switch towards the increase side. Delay in this may cause motoring action, which again is harmful for the machine. Auto Synchronizing: When the checks as described under manual synchronizing till the point where the synchronizing panel is switched on, and incoming, machine and synchroscope needle movements are watched. After this, press the auto-synchronizing switch ON with the help of the key. Just when the breaker closes, immediately take the load through flip switch o0f Load adjuster. Switch off the synchronizing switch and keep the key in the keyboard.

N.

Operating Limits:

The rated output of the generator is obtained at rated voltage, current and power factor of the generator as well as at the designed inlet cooling air temperature. In course of operation, certain deviations from the rated operating conditions may occur. Voltage and current: The generator can develop rated output at rated power factor of 0.9 lagging with permissible change in voltage within +-5% of rated value. The stator current correspondingly will change within the limit of +- 5%. of the rated value. Operation of machine at voltage exceeding 110% of the rated voltage is forbidden. Stator current should not increase more than +5% of the rated value. Following chart shows permissible variation limits: 12.10 11.99 11.88 11.77 11.66 11.55 11.00 10.45 09.9 Gen voltage 103.5 105.8 108.1 110.4 112.7 115.0 115.0 115.0 108.1 MW output at 0.9 pf lagging 5.49 5.62 5.82 6.03 6.16 6.36 6.7 7.03 7.03 Stator current (KA) When stator current tends to increase beyond 7.03 KA, reduce MW output of the machine. Frequency: The generator is allowed to operate at rated output (115MW) at frequency variation within +-5% of the rated frequency 52.5 Hz to 47.5 Hz. When the frequency level is lower than 50Hz the generator voltage is not allowed to increase over its rated value of 11 KV in order to prevent the generator transformer being over fluxed. Power factor: The generator can operate at a continuous lower lagging pf provided the rotor current does not exceed 1365 amperes. Admissible operating temperatures: Description of item Stator winding Stator core Rotor winding Thrust and guide bearing Main transformer Max. Allowable temperature Celsius 105 105 120 80 (segment) and 65 (in oil bath) 80 (segment) and 75 (in oil bath) in

In no case should the temperature of the above items should exceed their limits. Vibration: Under all operating duties and at rated speed, the admissible vibrations on the horizontal plane of the generator bracket should not exceed the value of 0.18 mm(180 micron). Vibration level at TGB should not be more than 150 micron.

O. Checks and Instructions during running of the machine: Control Room: While the machine is operating, watch will be kept on all the parameters of the machine, feeders and grid conditions. Any variation in load shall be done supported with sufficient reason and in consultation with the shift in-charge. 2. The machine shall not be operated in the forbidden zone. 3. Ensure that the DC supply through distribution board is available to all the control and annunciation panel of the running machine and in no case will it be switched off. 4. Ensure through test check of the push button provided in the desk for healthy trip indication. 5. While generating active power, due consideration for generation of reactive power may also be given depending upon the system conditions but should not be exceeded beyond the permissible limits of the stator and rotor current. 6. Ensure that the machine is running within the operating limits as described before. 7. Any annunciation appearing on the panel shall be accepted and recorded before resetting. In case of non-resetting of the annunciation, remedial measures must be taken to rectify the fault before tripping of the machine. In case of extreme exigencies, the shift in charge, if so decides, may press the emergency push button for stopping of the machine. In case of fire in stator, CO2 release button may be operated. 8. In case of failure of AVR or blowing off of fuse of the PT, immediate action will be taken top control the voltage manually by selecting the voltage selector switch in manual mode and flipping the Excitation control switch in increase and decrease direction as requirement. While switching the regulator mode from auto to manual when AVR fault has been attended, check if the reading of the matching voltmeter on the control desk is zero. If not, bring it to zero through corresponding increase/ decrease of potentiometer on the control desk to avoid any reactive surges. 9. Ensure that any equipment under maintenance has a warning board MEN AT WORK hung on to avoid any operation by mistake. 10. All parameters of the machine and feeder on hourly basis as per format given in the next section must be recorded during each shift and signed. Unit Control Panel: 1. Ensure that any annunciation appearing on the panel window is immediately accepted and noted before resetting. The matter should be brought in the notice of the shift in charge before resetting. In case of non-resetting, the maintenance in charge should be contacted by the shift in charge without loss of time. This should be entered in the complaint register clearly showing the nature of fault, date, time and name of the responsible maintenance officer to whom the fault has been reported along with the time. 1.

2.

3.

Ensure that the temperatures of various installations such as stator temperature, air cooler temperature, TGB, UGB, LGB, and thrust bearing temperatures as indicated by the digital temperature meter on the UCP is recorded on hourly basis. In case of rise in temperature from normal value, the operator on duty should immediately inform it to the shift in-charge and remedial measures should be taken rectify the rise in temperature. The temperature recorded from the unit control panel meter must be crosschecked with the TSDs installed at 389.0 and 392.85 mtr. Check that the control knob of the governor is in Auto position.

Turbines: 1. TGB Check oil level of housing. In case of abnormality, report to shift in charge Check cooling water supply to the TGB coolers, ensure 3-4 Kg/cm 2 pressure at the inlet. Monitor temperature of TGB and record in logbook. Any rise in temperature should be informed to shift in charge. 2. Guide apparatus and Turbine top cover: Check if all shear pins are intact. Ensure that there is no abnormal leakage from the upper and lower bushes. Check against oil leakage from guide apparatus of servomotors. Check that shaft seal gets clean water at 3 Kg/cm2. In case of top cover flooding, check that the gravity drain and ejector system is working. In case of any abnormality, report to the shift in charge. Hourly readings of the penstock pressure, spiral pressure, draft tube pressure and TGB temperatures must be recorded in the log sheet. Concerned meters are installed in 389.00 m EL. 3. CO2 system at El 396.95 m.: Ensure that the CO2 banks have been connected to work on the auto mode. Check that the DC supply is available to the control circuit of CO2 system. Ensure for any annunciation on the CO2 control panel. 4. Unit Auxiliary Board at El.396.95 m.; Ensure that all the breakers supplying unit auxiliaries are ON. During operation of the unit, auxiliary supply is fed through the respective auxiliary supply breaker. In this condition, the station service breaker must be OFF. If the auxiliary supply is to be shifted to the station service or the standby DG set, care must be taken against intermixing of these two separate sources of supply. Note that when supply sources of unit auxiliaries are to be changed from unit auxiliary transformer to station / DG supply, or vice versa, the breaker through which auxiliaries are being fed should be made Off first and then only shall the breaker of the other source should be made On. Ensure that all the breakers, which are not in function for the present but may be required, to be put in operation at any moment are in a charged

condition. The spring charging indication can be seen from the indicator provided on the breakers. In case of tripping of any breakers or any annunciation on the panel, the operated relays should be recoded in the log sheet.

5. Other checks: the checks on the governing system, OPU, HP and LP compressors, drainage system, filtration plant for filtered water supply to shaft seal may be done. P. Activities, Precautions during and after tripping of the machine: To prevent the generators, its auxiliaries and switchyard equipment during any severe fault, which may develop in the generating unit or associated system, the machine is tripped by the concerned relays. The faults have been grouped under here categories: Electrical lockout: Covering all the electrical faults. The master relay 30Y gets activated through different initiating relays, trips the generator breaker, field breaker and gives closing command to the guide vanes and penstock gate. Non-electrical lockout: Covering all the mechanical faults of the aturbine, generator, etc. The master relay 30X gets activated through different initiating relays, trip the generator breaker, field breaker and gives closing command to the guide vanes and penstock gate. Non lockout trip: It covers certain line faults thereby opening only the generator breaker to isolate the machine from the system while the machine keeps on spinning. The master relay to operate the generator breaker is 30Z. Under any of the above conditions, various annunciations may appear on the annunciation panel of the UCB and in the control room. When such tripping occurs, action must be taken immediately. Any annunciation on the control room panel, UCB, SSB, etc must be immediately accepted and recorded. It should be ensured by the shift in charge that no such annunciation is reset until it has been recorded. Ensure that the auxiliaries are functioning properly during stopping period so that the machine does not get adversely affected for want of oil/ water circulation. Ensure that the brakes are applied at the desired moment on auto/ manual operation. During stopping, the brakes should be applied at 30% of the machine speed. It must be kept in mind that if the brakes are not applied at the right speed and if the machine is allowed to roll for a longer time more than 4 mins, then the oil film between the mirror surface and the thrust pad may become weak and the pads can get damaged. The fault appearing on the machine should be analyzed on spot and recorded in the logbook.

If the machine trips due to Line/ Grid problem, then the shift in charge should enquire the cause from Kishenpur s/s or from NRLDC through phone/wireless and information recorded in the tripping register. If the fault does not reset, then the shift in-charge should immediately inform the matter to the concerned maintenance in-charge and record the complaint. Shift in-charge will decide to restart the unit depending upon the fault conditions. In case of fault warranting stopping of machine, necessary action must be taken to start another machine if any, which is free from fault. Shift in-charge will also take due consideration to avoid any loss of generation without sufficient reasons.

Stopping Sequence of the Machine When it is decided to stop the machine, first ensure that the auxiliaries which are normally fed through the UAT are switched over to the station service source or DG set by opening the UAT breaker and closing the station service / diesel power breaker, as is applicable. The auxiliary power is to be restored within two mints to avoid tripping of the machine on account of stoppage of auxiliaries. After ensuring the above checks, turn the master start switch to STOP position. The machine stops in the following steps: Unit stop relay is energized. The electric motor of the gate limiter is switched ON for closing the gate apparatus. Main slide valve of the governor moves to closing. The guide vane opening restricts to idle run position and generator breaker is opened. At the same time field breaker is also opened. When speed drops to 70% governor relay is switched off. When speed drops to 30% of the rated speed, the brake circuit is actuated by the speed relay. In case braking under automatic system fails, apply manual braking to avoid thrust bearing damage. Machine comes to standstill and brakes are released. Cooling water system is disconnected by closing the concerned valves manually. Stop the other auxiliaries manually.

6. Maintenance of Power Station

Before start the maintenance, following work will be done: 1. Make a scheduled for maintenance. 2. Take shut down permit from NRLDC. 3. Disconnect all supply.

4. Locked Penstock valve. 5. Locked servomotor. 6. Put a shutdown permit on control room desk. 7. Lowering of draft tube gates and insuring of complete sealing of both gates. 8. Put a shut down board on machine control panel in control room.

A. Electrical Maintenance of Power House 1. Generator

Daily Maintenance Daily Inspection of generator & accessories: Stator coil & core: check if cooled air & cooling water has abnormal temperature. Check thrust & guide bearings temperature. If abnormal check for abnormal vibration, balancing, dirty oil coolers, cooling water flow failure, foreign material in oil & bearing clearances. Check for abnormal noise around the stator- stator core noise. If so, check for core looseness especially at frame joints. If abnormal, add additional paramex paper in core joints as needed. Visually check for water leakage from air coolers; if so plug leaking tubes. Visually check bearing oil level at oil level gauges in bearings. If level is high it is due to water leakage. If low, it is due to leakage of oil from the housing. Visually inspect the brushes of the collector for sparking & deposition of carbon dust mixed with oil vapour. If so, clean the deposited carbon dust. Check the braking air pressure on the air pressure gauge in the brake/ jack system. If pressure low, check for air leakage from pipeline. Weekly Maintenance: Visual inspection of the collector rings for accumulation of the carbon dust. If needing cleaning, do so with compressed air & measure IR value by 500V meager. If sparks are seen, or chatter sound heard, or else there is abnormal wear & clearance between the brush holder & collector ring; smoothen collector surface & clean collector rings. Specified pressure is 0.18 kg/cm2 corresponding to a load of 1.7 Kg on the brush. Visually check for excessive wear of the brake lining in the brake system. If wear is more than 4-5 mm per 50 times of brake application, then reduce the brake application speed & pressure, check air pressure & clean the brake track surface. Visually check the brake track for discolorations & cleanliness. If needed, clean the brake track surface. Also check the oil sludge/ moisture trap for cleanliness. If required drain the oil sludge 7 moisture trap & clean. Visually check the solenoid valve for automatic brake application for air leakage. If required attend the air leakage.

Monthly Maintenance: Visually check the back of the stator core for flatness of laminations, rusting, looseness of punchings especially at the top & bottom. For the first problem, adjust back of core packing or jackscrews. For the latter, if necessary, insert paramex paper between punching. Visually check the general condition of the field coil in the field winding- clean if necessary by compressed air. Check visually or by feeler gauge the tightness of the top insulation washer. Also check visually for the deformation of the field leads. Six Monthly Maintenance: Stator core: Check with torque spanner the tightness of bolts in the stator core. This tightness should be checked 3 months after commissioning & thereafter half yearly. Stator Winding: Check by tapping on the slot wedges of the stator winding. Slot wedges should be tightened with additional packers under wedge. Any clearance between coil & slot wall should be filled with conducting glass laminates. Wedges are to be locked both at top & bottom. Check for tightness of the end winding packing blocks- if required, additional epoxy glass end winding packing may be used to tighten the loose blocks. Check for the tightness of the mouth of slot blocks. Visually check after cleaning the coil end surface for cracks or damage of insulation. Coils shall be replaced if found damaged just beyond the core. Visually check the support ring & coil end - bind tightly if found loose. Visually check the support blocks of support rings retighten the bolts if the same are found loose. Annual Maintenance:Check the tightness of pole keys and key retainer. Check the tightness of field cable & electrical connections. Check the IR value of stator winding with 5KV meager test kit. Check the IR value of field winding with 250/500Volt meager Measure voltage drop per pole by supplying 230Volt AC across all pole connected in series. Cleaning of stator core, stator winding and generator winding main terminal connection. Measure stator winding and poles resistance with low ohm meter. Cleaning and tightening of rotor pole winding connection, slip rings and carbon brushes Maintenance of brake and Jacks cleaning of Brake lining. Cleaning and maintenance of surface coolers. Checking, cleaning and tightening of Neutral grounding transformer and its connections. RTD calibration 2. Static Excitation System: Daily Maintenance

Visual inspection of Excitation panel. Check field temperature. Check all indication bulb are O.K. Check cooling fan is running. Weekly Maintenance: Monitoring of daily maintenance done and recording of any abnormality observed along with rectification there of. Check operation of cooling fan transfer scheme. Monthly Maintenance Check fan outlet dampers for free operation and shutter switch operation. Visually check thyristor rectifier operation monitor light during normal operation. Cleaning of air filter. Half Yearly Maintenance Visual inlet air filters and cleans. Electrical circuit should be thoroughly cleaned /checked. Check rectifier surge protection RC network for open and short circuit. Check operation of cooling fan. Check cooling fan motor lubrication. Check field circuit breaker operation. Annual Maintenance Cleaning and maintenance of exciter fan like tightening of connection and foundation bolts. Check operation of relays, contractors, breakers, inspect contact, check operation of all the alarm and protection circuits. Test/Inspect excitation transformer. Cleaning and maintenance of AVR Cleaning and maintenance of AVR, tightening of TBs of control circuit, tightening of terminals of power circuit. The electrical circuit should be thoroughly cleaned/checked. Cleaning and maintenance of field breaker and thyristor. Check fixed and movable contacts for any damage. Lubricate all movable parts. Check up field flashing contactor for contact wear. Internal Inspection of cleaning of Excitation transformer 3. Governor OPU and Control Panel: Daily Maintenance Visual inspection for unusual oil level, pressure and temperature Check for excessive or unusual noise from pump/motor. Check for normal power supply and auto position of selector switch. Weekly Maintenance Monitoring of daily maintenance done and recording of any abnormality observed along with rectification thereof.

Check pumps are stating /stopping properly at preset pressure. Half Yearly Maintenance Cleaning and tightening of connection and TBs. Checking of auxiliary relays and contractors. Checking of control circuit, operation of alarms & indications Check pressure switch setting & adjust if required. Annual Maintenance OPU: Main oil pumps: Check the gears for wear & proper clearances. Examine the coupling between pump & motor. Inspect the bushes & bolts for wear. Examine the shaft & gland & check for oil leakages. Inspect motor, clean it, and check the insulation. Inspect bearings for proper lubrication, check the air gap. Check valves in air circuit for proper operation. Check NRVs, bypass valves & safety valves in the oil circuit. Clean the oil sump & filter the oil. Check all pipes & pipe joints for leaks, Pressure receiver: inspect the pressure switches. Clean the contacts & check the operation. Paint it once a year. 4. Generator Transformer Daily Maintenance Walk around the transformer to check for unusual noise /vibration and oil leakage. Check for required oil level in conservator tank. Check winding temperature & oil temperature gauge readings. Weekly Maintenance Monitoring of daily maintenance done and recording of any abnormality observed along with rectification thereof. Visual inspection of inside the control panel should be done to find out abnormalities like rusting, corrosion, water condensation, sparking, humming noises etc. Change the operating sequence of all the oil circulating pumps and ensure proper change over. GDR should be checked for any gas accumulation. Monthly Maintenance:Check the temperature of oil and water pipes for ascertaining the efficiency of cooling system. Check the condition of dehydrating breathers to ensure that the air intake is from the bottom of the device only and co lour of silica gel. Check for any leakage in the cooling system.

Quarterly Maintenance Take transformer oil sample for sending to lab for dissolve gas analysis and other tests for monitoring health of transformer. Sample should be drawn in pump running condition from. Bucholz relay valve in a syringe which should be sent to lab directly. Yearly Maintenance General cleaning of transformers. Disconnection of LV, HV& HVN Bushing terminals and measurement of IR value. HOT spot calibration, OTI & WTI comparison, Remote WTI calibration Checking of Alarm & Trip value of OTI &WTI. Cleaning and testing of oil coolers. Cleaning of HV, LV &HVN Bushing and Lightening arrester. Checking / Tightening of LV winding terminals by lowering main tank oil level. Readjustment height of surge counter. Replacement of gaskets at LV Bushing, oil pipe lines and inspection window. Testing of Air Bag cell of conservator with oxygen. Topping up oil, Replacement of silica gel. Dehydration of transformer oil , measurement of IR values and BDV during dehydration. Low voltage testing i.e. Ratio test, Magnetization test, short circuit test, HV&LV winding resistance, IR value and BDV of oil. Checking/replacement of oil flow indicator and water flow indicators. Checking of Buchholz relay, MOG and PRV Checking of control circuit of oil circulating pump and protection circuits. Tapping of oil in WTI & OTI TSD pockets. 5. Unit Control Panel Daily Maintenance: Checking of generator temperature and meter readings. Checking of all indication lamps. No alarm should be appear on the Unit Control Board. Weekly Maintenance:Monitoring of daily maintenance done and recording of any abnormality observed along with rectification there of. Half Yearly Maintenance Cleaning and tightening of TBs. Checking of relays, auxiliary contactors & timers. Annual Maintenance General cleaning of panels/equipments Tightening of TB connections

Cleaning and checking of oil level indicators, Flow meter, Brake Pad Limit switches, Servomotor limit switches, TJB, GJB, coils and contacts of ESV & Master controller contacts. Checking of control fuses, indication lamp assembly with LED type, control switches, push buttons and meters etc. Calibration /replacement of TSDs and checking /replacement of RTDs Functional checking of Indication circuit, Alarm annunciation Ckts.( Up to control room),Unit start stop automation circuits. Checking/rectification of station DC unbalance, if any Checking of Unit automation and protection circuits by simulating fault condition testing of speed relay 6 Unit Auxiliary Equipment Control Panels Daily Maintenance: Checking of generator temperature and meter readings. Checking of all indication lamps. No alarm should be appearing on the Unit Control Board. Weekly Maintenance:Monitoring of daily maintenance done and recording of any abnormality observed along with rectification there of. Half Yearly Maintenance Cleaning and tightening of TBs. Checking of relays, auxiliary contactors & timers. Annual Maintenance General cleaning of panel. Tightening of connection Cleaning and checking of relays and relays contacts Checking of fuses/power fuses, indication lamp assembly with LED type, control switches push buttons and meters etc., Checking of brake dust collector /Brake auto circuit Cleaning/checking of pressure switches, Oil level Sensors Cleaning and checking of Power Contactors, O/L relays, Timers etc. Functional checking of unit auxiliaries in Auto and manual mode. Auto circuit of CGLS is to be made through. 7. Electrical Cabinet of Governor Daily Maintenance Checking of all indications Visual inspection of Panel for any abnormality. Annual Maintenance:

General cleaning of panels Tightening of connections Cleaning and checking of control Relays and Relay contacts Checking /Adjustment of speed Relays. Dry stroke checking of gate limit, Motorized Potentiometer, Feedback Pot., Magnetic amplifier etc. 8. Unit Auxiliary Board & Station Service Boards Daily Maintenance Check all indication lamps Check for any abnormal noise/odour. Weekly Maintenance Monitoring of daily maintenance done and the recording of any abnormality observed along with rectification there of. Quarterly Maintenance Checking of MCCB Checking of Breakers. Cleaning of panels. Annual Maintenance Cleaning of panels. Tightening of TB connections (Control & Power Circuit) Cleaning of Relays and relays contacts Checking of Relays by secondary injection. Checking of Relays Logic/Tripping scheme & Interlocks Checking/Replacement of control fuses, switches etc. Checking of indication circuit Checking & cleaning of ACBs, MCCBs, Power Cable connections etc. 9. Control & Relay Panels and Control Desk. Daily Maintenance Cleaning of Control Room Panels. Checking of Indication lamps Checking of annunciation and alarm systems. Weekly Maintenance Monitoring of daily maintenance done and the recording of any abnormality observed along with rectification there of. Quarterly Maintenance Cleaning and tightening of TBs. Cleaning of relays and monitors Checking of control switches.

Annual Maintenance Cleaning of panels Tightening of TBs connections Cleaning of Relays and Relays contacts. Checking of Annunciation in control panel. Checking of Event logger triggering Checking of Indications on Control Desk Checking of indication of Relays Panels. Checking /Replacement of control fuses, switches etc. Testing for protection of Relays. Checking of Relay Logic. Tripping scheme. 10. UAT,PT Cubicle ,NGT, Lightening arrester Daily Maintenance Visual inspection for any abnormal sound / odour. Weekly Maintenance Monitoring of daily maintenance done and recording of any abnormality observed along with rectification thereof. Annual Maintenance Internal inspection of UATs, PTs, NGTs and excitation transformer. Tightening of tap changing link and bolted connection. Check insulation resistance. Test winding resistance. Insulators terminals and terminal boards should be inspected for discharge /tightness. 11. 220 Volt DC Battery System Daily Maintenance Cleaning of battery cells. Check the charging currents and voltage. Check all indication lamps. Check that the exhaust fan is working. Weekly Maintenance Check the cells for any leakage Check and record room temperature. Interchanging the charging mode. Check specific gravity and voltage of pilot cells. Monthly Maintenance Cleaning and tightening of connections. Applying petroleum jelly on terminals.

Half yearly Maintenance Cleaning and tightening of connection of battery banks, battery chargers and DC distribution boards. Check the operation of DC breakers of Distribution boards. Check control and indicating circuits. Annual Maintenance Cleaning and tightening of battery terminals. Cleaning and tightening of TBs of charger and distribution panels. Check the condition of cell electrodes. Check/Test the operation of relays 12. UPS System Daily Maintenance Visual inspection of UPS system. Check abnormal chattering noise/odour. Check selector positions. Check indicating lamps and fuses. Yearly Maintenance Cleaning and tightening of UPS terminal connections. Checking of meters and relays Check alarm and control circuits. 13. Station Service Transformer Daily Maintenance Visual Inspection of Transformer for any abnormal noise/odour. Weekly Maintenance Monitoring of daily maintenance done and recording of any abnormality observed along with rectification there of. Yearly Maintenance Cleaning and tightening of terminal connections. Cleaning of HT and LT Bushings. Checking of IR value of HT and LT windings Perform Ratio Test 14. Pumps and Control Panel Daily maintenance Visual inspection Check that pumps are running properly. Checking of Indication lamps.

Weekly Maintenance Monitoring of daily maintenance done and recording of any abnormality observed along with rectification there of. Half yearly Maintenance Cleaning and tightening of connection. Cleaning of relays and contactor. Check the IR value of motors and Power cables Checking of earth connection. Check motor current on load. Annual Maintenance Cleaning and tightening of connections. Cleaning of relays and contractors. Testing of control and alarm circuits. Check the IR value of motors and Power cables Checking of earth connection. Check motor current on load. 15. EOT crane Daily Maintenance Visual Inspection for unusual sound / odour. Check crane for smooth running. Weekly Maintenance Monitoring of daily maintenance done and recording of any abnormality observed along with rectification there of. Check indication lamps and alarm circuits. Monthly Maintenance Check frequently by operating hoist with and without load, stopping at various positions to test holding power and observe amount drift. Check control and Power cables for any damage. Check indication and alarm circuits. Annual Maintenance Checking of control circuit. Tightening of TBs and connections. Cleaning of relays and contractor. Checking of brakes and limit switches. Checking and cleaning of current collectors and buses. 16. Compressor and control Panel Daily Maintenance Visual Inspection. Check that the control gear of compressor is in auto mode. Check the system for air leakage.

Check the compressors for any abnormal noise / odour. Check indicating lamps. Weekly Maintenance Monitoring of daily maintenance done and recording of any abnormality observed along with rectification there of. Check pressure switches for proper operation. Annual Maintenance Cleaning of panels. Cleaning and tightening of TBs connections. Cleaning of relays and contactors. Testing of alarm and control circuits. Check IR values of Motors and cables. Checking of pressure switches setting. Greasing of motors.

B. Mechanical Maintenance of Power House

1. Thrust bearing: Daily Maintenance Check the oil level. Check for the temperature of bearing and oil. Annual maintenance Check the condition of spring. Check all oil channel Check clearances of guide bearing pads with the feeler gauge. If pads have to be reset, the shaft must be centered first. Examine the condition of guide pads & slight scouring marks can be attended by water emery paper. Visually check the condition of the white metal in the thrust pads. Slight scouring can be attended by water emery paper grade 400. Replace all pads if excessive marks are noticed. Check a sample of bearing oil for acidity, surface tension & precipitation value. 2. Cooler tubes of air cooler: Annual Maintenance Clean inside & outside of cooler tubes. Check for any tube leakage by pressurizing to a pressure slightly more than maximum expected working pressure. Cooler tubes of oil coolers: Clean inside & outside of oil cooler tubes. Check for any tube leakage by pressurizing to a pressure slightly more than maximum expected working pressure. 3. HS Lube System: Annual Maintenance Inspect grease & bearings of HS Lube motor. Check the condition of the HP hose assembly & if necessary, replace them.

4. Permanent Magnet Generator: Annual Maintenance Check the general condition & cleanliness of air gap & windings. Check the air gap. Clean the stator & field windings. Check that the OC voltage is more than 100V or else re-magnetize. 5. Shaft run out & centering & rotor level Annual Maintenance Readjust if necessary. Water flow relays, visual flow indicators & flow meters: Inspect & clean water passages, if necessary remove silt. 6. Oil Level Indicators: Annual Maintenance Clean the rod probe. 7. Braking & Jacking system: Annual Maintenance Check the compressor unit for air supply pipeline: Clean the filter element & bowl of filter. Similarly clean the bowl of the lubricator also. Cessation of oil dripping through the sight glass is an indication that cleaning is necessary. Brake track fixing: Check tightness of holding down screws. Brake limit switches: Check for proper operation & cleanliness. Electrical connections: There are pole-to-pole connections, brush gear connections, RTD connection & heater terminal connection. Check the tightness of all electrical jointstighten if necessary. Brush gear: Visually clean the insulation parts, clean with compressed air if necessary. Rotor assembly: Visually check for looseness of fasteners. Tighten all the approachable fasteners on rotor assembly including tightening of the pole & rime keys & lock all of them. Check with dial gauge the slipring & coupling for shaft vibration / runout & readjust if found more than the specified values. Check for the looseness of balance weights by hammering- if required, retighten & lock. Generator auxiliaries: Ensure that these are in good working condition. Cooling water valves: Check for proper operation. Clean & replace glands where needed. Check for proper operation of the plunger & contact mechanism of the over speed device. 8. Governing System Daily Maintenance Visual inspection of the system only Monthly Maintenance Check all the pipes for tightness.

Remove and clean filtering element of twin filter. Annual Maintenance Drain out pressure tank and sump tank and clean sludge etc. Keep a sample of old oil for testing and refill to normal level after filtration & dehydration. Check operation of all the pumps. Check floats and sealing surface. Check the leakage of all valves and NRVs. Check the pressure setting and safety valves. Check all the foundation and coupling volts. Clean filter and breathers. Check all indicators for correct calibration. Check the bolts of pipe line. Re-energize the over sped detector. Check proper functioning of over speed device. 9. Compressed air supply. Daily Inspection: Pay attention to abnormal noise, smell, vibration, temperature & leakage of oil. Periodic maintenance: To keep the oil clean, it is recommended to clean the oil every month for six months & then once a year by taking out the complete oil from the system. Inspect oil leakage from the flanges & pipe connections, valve gland- packing, regularly. Sample of the oil should be sent for analysis yearly & oil changed if recommended. The oil strainer should be inspected & cleaned every week for first three weeks & thereafter every three months. Check operation of idler valve everyday for a month after installation. Switch over motors from duty to standby & vice versa every week through the control selector switch. Check the operation of the safety relief valve at least once in a year. Check the level of oil in the pressure receiver & sump tank every day. Check the operation of pressure switches once every six months. 10. Turbine & Its Auxiliaries: Daily Checks: Check runner for noise / vibration. If abnormal, stop machine & check rotating parts & water passage for any foreign material. Check top & bottom labyrinth clearance. Check for excessive leakage in the shaft seal arrangement. If so, stop machine, apply the isolating seal & examine the rubber ring. Check the flow of cooling water by examining the pipelines for any blockage. Guide bearing: Check the temperature, leakage of oil from the bearing, level of oil in the bearing, and any abnormal vibration on bearing support. If anything unusual is found, stop the machine & attend to the defects. Penstock Gates: Check for leakages from gates, oil leakage from servomotor.

Weekly Checks: Guide Apparatus: Check for looseness of apparatus & for oil & water leakage. Runner Aeration Valve: Check for leakage of water. Penstock Intake Gates: Check for leakages, verify the settings in the limit switches. Pressure Gauges: Check correct working of the gauges- lubricate if necessary. Flow Relays: Checks to be done as per manufacturers guidelines. Water Strainer in Cooling Water: Check & clean the strainer weekly initially & then monthly. Oil Pressure System: Check the working of the bypass valve. Check for leakages. Check the level of oil- top up if necessary. Check the oil pressure & level of oil in the pressure vessel. Inspect & clean the oil strainer. CGLU: check for grease leaks & ensure that the plungers are all up or all down. EHG: Check for oil leakage in the actuator. Clean oil line at an interval suitable to the site conditions. Monthly Checks: Main shaft: Check nuts & bolts of the main shaft & the shaft sleeve. Tighten if found loose. Guide Bearing: Check the cooling water system. Check for oil leaks. Centrifuge oil & top up if necessary to the required level. During very wet weather, centrifuge oil after every 15 days. Clean up any oil in the turbine pit. Check the guide bearing clearances until they stay constant (after maintenance). Shaft Seal: Check nuts & bolts - tighten if loose. Penstock Intake Gate: Check for leaks in the piping. Check all connections for tightness. Check servo-linkages, looking for backlash. Cooling Water System: Check the piping & valves in system & inspect strainer. Repair/ replace leaking valve. Pressure Gauges & Recorders: Inspect oil or water pipings & the respective valves connected to the gauges & recorders for leaks. Calibrate gauge if required. Flow relays: Check & replace damaged part. Moving joints: Check & lubricate all ungreased moving joints using light spindle oil. EHG- Hydro Mechanical Cabinet: Points needing greasing & lubrication should be seen to. Check for leakage from pipes & other abnormalities. Do not dismantle the governor without assistance of a specialist. Turbine Protection: Check for cleanliness of panels, wiring, terminal block, etc. If dirty, dust & polish panel/ cabinets if required. Clean the relays & their associated equipments if required. Check operation of all relays. Check over speed tripping. Check opening & closing of the penstock gates. Check locking & unlocking of actuator. Check stop relay. Check signals & alarms. Check overload protection of the starters. Check the heaters & lights inside panel.

Quarterly Checks: Spiral Casing: Check for cavitation, erosion & other damages. Guide vanes: Check for cavitation erosion & other damages. Check guide vane bedding & top & bottom clearances. Runner: Check for cavitation, erosion pitting & any other defects. Guide Apparatus: Examine the guide apparatus & all connecting rods for backlash. Draft Tube: Check for cavitation erosion & any other damages. Penstock Gates: Check the actuating solenoids for remote operation of valve. Check operation of limit switches. Cooling Water System: Check the relays for failure clean its contacts & check operation. Half Yearly Checks: Regulating gear: Remove all deposits from face of the pivot ring, top cover & guide vanes. Pit Liner: Clean turbine pit, remove gravel & sand, etc. Penstock gate: Check operation of penstock gate raising and lowering time. EHG: As per instructions. Annual Checks: Water ways: Dewater the plant & examine the water ways for damage. Clean the strainer grills. Foundation: Check vibration & check concrete foundation for erosion & cracks. Check foundation bolts. Pit liner: Check for looseness & cracks in welds- rectify the defects. Clean & paint. Pivot ring / top cover: Check the top cover for erosion, corrosion & cracks in weldsclean & paint if necessary. Runner: Keep a record of clearances between the runner and head cover. Visual inspection of runner and runner cone Check tightness of runner and cone volts. Check for any cracks. Check the erosion on runner crown & skirts. Check epoxy paint. Check for any pitting. Check clearances of labyrinth. Shaft: Check wobbling. Check fatigue cracks- hone if necessary. Check journal for scouring pit marks & discoloring, etc. Shaft gland: Check shaft sleeve fro wear. Check bolts, nuts, & dowels.

Couplings: Check nuts & bolts, keys, set screws & dowels for tightness. Check for fatigue & wear. Check alignment with a dial indicator. Guide bearing: Check the surface of the Babbitt material for scouring, hard spots & cracks. Check clearances & play if any, in the pads. Check oil circulation pipes & valves for leaks. Check oil sump for leaks. Check oil level. Samples of oil should be sent for analysis- change as per recommendation. Check bolts, nuts & dowels for tightness. Penstock gate: Check for cracks, pitting & cavitations. Inspect rubber seals.

C. Capital Maintenance
1. Dismantling, cleaning & repairing of mechanism & parts subjected to erosion & wear :-Spiral casing & draft tube, draft tube cone including draft tube gate & dewatering mechanism. -Guide apparatus & servomotors -Runner -TGB -System of lubrication & oil -All parts of turbine subjected to cavitations. Dismantling, cleaning if necessary, replacement of parts subjected to erosion & wear:-System of breaking the unit. -Dashpot mechanism -Distributing pilot valve of bypass & main servomotors of turbine inlet valve -System of lubrication of unit, oil pumps, oil coolers & filters. -Oil pressure system -Oil pipe lines & furnishings of systems of governing & lubrication -Hydro mechanical equipment of governor, various distributing & pilot valves of system of governing & feedback mechanism. Check the clearances of the guide bearing, guide vanes labyrinth seals, etc and compare them with the readings obtain during erection or previous capital maintenance. Carry out hydraulic testing of oil & air supply system. Check & set right all the safety devices of the unit. Check the vibration level of the unit & compare it with the origin bal level. Carry out load throw off test of the unit. Repair & recalibrate the measuring instruments for automation & control of the unit. Check & test the system of governing of the unit. Tabulate & formulate all the measurements taken before & after the capital maintenance & compare them with the ones obtained during commissioning. Draw out a fresh list of parts to be manufactured & kept as spares. Carry out proper painting.

2.

3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Preventive Maintenance: 1. Checking, cleaning & repair of the defects in the turbine mechanism:

2. 3. 4. 5. 6.

Guide apparatus Runner Turbine sealing Turbine inlet valve Mechanical & electrical transmission Mechanism of automation & protection. System of governing System of lubrication System of braking Valve, pressure relays, motors & pumps of oil pressure system. Electrical & hydro mechanical cabinets / system of governor. Change the minor parts subjected to erosion especially the sealing rings, cup seals, etc. Check the oil pipe lines, air pipe lines & fittings & furnishings for the system of governing, lubrication & control of turbine & inlet valve. Lubrication of the journals of guide vanes & all other journals. Rectify all other defects noticed during operation. Check vibration level of each unit and record the readings.

Dismantling of Turbine: 1. Before dismantling any part of the machine, it is advisable to match mark the parts if they are not already marked properly. This ensures correct reassembly. 2. All loose components should be labeled for easy identification during reassembly. 3. When reassembling any part of the machine, use molybdenum disulphide nor graphite grease or any other anti seizing compound on all threads & sliding surfaces eg fitted bolts & dowels to prevent scratching. 4. The runner has to be removed after dismantling the guide bearing, top cover, main shaft & generator. Before that close the penstock gates, isolate all solenoid operated valves. Ensure that mechanical lock is applied to the penstock gate. Paste the safety notice. Dewater the turbine & drain the cooling water system.