IJSTE - International Journal of Science Technology & Engineering | Volume 1 | Issue 11 | May 2015

ISSN (online): 2349-784X

Dimensioning & Design of High head

Underground Hydroelectric Power Plant
Superstructure
Hardik R. Patel
P.G. Student
Department of Civil Engineering
Merchant Institute of Technology Mehsana-384315,(GujaratIndia)

Prof. Zalakkumar R. Chhaya

Assistant Professor
Department of Civil Engineering
L.D. College of Engineering, Ahmedabad-15(Gujarat-India)

Abstract
Hydroelectric power plant is a large structure comprises heavy structural mechanics itself. The whole plant is analysed as
Superstructure and Substructure. In this paper, preliminary dimensions of a high head and capacity power plant are computed as
per IS 12800, and from the computed dimensions structural modelling and design of super structure is carried out in Staad.Pro as
per IS 4247(Part I). An attempt is made to make calculations of dimensioning as per the codal provisions and design of
components of super structure using the software. Loadings and combinations are given as per the referenced IS codes including
Earthquake Static and Earth loads (for underground structures). The objective of the paper is to demonstrate procedure of fixing
dimensions and design of structure in Staad.Pro.
Keywords: Preliminary Dimensions, Superstructure, Underground Structure, Earthquake Loads
________________________________________________________________________________________________________

I. INTRODUCTION
Hydroelectric power plant consist super structure made of Heavy beams and columns with Steel roofing and Substructure with
massive concrete, in totality of almost around 50 to 60 m height. The first and essential part of any construction is the
dimensioning of components of power plant derived from the dimensions of functional components of it. Here hydroelectric
plant consist large equipments/Components mainly:
1) Heavy E.O.T.
2) Generator with stator and rotor
3) Turbine
4) Scroll case
5) Draft tube
IS 4247 is providing detailed guidelines of preliminary dimensioning of Power plant.
1) Roof
2) Roof supports
3) Gantry columns
4) Gantry girder
5) Beam or braces
6) Floors and

II. GROSS WATER HEAD, NET HEAD AND CAPACITY OF POWER PLANT
A. Gross Head:
It is a difference of head water level (u/s) and tail water level (d/s) when no water is flowing.
B. Net Head:
The head available for doing work on the turbine, that is, the difference between the total heads at inlet and outlet of turbine.

All rights reserved by www.ijste.org

175

Dimensioning & Design of High head Underground Hydroelectric Power Plant Superstructure
(IJSTE/ Volume 1 / Issue 11 / 028)

C. Capacity:
The capacity of a power plant is capacity of the total number of generators installed in a power plant. It depends on variation in
head, discharge, speed and efficiency for a turbine and speed, power factor and temperature rise in a generator.

III. PRELIMINARY DIMENTIONING OF POWER PLANT

Give Data:
Type of machine: Francis Turbine
Total number of machine: 6
Unit capacity:200 MW
Maximum Head : 120m
Rated Head :115 m
Minimum Head : 90 m
Barometric pressure at power house site :10 m
Vapour pressure at power house: 0.4 m
Power factor :0.9
A. Step 1: Synchronous Speed:
From Fig 1 IS 12800(part 1):1993 specific speed of machine may be taken as 190 r.p.m
Trial synchronous speed machine = ns x H^1.25
= 138
(p x 1.358)^0.5
Where
ns = 190 r.p.m
H = 115 m
P=200000 KW
Corrected specific speed =
=191 r.p.m
ns=176 r.p.m
H = 120 m
P=200000 KW
B. Step 2: Turbine Setting:

Where Hs =10 m
Hv=0.4 m
H- 120 m
=0.12 from fig 3 IS 12800(part 1): corresponding a specific speed of 191 r.p.m
With a further margin of 0.5 meters the center linr of the distributor should be set 4.8+0.5=5.3 meters below minimum tailrace
level
C. Step 3: Size of Runner:
Discharge diameter

=4.7 meters

Where
H=115 m
n = 191 r.p.m
ku=0.705 From fig 6 corresponding to a specific speed 191r.p.m
D. Step 4: Dimension of Spiral Case:
As the gross head above the turbine is more than 30 m metallic, spiral casing should be used .The main dimensions of the spiral
casing as determined in accordance with fig 8,9, and 10.

All rights reserved by www.ijste.org

176

Dimensioning & Design of High head Underground Hydroelectric Power Plant Superstructure
(IJSTE/ Volume 1 / Issue 11 / 028)

A=1.13 X 4.7=5.32 m
B=1.40 X 4.7=5.21 m
C=1.50 X 4.7=5.58 m
D=1.67 X 4.7=7.88 m
E=1.27 X 4.7=5.99 m
F=1.65 X 4.7=7.88 m
G=1.40 X 4.7=6.63 m
H=1.22 X .7=5.78 m

E. Step 5: Size of Draft Tube:

As Determined in accordance with IS 5496-1969 Should be a below Height of draft tube at exit end h= 0.94 D3 to 1.32 D3
h.=1.25 x 4.7=5.88m
Depth of draft tube H for francis Turbine is 2.5 to 3.00 D3
Taking H1=2.75 x 4.7=12.92m
Length of draft tube L=4 to 5 D3
Taking L=4.5 x 4.7 =21.15 m
Cleat width B of the draft tube at exit end =2.6 to 3.3 D3
Taking B= 3 x 4.7=14.0 m
Since the cleat width of the draft tube is excessive a pier of 1.5 m width should be introduced in the center of the draft tube
.The total width of the draft tube will be 15.5 m
Discharge in cumecs

=197 cumecs

Where
P= 200000 Kw
H=115 m
= 0.9

Fig. 1:

F. Step 6: Generator Parameters:

Fig. 2: Generator Parameter

Air gap Diameter Dg

All rights reserved by www.ijste.org

177

Dimensioning & Design of High head Underground Hydroelectric Power Plant Superstructure
(IJSTE/ Volume 1 / Issue 11 / 028)

Total no of pair of pole

Where f=50 and ns 191 r.p.m
From fig 15 taking Dg =10.02m
Outer diameter
= 11 m
Where
Dg=10.42m P=16 no
Stator frame Diameter Df = Do+1.2 m
= 12.2 m
Inner Diameter of generator barrel Db= Dt+1.8
=12.2+1.8 =14 m
Core length of stator
=2.5 m
Where
W=200000/0.9= 222222
Ko=6.52 From fig 16
Dg=10.42 m
Length of stator frame Lt = Le+1.5=2.5+1.5=4m
Axial hydraulic thrust
=292 tones
Where
K=0.11 From fig 17
H max=120 m
Weight of generator rotor W=Le x rotar weight =701 tones
Where
Le=2.5 m
Rotar weight =280.5 tones/m from fig
Weight of turbine ruuner =36.3 from fig 19
Height of load bearing bracket h1=Total weight of rotating parts +Axial thrust
= 701+36.5+292
= 1029 tones
Height of load bearing bracket =

=2.97 m

Where
Suspended type of construction k=0.85
Dt =12.2 m
G. Step 7: Overall Dimension of Power Station:
Outer diameter of generator = inside diameter of generator + 2 x wall thick
=14+0.6+0.6=15.2 m
Width of Right side =7.6+2(from IS 12800-1993)=9.6m
Width of left side = 7.6+2+2=11.6 m
Total width of power station =11.6+9.6=21.2m
Length of erection bay=9.6+9.6=19.2m
Length of power station=6x 19.2+19.2+6=140.4 m
Height of machine at power station=H1+hj+Lt+k=12.92+2.97+4+6=25 .89m

IV. LOAD CALCULATION OF SUPERSTRUCTURE

A. Design A Steel Roof Truss For The Following Data:
Table - 1

Span of roof truss

Spacing of roof truss
Rise of truss
Height of truss above the G.l
Weight of purlin
Total no of purlin each side

21.2m
9.6m
4m
26m
90 N/m2
12

All rights reserved by www.ijste.org

178

Dimensioning & Design of High head Underground Hydroelectric Power Plant Superstructure
(IJSTE/ Volume 1 / Issue 11 / 028)

1) Step 1: Preliminary Calculation:

Angle of roof truss ():
tan =4/10.6=0.37
=20.67
Length of P.R =
= 11.11m
Half plan area= x Spacing of R.T
=10.4 x 9.6
= 101.76 m2
Half slope area: length of P.R x Spacing of R.T
=11.11 X 9.6
=108.76 m2
2) Step 2: Dead load (D.l) :(Ref IS 875-1987 Part 1):
Weight of roofing material:
For G.I sheets @ 130 N/m2 (on slope area)
W.t of roofing material =130 x108.76
= 14138.84 N
W.t of purlin= weight of purlin X Half plane area
=120 X 101.76
= 13228.8 N
Self-weight of Roof truss: [
]
=12279.04 N/m2
Weigh of wind bracing:
12n/m2 assume W.t of wind bracing =12 101.76
=1221.12 N
Total D.L = 40868.8 N
D.L per panel point=3.14 KN
3) Step 3 Live Load (Ref IS 875-1987 Part 2)
L.L on purlin= 750-20(-10) N/m2
=750-20(20.67-10)
=536.6 >400 N/m2 O.K
L.L or R.T= 2/3 536.6=357.73
Total L.L=357.73 101.76
=36.402 kN
L.L on panel point=2.80 KNStep 3 Design of Purlin
Dead of purlin:
Weight of purlin=130 13
=1690 N
Self-weight of roofing material=
Length of each panel
No of each side panel Self weight of purlin
=0.87 13 130=1470.3 N
Total Dead load =0.32 KN/m
Live load on purlin:
L.L on purlin=536.6 N/m2
Cos 20.67=x/0.87
X=0.81m
Plane Area of one panel=0.87 13
= 11.31m2
L.L on purlin= (0.87 13 536.5)=0. 63 KN/m

B. Design A Gantry Girder For The Following Data:

Crane capacity

200KN

All rights reserved by www.ijste.org

179

Dimensioning & Design of High head Underground Hydroelectric Power Plant Superstructure
(IJSTE/ Volume 1 / Issue 11 / 028)

Span of gantry girder

Span of crane girder
Self W.T of crane girder exuding trolley
Self W.T of trolley crab
Minimum hook approach
Wheel base of crane
Self W.T of rail section
Take yield stress of steel

21.2 m
9.6 m
200KN
40KN
1.2 KN
3.5KN
300N/m
250 MPa

Fig. 3:

Maximum wheel load:

Crane capacity + W.T of trolley(crab)
=200+40
=240KN
Minimum hook approach=1.2m
Total weight of crane girder=200 KN
Weight of crane girder per m=
=9.43KN/m

Fig. 4:

Taking moment @ c
RD 21.2=240 1.2+9.43 21.2 10.6
RD=113.5 KN
Rc =Total load RD
=(240+9.43 21.2)-113.5
= 325.78 KN
At the each end of crane girder there are two wheels
Load on each wheel =
=162.89 KN

All rights reserved by www.ijste.org

180

Dimensioning & Design of High head Underground Hydroelectric Power Plant Superstructure
(IJSTE/ Volume 1 / Issue 11 / 028)

1) Maximum B.M in the Gantry Girder (In Vertical Plane):

Fig. 5:

Assume self-weight of gantry girder = 2 KN/m

Weight of rail section=0.3 KN/m
Total weight w=2.3 KN/m
Maximum B.M will occur a
Taking moment @ A
= (163.20+163.20+3.92 4.6)-203.98 =144.45 KN
RB 9.6= (163.20 3.925)+ (163.20 7.425)+(3.92 9.2 4.6)
RB=203.98 KN
RA =Total load - RB
Taking Max reaction =203.98 KN
C. Superstructure Model in Staad.Pro and Its Results:

Fig. 6: Superstructure Model in Staad.pro

Fig. 7:

All rights reserved by www.ijste.org

181

Dimensioning & Design of High head Underground Hydroelectric Power Plant Superstructure
(IJSTE/ Volume 1 / Issue 11 / 028)

Table 2
Beam No 13 Reinforcement Details
Horizontal Vertical Horizontal

Moment

Node

L/C

Fx kN

Fy kN

Fz kN

Mx kNm

My kNm

Mz kNm

Max Fx

506

6 EARTH PRESSURE

453.724

-12.254

-0.015

0.013

0.214

-691.68

Min Fx

632

6 EARTH PRESSURE

-380.496

-72.077

-5.143

Max Fy

508

4 1.5DL+1.5L.L

-120.342

2810.544

-2.336

-5.061

-0.228

223.21

Min Fy

13

7 EQZ

1.362

-196.259

-20.764

-104.433

-15.636

-3.023

Max Fz

44

16 1.5DL-1.5EQZ

-8.44

2373.202

141.865

436.606

2.216

153.521

Min Fz

539

14 1.5DL+1.5EQZ

-8.452

2373.235

-141.865

-436.605

-2.204

153.646

Max Mx

572

12 1.2DL+1.2LL-1.2EQZ

-8.135

1219.005

68.306

871.067

9.669

320.168

Min Mx

11

10 1.2DL+1.2LL+1.2EQZ

-8.105

1218.984

-68.306

-871.067

-9.706

319.898

Max My

11

6 EARTH PRESSURE

250.018

-12.5

0.746

-0.005

273.034

-680.465

Min My

572

6 EARTH PRESSURE

250.016

-12.5

-0.747

0.005

-273.038

-680.454

Max Mz

308

9 1.2DL+1.2LL+1.2EQX

-127.512

2222.534

-0.081

-0.222

0.161

2172.917

Min Mz

275

19 0.9DL-1.5EQX

139.272

1393.542

0.052

0.132

0.216

-1889.73

Fig. 8:

Fig. 9:

All rights reserved by www.ijste.org

182

Dimensioning & Design of High head Underground Hydroelectric Power Plant Superstructure
(IJSTE/ Volume 1 / Issue 11 / 028)

Table 3
Column No 12 Reinforcement Details

V. DISCUSSION
From the paper following can be discussed:
Analysis and design 1200Mw capacity hydroelectric power plant super structure was carried out using Staad.Pro
Dimensions of Plant are computed based on IS 12800(part 1) :1993
Base Shear due to EQ static loading is almost 3371 kN.
The modeling of super structure is carried out with guidelines of IS 4247 (part 1)-1998

REFERENCES
[1]
[2]
[3]
[4]
[5]
[6]

Hydroelectric engineering By P.S.NIGAM

IS 1893:2002(part 1) Criteria for Earthquake resistant Design of structure Part 1: General provision and Building.
IS 800:1984 Code of Practice For General Construction In Steel
Guidelines for selection of turbine Preliminary dimensioning and layout of surface hydroelectric power house IS 12800(part 1) :1993
Structural Design of surface Hydroelectric power station IS 4247(Part 1)-1993
Code of practice for structural design of surface hydroelectric power station IS 4247(Part 2)-1992

All rights reserved by www.ijste.org

183