Karcham Wangtoo HPS (4 X 250 MW)

Baspa II HPS ( 3 X 100 MW)

 KWHPS : Presentation Overview
JSW Over view

KWHPS..Salient features

Silt content in Satluj river

Petrographic Analysis

Effect of silt erosion in Karcham Wangtoo

Brief case study on silt erosion of GV

Impact of modified profile

Challenges ahead

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 JSW Overview..

JSW Steel is one of India’s JSW Energy operates JSW Infrastructure has an
leading integrated steel 4,531 MW (Thermal - 3140 operating capacity of 68
manufacturers with a capacity of MW & Hydel - 1,391 MW) MTPA and operates
18 MTPA. environment-friendly
seaports and terminals in
Maharashtra and Goa

JSW Cements current JSW Sports

production capacity is 10.3 JSW Foundation
MTPA JSW Ventures….

3
Karcham Wangtoo HPS….Salient Features

LOCATION Kinnaur, Himachal Pradesh

RIVER Satluj
CATCHMENT AREA 48755 Sq.Km. (79.5% Snow Area)
DAM Concrete Gravity Dam (Height- 88m)
SEDIMENTATION CHAMBER 4 No., 30m(W)x18m(H)x494m(L)
Particle size to be removed ≥ 0.2mm
HEAD RACE TUNNEL 10.48m dia. circular x 16.925 Km Long
SURGE SHAFT: 16 /27 m dia. x 128 m height
PRESSURE SHAFTS 4 nos., 5.0m dia. ,Steel lined
POWER HOUSE CAVERN Under ground, 188m (L) x 22m (W) x 52.90m (H)
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Karcham Wangtoo HPS…Salient Features of Turbine

Turbine Type Vertical Francis

Capacity 4 x 250 MW
Design Head 269 m
Rated Speed 214.3 rpm
Runner Diameter 4850/3570 mm

Rotation Counter clockwise

Underwater parts HVOF coated

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Silt content in Satluj river..

River Satluj has been carrying substantial silt load during the monsoon months
from June to September with sediment concentration exceeding 5000 ppm to
more than 50000 ppm.

The suspended sediment load corresponding to 5000 ppm in the river typically
comprises coarse particles ( more than 0.2 mm) about 17% and medium / fine
particles less than 0.2 mm about 83%.

Water flowing through Turbine is having silt content of the order of 1000 to 5000
ppm in monsoon from July-October with particle size upto 200 microns. The silt
content mostly of hard quartz (80-90%) with hardness 6 to 7 Mho.

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Petrographic analysis of river water

IIT Delhi 2003

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Petrographic analysis of river water

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Petrographic analysis of river water

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Petrological analysis of Turbine water

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 Effect of Silt erosion in Karcham Wangtoo

 Turbine parts affected by silt in order of severity –

 Guide Vanes
 Facing plate
 Wearing Ring Segments
 Bottom Ring & Head Cover
 Runner
 Labyrinths
 GV bushes
 Brief case study on silt erosion of GV

 Karcham Wangtoo HPS Turbines are prone to very high silt erosion during
monsoon seasons
 Average silt load that passes through the turbine are in the range of 11-12
Lakh MT/year.
Damages in Guide Vanes
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Damages in Turbine parts in 2013

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 Damages in Turbine parts in 2013

Facing Plates Lower bush Middle bush

Is the river silt real culprit ?
General arrangement
of Guide Vanes
Brief case study on silt erosion of GV
Old vs new
GV profile
Old vs new GV
solid model
 Guide Vanes after 1 year of operation

Old design GVs Modified design GVs

 Guide Vanes after 2 years of continuous operation

Old design GVs Modified design GVs

 Impact of modified profile

Approx. cost saving per year per unit…

» GV repair and HVOF coating cost -
» Facing Plate repair+ HVOF coating/replacement cost –
» Lower & Middle bush replacement cost –
» Lip seal replacement cost-
» Head cover & Bottom Ring repair cost-
» Lower downtime cost-
» Lower manpower & material cost-
» Increased availability/capacity charge-

Approx. cost saving per year/unit > 2 Cr.

 Take away….

Silt is in nature’s hand

Design is in human’s hand

A better design can fight Million Tonnes of Slit

& Save millions of rupees
 Challenges ahead…

Transportation of heavy parts for repair & HVOF coating

Quality issues with on-site HVOF coating
Alternative to HVOF
Reduction of Outage due to high silt
– Material to sustain higher silt level
– Better forecast of Silt during monsoon
High Shut down time during maintenance
User friendly design – easy replaceability
Cost effectiveness
Effective online silt measurement system
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