INTRODUCTION

Consequent to the reform in power sector in Odisha, Odisha Hydro Power Corporation Ltd. (OHPC) was incorporated in 21 st April 1995 under the companies Act 1956. Its objective are:

To carry on the business of purchasing, selling, importing, exporting, producing, trading, manufacturing or otherwise dealing in hydro electric power, thermal and nuclear electric power based on any non-conventional sources of energy. To acquire, establish,operate, maintain, renovate, modernize in the State of Orissa and else while hydro electric generating stations, thermal and nuclear electric generating stations and any other electric generating stations based on any nonconventional sources of energy. To study, investigate, collect information and data, review operations, plan, research, design, prepare feasibility reports, prepare project reports, diagnose operational difficulties and weaknesses and advise on the remedial measures to improve and modernize existing stations and facilitate and to undertake for and on behalf of others the setting up of hydro electric power plants, thermal and nuclear electric power plants and any other power plants based on any non-conventional source of energy. The objectives incidental or ancillary to the attainment of the main objects are to acquire business / companies for carrying on business of electric power, to acquire know-how, to carry on consultancy services in any field of activity in which it is engaged, to act as an entrepreneur on behalf of the Central or any State Govt.
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VISION To be a leading power utility in the energy sector through diversified energy portfolio with due care & concern to the environment. MISSION To develop water resources in the State and elsewhere in the Country while augmenting hydro power generating capacity by setting up new hydro power projects. To adopt state of the art technology for up gradation of the existing hydro power stations to achieve the highest level of efficiency. To establish and operate thermal power plants through joint ventures and also explore the opportunities to develop renewable energy resources viz small hydro, wind, solar. To develop & operate coal mines allocated jointly in favour of OHPC and other public sector undertakings by the Ministry of Coal, Govt. of India. To improve productivity through effective planning and implementation of ERP system with development of robust & concurrent IT infrastructure. To professionalize the work force in line with the modern management / technical know how.
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POWER STATIONS OF OHPC

Power Stations Hirakud -I (Burla) Hirakud -II (Chipilma) Balimela Rengali Upper Kolab Upper Indravati Machkund 2 x 49.5 MW Under Operation Total (MW) 275.5 MW

+ 2 x 32 MW + 3 x 37.5 MW

3 x 24 MW 6 x 60 MW 5 x 50 MW 4 x 80 MW 4 x 150 MW 3 x 21.25 MW + 3 x 17 MW

72 MW

+ 2 x 75 MW

510 MW 250 MW 320 MW 600 MW 114.75 MW

ACHIEVEMENTS OF OHPC IN 2010-2011

Average availability of the Power Stations was 87.1% against the average standard of 85%. Installation of Trash Rack Cleaning machine (TRCM) at Chiplima H.E.P for cleaning of weeds. As a result, the generation of CHEP has been maximized to 254.42 MU for the FY 2010-11. The accounts of 2009-10 was audited, adopted and filed with Ministry of Corporate Affairs (MCA) within the statutory time limit (30th Sept.2010)

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TECHNICAL ACTIVITIES OF OHPC On Introduction of Availability Based Tariff with effect from April 2003 and application of Electricity Act 2003 it has become important on the part of generators to maintain high level of machine availability and plant load factor. Hydro power generation has special place in the load management under the ABT regime. For efficient running of their Hydro Power stations, the technical wing of OHPC has been Reorganized to carry out the following activities.

Monitoring the functioning of Power Plants. Preparation of data base. Monitoring of Renovation and Modernization Programs. Planning for future R&M Programs and new projects. Inventory & procurement monitoring. Generation and Maintenance Planning and monitoring. Tariff and PPA including coordination with GRIDCO and OERC Computerization and online communication Coordination with Govt and SemiGovt bodies.

Corporation Organization (Head Quarters)

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HIRAKUD HYDRO ELECTRIC POWER PLANT

Hirakud Dam Project is a multipurpose scheme intended for flood control, irrigation and power generation. The dam is built across river Mahanadi at about 15 km upstream of Sambalpur town in the state of Odisha. This is one of the oldest hydel projects of India, being the first post-independence major multi purpose river valley project in the country. Pandit Jawaharlal Nehru laid the foundation stone in 1948. The dam is located at a distance of 6 km from national High way no. 6. The nearest rail head is Hirakud Railway Station which is at a distance of 8 km from the dam site. The project provides 1,55,635 hectares of Kharif and 1,08,385 ha of Rabi irrigation in the districts of Sambalpur, Bargarh, Bolangir and Subarnapur. The water released through the power house irrigates further 4,36,000 ha of C.C.A in Mahanadi Delta. The installed capacity for power generation is 347.5 MW through its two power houses at Burla, at the right bank and Chiplima, at 22 km down stream of Dam. Besides, the project provides flood protection to 9500 sq. km of delta area in districts of Cuttack and Puri. Hirakud Dam is a composite structure of earth, concrete and masonary. The Main dam having an overall length of 4.8 km spans between hills Laxmidungri on left and Chandli-dungri on the right. The dam is flanged by 21 km long earthen dykes, both on left and right sides to close the low saddles beyond the abutment hills. It has
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the distinction of being at one time the longest earth dam in the world, being 25.8 km long with dams and dykes taken together. It also has the rare distinction of forming the biggest artificial lake in Asia with reservoir spread of 743 sq. km at full reservoir level. Hirakud dam intercepts 83400 sq. km of Mahanadi catchment. The reservoir has life storage of 5818 million cubic meter with gross storage of 8136 million cubic meter. Brief History of the project After high floods of 1937, Er. M. Visveswaraya gave proposal for detail investigation for storage reservoirs in Mahanadi basin to tackle problem of flood in Mahanadi delta. The multi purpose Hirakud Dam project is the first stage of the plan of Dr. Ajodhya Nath Khosla, the then Governor of Odisha. The commissioning of Unit III of Burla Power House was completed on 18.12 56. In 1945, under the chairmanship of Dr. B. R. Ambedkar, the then Member of Labour, it was decided to invest in the potential benefits of controlling the Mahanadi for multi-purpose use. The Central Waterways, Irrigation and Navigation Commission took up the work. On 15 Mar 1946, Sir Howthrone Lewis, then the Governor of Orissa, laid the foundation stone of the Hirakud Dam. A project report was submitted to the government in June 1947. Pandit Jawaharlal Nehru laid the first batch of concrete on 12 April 1948. The dam was completed in 1953 and was formally inaugurated by Prime Minister Jawaharlal Nehru on 13 January 1957. The total cost of the project was Rs. 100.02crores in 1957. Power generation along with agricultural irrigation started in 1956, achieving full potential in 1966.

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Structure of the dam The Hirakud Dam is a composite structure of earth, concrete and masonry. 10 km (6 mi) north of Sambalpur, it is the longest major earthen dam in Asia, measuring 25.8 km (16 mi) including dykes, and stands across the river Mahanadi. The main dam has an overall length of 4.8 km (3 mi)spanning between two hills; the Lamdungri on the left and the Chandili Dunguri on the right. The dam is flanked by 21 km (13 mi) of earthen dykes on both the left and right sides, closing the low saddles beyond the adjoining hills. The dam and dykes together measure 25.8 km (16 mi). It also forms the biggest artificial lake in Asia, with a reservoir holding 743 km2 (287 sq mi) at full capacity, with a shoreline of over 639 km (397 mi). There are two observation towers on the dam one at each side. One is "Gandhi Minar" and the other one is "Nehru Minar". Both the observation towers present breathtaking views of the lake.

Power houses The dam supports two different hydroelectric power houses. Power House I is located at the base (toe) of the main dam section and contains 3 x 37.5 MW Kaplan turbine and 2 x 24 MW Francis turbine generators for an installed capacity of 259.5 MW. Power Station II is located 19 km (12 mi) southeast of the dam 212110N 835500E at Chipilima. It contains 3 x 24 MW generators. The entire installed capacity of the dam's power houses is 307.5 MW. Power House I and II were built in three stages. During stage I, four generators were installed at PH I and in stage II, the power channel two and Power House II was constructed. All three generators were installed at PH II along with two more at PH I by 1963. Between 1982 and 1990, the seventh and final generator was installed at PHI.

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The power component of HPS consists of:

Power House I at Burla. Power Channel- a 25 km long water conductor system to carry the tailrace water from Burla power house to Chiplima power house. Power House- II at Chiplima.

These components were completed under three stages which are briefly described below:

Stage -I The main features of Stage I are dam and appurtenant works, canal system and power generation & transmission. Four generating units with installed capacity 123 MW (2x37.5 + 2x24) were completed in PH-I at Burla.

Stage- II The main feature of stage II are Power channel, power generation at PH I & II and transmission system. Two more generating units with installed capacity of 75 MW (2 x 37.5) were added in power house Burla. Three generating units with installed capacity of 72 MW (3x 24) were completed in Power House- II at Chiplima. The work under stage II was started on Jan. 1957 and was inaugurated by late Dr. A. N. Khosla.

Stage- III The work under stage III covers the installation of 7th Unit (37.5 MW) at Power House-I, Burla. The work started on 1st December, 1982 and completed on 13th September, 1990.
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Stage-I 1937 1945 1946 13.4.1948 February 1949 The Hirakud Scheme conceived by Er. M. Visveswaraya Agreement on unified development of the Mahanadi valley carried out between the Govt. of Odisha and Eastern states. Foundation laying ceremony of the Hirakud Dam by Sri Hawthorne Lewis. I.C.S, Govt. of Odisha. Foundation laid by Sri Jawaharlal Nehru. Construction of the project commenced.

Preliminary design of Hirakud dam by Aug 1948-Dec. 1949 International Engineering Co., Danver, USA. March, 1952 Nov. 1953 Aug. 1956 7.9.1956 18.12 .1956 13.1.1957 13.05.1957 11.11.1957 11.05.1957 Appointment of Hirakud Control Board. The presentation of revised estimate amounting to Rs. 70.78 Crores to the Control Board during its 7th Meeting. Hirakud dam completed. Irrigation water let out in the right side main canal.(Unit-3,24MW) First Hydro Power plant commissioned. The project inaugurated by Sri. Jawaharlal Nehru. 24MW,Unit-4 of Burla P.H. Commissioned 37.5MW,Unit-2 of Burla P.H. Commissioned 37.5MW,Unit-1 of Burla P.H. Commissioned

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Stage-II July, 1956 January, 1957 April, 1957 19.04.1962 July, 1962 15.07.1962 26.11.1962 05.08.1963 14.9.1963 01.02.1964 Stage III Aug. 1982 March 1983 Nov. 1986 March 1987 13.9.1990 Hirakud stage III Project sanctioned by Planning Commission. Civil construction work started. Civil foundation work completed. Erection of draft tube gate, penstock gate, spiral casing completed. 37.5 MW generator No. 7 at Burla P.H commissioned. Chiplima scheme sanctioned. Civil construction work started. Electrical construction work started. 37.5 MW Generator No. 5 at Burla Power House commissioned. Water let out in Power channel 24 MW generator No. 1 at Chiplima Power House Commissioned. 24 MW Generator No. 2 at Chilplima Power House Commissioned. 37.5 MW Generator No. 6 at Burla PH commissioned. Inauguration of the project by Dr. A.N. Khosla. 24 MW Generator No. 3 at Chiplima commissioned

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RENOVATION IN HHEP

STAGE-I

Sl no. 1

Power Commissioning Specification station dates Renovation 37.5 MW hydro Burla 11.5.1958 16.04.1998, uprated to generating set 49.5 MW by GEC (Unit I) Make: Alstom, UK English Electric, UK 37.5 MW hydro Burla 11.11.1957 01.04.1998, Uprated to generating set 49.5 MW by GEC, (Unit II)Make: ALSTOM, UK English Electric, UK 24 MW hydro Burla 18.12.1956 Uprated to 32 MW by generating set VOITH SIEMENS , (Unit III) GERMANY on Make: J.M. 27.08.2005 Voith, Germany/ Siemens 24 MW hydro Burla 13.5.1957 Uprated to 32 MW by generating set VOITH SIEMENS , (Unit IV) Make: GERMANY on J.M. Voith, 28.10.2005 Germany/ Siemens

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STAGE-II Sl. No. Specfication 1 37.5 MW hydro generating set (Unit V) Make: Hitachi, Japan 2 37.5 MW hydro generating set (Unit VI) Make: Hitachi, Japan 3 24 MW hydro generating set (Unit I) Make: J.M. Voith, Germany/ Siemens 4 24 MW hydro generating set (Unit II) Make: J.M. Voith, Germany/ Siemens 5 24 MW hydro generating set (Unit III) Make: LMZ,RUSSIA Power station Burla Commissioning datesdates Renovation 19.4.1962

Burla

5.8.1963

Chiplima

15.7.1962

29.7.1998, Renovated by L&T and BHEL 01.01.2008 Under Renovated by BHEL.

Chiplima

26.11.1962

Chiplima

1.2.1964

STAGE-III Sl. No. 1 Item 37.5 MW hydro generating set (Unit VII) Make: Hitachi, Japan Power Commissioning Renovation station dates Burla 13.9.1990

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HHEP SPECIFICATIONS : 1. Name of the Power Station 2. Name of the River 3. Location (I) State (ii) Nearest town (iii) Distance 4. Total Installed Capacity of each Unit (a) No. of Units (b) Installed capacity of each Unit Burla Power House Mahanadi Odisha Sambalpur 15 Kms. from Sambalpur

7 # 1, 2 - 49.5MW # 3,4 - 32 MW # 5,6,7 -37.5MW 275.5 MW

(c ) Total Installed capacity 5. Reservoir / Pondage a) Name of the Dam b) Type of Dam c) Height of Dam d) Length of Dam

e) Catchment area f) Average Annual Inflow g) FRL / MWL h) MDDL I) Storage capacity

Hirakud Straight Edged Earth Dam 80.96 mt (Max) 4800 mts. (4.8 Kms.)(Total 25.8 km including Dykes) 83400 Sq. k.m. 36,750 Million Cum 192.024 Mt (630 ft.) 179.830 mt (590 ft.) 7189 M.cum
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6. Water Turbine a) No. of turbines b) Type of turbines

7 (Seven) Kaplan (# 1,2,5,6,7) Francis (# 3 & 4) 35.5 mt. 26.5 mts. # 1,2,3 & 4 - 32.3 mt. # 3 & 4 - 30.78 mt. # 5, 6 & 7 - 26.5 mt. 150 rpm 330 rpm (#1,2,5,6 & 7) 377 rpm (# 3, 4) Open channel

c) Net Head (I) Maxl. Head (ii) Minimum (iii) rated net (iv) Design head d) Nurmal Speed e) Runaway Speed 7. Tail race Type of Tunnel / Channel 8. Generators I) No. of Units ii) Type iii) Make

iv) Voltage v) Current

vi) Power Factor

7 (Seven) Semi Umbrella Vertical #1&2ALSTOM # 3 & 4 - (Voith Siemens) # 5,6 & 7 Hitachi 11 KV # 1,2 - 3149 amp # 3, 4 - 2506 amp # 5,6 & 7 - 2187 amp 0.9

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WORKING OF A HYDRO POWER PLANT

Hydropower plants harness water's energy and use simple mechanics to convert that energy into electricity. HYDRO POWER PLANT are actually based on a rather simple concept -- water flowing through a dam turns a turbine, which turns a generator. Water from dam enters the turbine through trash rack, intake structure and penstock and gets discharged to the tailrace through draft tube. To control the flow, hydraulic intake gates are provided for each machine Flowing water creates energy that can be captured and turned into electricity. This is called hydroelectric power or hydropower. The hydroelectric power plant uses a dam on a river to store water in a reservoir. Water released from the reservoir flows through a turbine, spinning it, which in turn activates a generator to produce electricity. But hydroelectric power doesn't necessarily require a large dam. Some hydroelectric power plants just use a small canal to channel the river water through a turbine. RAIN PRECIPITION PRINCIPLE OF HYDRO POWER PLANT WATER CYCLE The continuous cycle in which water changes from water vapor in the atmosphere to liquid water through condensation and precipitation and then back to water vapor through evaporation, transpiration, and respiration Water cycle in nature: Water surface evaporation Precipitation of clouds Collected back to the oceans VAPORATION

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BASIC COMPONENTS OF HIRAKUD HYDRO POWER PLANT

(1)Dam (2)Intake (3) Turbine (4) Generators (5) Transformer (6) Power lines (7) Outflow

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DAMS:

Storage dams impound water . Purpose - Irrigation - Flood control - Power generation Diversion dams For diversion To provide sufficient pressure Detention dams To Minimize the effect of sudden floods To trap sediment Overflow dams They carry water discharge over their crests Rockfill dams Rock instead of earth Embankment dams hold back water by the force of gravity acting upon their mass Gravity dams Most gravity dams are made from concrete, a mixture of port land cement, water, and aggregates They are much thicker at the base than the top.

Water reservoir is placed behind the dam where Potential energy is stored.. Intake or control gates are the gates inside of the dam. Which inlet gates . The penstock carries the water controlled by the control gates.

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Hirakud Dam Official name Location Coordinates Hirakud Dam Hirakud Dam 21.57N 83.87ECoordinates: 83.87E 1957 101 Crore Rs in 1957 Dam and spillways Type of dam Height Length Impounds Spillways Spillway capacity Dam and Reservoir 60.96 m (200 ft) 4.8 km (3 mi) (main section) 25.8 km (16 mi) (entire dam) Mahanadi 64 sluice-gates 42,450 cubic metres per second (1,499,000 cu ft/s) Reservoir Capacity Catchment area 5,896,000,000 m3(4,779,965 acreft) 83,400 km2 (32,201 sq mi) 21.57N

Construction began 1948 Opening date Construction cost

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Selection site for the Dam

(1) Quantity of water available Previous records of rainfall are studied and minimum and maximum quantity of water available during the year is estimated. After allowing for losses due to evaporation and percolation the net volume of water available for power generation can be determined. Rain fall (mm) Mean annual : Maximum annual : Minimum annual : Run-off (M.ha.m) : Average annual : Max. annual : Min. annual : (2) Storage of water Wide evaporation during the year makes it necessary to store water for continuous generation of power through out the year. Top dam level F.R.L/ M.W.L Dead storage level Storage capacity In M. cu. M / MACFT Gross : : : : R.L. 195.680 M (R.L 642 ft) R.L. 192.024 M (R.L 630 ft) R.L. 179.830 M (R.L 590 ft) Original 8136(6.60) Revised (1988) 7189(5.83) Original 1381.25 (190045) 1808.73 (1919) 940.31(1902) Original Revised 1038

2518 607 Post construction 6.17 (1926-46) 3.36 (1958-92) 8.62 (1919) 9.09 (1961) 2.54 (1902) 1.14 (1979)

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HYDRO TURBINES : Water turbines convert HYDROLIC energy to MECHANICAL energy.

Classifications of Hyrdo Turbines

There are two main types of hydro turbines: TURBINE SPECIFICATION (1) Impulse Turbine (a) Pelton Wheel (2) Reaction Turbine (a) Francis (b) Kalpan Net head: Rated output : Number: Type : 7 Kaplan turbine (Unit 1,2,5,6&7) Francis (unit 3&4) 26.5 m to 35.5 m 52000 HP (Unit 5,6&7), 66354HP(1 & 2) 49200 HP (Unit 3 & 4)

Normal speed : Run away speed :

150 rpm 342 rpm (Unit 1,2) 377 rpm (Unit 3 & 4) 372 rpm (Unit 5,6&7)

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(1)

Impulse Turbine

The impulse turbine generally uses the velocity of the water to move the runner and discharges to atmospheric pressure. The water stream hits each bucket on the runner.

(a)

Pelton wheel

A pelton wheel has one or more free jets discharging water into an aerated space and impinging on the buckets of a runner.

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(2)

Reaction Turbine

A reaction turbine develops power from the combined action of pressure and moving water. The runner is placed directly in the water stream flowing over the blades rather than striking each individually.

(a)

Francis

A Francis turbine has a runner with fixed buckets (vanes), usually nine or more. Water is introduced just above the runner and all around it and then falls through, causing it to spin.

(b)

Kaplan

Both the blades and the wicket gates are adjustable, allowing for a wider range of operation.

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Among turbine auxiliary systems we find lubricating oil supply consoles, barring or turning gear units, trip-throttle or similar emergency stop valves, gland sealing arrangements, and lube oil reclaimers or purifiers. Turbine & its Auxiliaries Regular inspection of runners of turbines should be carried out and record to that effect should be invariably maintained. Many a times it is not possible for Francis Turbine being always immersed in water and needs isolation on either side. For this it is done as recommended by manufacturer without any compromise. Due to cavitation there may be huge damages to turbine wheel causing adverse effect on performance and consequently efficiency. Sometimes, it would be necessary to undertake in-situ repairs of turbine buckets to recoupe/fillup erosions/ white pitting by using various cold compounds viz. Belzona compound, Loctite, SS Metalset, Throtex compound etc. This may give satisfactory results. Low heat input welding can also be tried at some of the locations to some extent. An effective system for monitoring of silt content (quantity and size in PPM) may be installed & commissioned by each power station and silt content may be monitored continuously on the basis of which action to mitigate the damaging effect to under water parts may be initiated reducing the down time of units / station. Best efficiency microprocessor based digital PID speed governors provide fast response. Periodical maintenance of speed governors alongwith all associated mechanical, electrical, electronics component should be carried out. The control circuit should be neatly dressed with identification marks. The electronic components and cards should be carefully maintained at appropriate temperature level to achieve desired performance. Periodical calibration and testing of transducers, meters etc. needs to be done. Desired purity level of hydraulic oil is to be maintained to give trouble free operations. History of each important part should be maintained.
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Following maintenance works also need to be taken up: Periodic NDT viz. Ultrasonic, etc. Polishing of the various under water parts of the turbines once in a year to minimize the white pitting. Inspection & testing of the runners from experts to decide residual life so as to initiate action for procurement of runners for replacement. Inspection of labyrinth seals in case of reaction turbines. Painting of runner housing with anticorrosive I tar based paints. Applying anti-erosion coating to the runner. Checking of brake jet operation in power stations having Pelton turbines once in three months.

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GENERATORS:

Generators convert MECHANICAL energy into ELECTRICAL energy.

GENERATOR SPECIFICATION

7 hydropower units were installed in this project with total installed capacity of 235.5 MW. Out of this 4 units have been up-rated during the year 1998 and 2005 increasing the present installed capacity to 275 per cent MW. Unit No-5 and 6 installed in the year 1962 and 1963 respectively with installed capacity of 37.5 MW each have now have outlived their designed life of 35 years. Generation in recent years:
YEAR

7 Semiumbrella vertical 11 KV Unit 1& 2 - 3149 Unit 3 & 4 - 2500 Unit 5,6 & 7- 2187 Capacity 49.5 MW(unit 1 & 2) 37.5 MW(unit 5,6&7) 32 MW(unit 3&4) Power 0.9 lagging Factor Speed 150 rpm Number Type: Voltage Current:

GENERATION (IN MUMU)

2010-11 2009-2010 2008-2009 2007-2008 2006-2007

714.7070 612.388 749.529 857.382 741.751

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Generator & its Auxiliaries Stator & rotor winding, bearings & excitation system are the main parts of a generator. As regards stator and rotor windings, regular recording of IR Values of these winding should be maintained at regular intervals.Tan Delta and DLA tests of stator winding indicates the status I condition of stator winding insulation. Likewise impedance test (voltage drop test across each pole) indicates condition of the rotor winding. Proper cooling system is to be maintained to limit rise in stator winding temperatures and consequently increase the life of stator winding. Inspection of the stator winding is also required to be carried out to verify its firmness in stator core slots and healthiness of overhang portion with firm end winding caps & end spacers, slot wedges checked for healthiness. Windings are revarnished to enhance their life. Looseness of stator core or inter lamination, core insulation are direct factors affecting winding heating due to eddy current loss. Thus recommended maintenance as per schedule should be carried out its records maintained and corrective actions be taken if necessary. Another precision and very critical components of generator are its guide and thrust bearings. The thrust bearing is main bearing holding complete thrust of rotating mass of turbine and generator unit. The generator and turbine guide bearings act as guides for controlling the vibrations of the unit . If T -G shaft alignment with accurate shaft level is achieved then the pad clearances are adjusted precisely and the rotating machine will operate smoothly without rise in bearing temperature and increase life of bearings. Following maintainance works also need to be taken up: Periodic checking of the foundations, tightening the bolts. Filling the foundations with epoxy. Checking the vibrations periodically & history of the recorded readings gives guidelines for realignment, looseness if any, unbalanced electrical components, increase in bearing gaps, coupling misalignment, uneven stator -rotor air gap etc.

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 Periodic cleaning or replacement of the generator air coolers and bearing oil coolers to improve performance of the generator. Primary and secondary testing of the protection system for its healthiness and correct operation. Inspection of circuits for protection & control circuits & mock trials of the fire fighting system alongwith evacuation system.

. Generator Components A. Hydrogen Seal Rings B. Fan Blades and Vanes C. Brushes and Brush Holders D. Shaft Grounding Devices E. Oil Deflectors

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TRANSFORMERS: Transformer converts the alternating current to high voltage current. Two coils are present in the Transformer: the supply coil(primary coil) and the outlet coil(secondary coil). Voltage required for various applications is 110V or 230V.

TRANSFORMER SPECIFICATIONS

Number Voltage Capacity

Phases Cooling system Make

7 11 / 132 kV 42 MVA (Unit 3,4,5,6&7) 60 MVA (Unit 1 &2) 3 Phase OFWF 1,2 BHEL 3,4 EMCO(After R & M) 5,6,7 GEC

Transformer maintainance Continuous monitoring of oil & winding temperature. Periodic oil filtration. Oil testing for various tests and Dissolved Gas Analysis. Tandelta & insulation resistance etc. as per schedule. Cleaning and replacement of oil cooler Testing protection system for healthiness. Mock trials of Checking, maintenance and inspection for Fire fighting system, CO2 & mulsifire. Periodic cleaning of transformer bushings & insulator strings.
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POWER HOUSE: Hirakud Power Station Specifications

Promoter Location Installed Capacity Unit Configuration Project Cost Main Plant Award Orissa Hydro Power Corporation Limited River Mahanadi, Orissa 275.5 MW 2 x 49.5 + 2 x 32 + 3 x 37.5 INR 100.02 Crore (in 1957) Unit I: English Electric, UK Unit II: English Electric, UK Unit III: J.M. Voith, Germany/ Siemens Unit IV: J.M. Voith, Germany/ Siemens Unit I: May 11,1958 Unit II: November 11,1957 Unit III: December 18,1956 Unit IV: May 13,1957 Unit V: April 19,1962 Unit VI: August 5,1963 Unit VII: September 13,1990

Date of Commissioning

The dam supports two different hydroelectric power houses. Power House I is located at the base (toe) of the main dam section and contains 3 x 37.5 MW Kaplan turbine and 2 x 24 MW Francis turbine generators for an installed capacity of 259.5 MW. Power Station II is located 19 km (12 mi) southeast of the dam 212110N 835500E at Chipilima. It contains 3 x 24 MW generators. The entire installed capacity of the dam's power houses is 307.5 MW. Power House I and II were built in three stages. During stage I, four generators were installed at PH I and in stage II, the power channel two and Power House II was constructed. All three generators were installed at PH II along with two more at PH I by 1963. Between 1982 and 1990, the seventh and final generator was installed at PH I
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SWITCHYARD: Switchyard forms an integral part of any power plant i.e. Industrial CPP, Thermal Power Utilities, Gas Turbines based power plants or Hydel power plants. These power plants have their main plant equipment integral controls (Boiler / Turbine / Gas Turbine / Hydro Turbine) as well as plant DCS System (BoP / Station C & I). While the entire power plant is integrated at the DCS level, true unification is achieved by incorporating / integrating switchyard controls (SCADA) also in the plant DCS.
Switchyard arrangements

132 KV Main & Reserve Bus Bar (Double Bus Bar)

No. of outgoing feeders:4

Switchyard of Burla power house

The switchyard is a junction connecting the Transmission & Distribution system to the power plant. Switchyard consists of the air insulated aluminium bus type and of high voltage SF6 insulated dead tank circuit breakers arranged in a ring bus configuration. Control, protection and monitoring for the switchyard will be located in the switchyard relay room of the electrical building. All protection and circuit breaker control will be powered from the station battery backed 220V DC system. Revenue metering are provided on the outgoinglines, recording net power to or from the switchyard 11 kV.

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EQUIPMENTS OF THE SWITCHYARD:

Line dig of a Switchyard

Bus Bar Bus Bar are used to interconnect the loads and sources of electrical power. It connects incoming and outgoing transmission lines. Also connect generator and main transformer in power plant. Material used: Copper or Aluminium Size of bus bar determines max. amount of current passed

Insulators Supported the poles and towers in such a way that currents from conductors do not flow to earth through these supports. Pin type & Suspension type: insulators are design for 11 kv.

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Lightning Arrestor Lightening Arrestor are used on power system to protect the s ystem from damaging effect of lightning. It does not absorb or stop the Lightning. It Divert the Lightning to Ground. It Clamp (limit) the Voltage produced by the Lightning It Only protects equipment electrically in parallel with it. Isolator An isolating disconnect switch are installed in each generator transformer connection to the bus. Circuit Breaker Circuit breaker is an automatically-operated electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit. Its function is to interrupt continuity, to immediately discontinue electrical connections. In switchyard High Capacity Circuit Breakersare used. Each circuit breaker are equipped with a no-loadbreaker, air insulated, disconnect switch on eachside In 400/220KV substation Power Grid there isSF6 circuit breaker system flow The SF6 is an electro-negative gas and has astrong tendency to absorb free electrons. The contacts of the breaker are opened in a high pressure flow of SF6 gas and an arc is struck between them. The conducting free electrons in the arc are rapidly captured by the gas to form relatively immobile negative ions. Unit 2,3,4,6 has SF6 circuit breakr. Unit 1,5,7 has OCB.

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Advantages of using SF6 Circuit breaker Very short arcing time. Can interrupt much larger currents. Noiseless operation due to its closed gascircuit. No moisture problem. No risk of fire since SF6 gas is non-inflammable Low maintenance cost. No carbon deposits so that trackingand insulation problems are eliminated

Disadvantages of using SF6 SF6 breakers are costly due to high cost of SF6. SF6 gas has to be reconditioned after everyoperation of the breaker, so additionalequipments are required

Instrument Transformers In switchyard, a power transformer is used to stepup or step down the voltage. Current and Voltage transformers are located at points within the switchyard to provide form etering and relaying. Current transformers, together with potential transformers, are known as instrument transformers. It controls excess and low current. It also helps in steping up or down the potential. Since the measuring instruments and protective devices are designed for low voltages (generally 110V) and currents(about 5A). Therefore, they will not work properly if mounted directly on power lines.

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Current Transformer The current transformer is used to measurethe very high current passing through the bus. It step downs the current and measurements are taken in the control room the ratings of CT is based on the ampere. These CTs are connected to the control room through cables.

Voltage Transformer There is a step down transformer, which step down the high voltage to a value that can be measured using the measuring instruments in the control room. This has an additional core for the carrier communication. The CVT are connected between phase and ground in parallel to the circuit. Arcing Horns Arcing horns are for the protection of the insulators in case of high voltage, which it cannot stand. They are two metal rods fitted at the topmost and bottommost parts of the insulator. During high voltage insulators can't resist this and cracks may be developed. In order to avoid these arcing horns are provided. They conduct the high voltage to the ground and protect the insulator. Control Panel Control panel mostly consists of meters and protective relays. The meters include ammeter, voltmeter, wattmeter, energy meter etc. The relays include fuse failure relay, auto reclose relay, check synchronizing relay ,auxiliary relay and transformer relays like OLTC out of step, winding temperature alarm , oil temperature alarm. The trip indicators included are CB SF6 gas density low, CB Air pressure low, VT fuse fail alarm, CB pole disctrip, carrier signal received, back up protection, auto reclose lock out, control DC supply fails, distance protection inoperative, carrier out of service, distance protection trip etc.
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Earthing It is to be provided in substations due to following reasons:To provide a means to carry electric current into the earth under normal and fault conditions , without exceeding any operating and equipment limits or adversely affecting continuity of service . To assure that a person in the vicinity of grounded facilities is not exposed to the danger of electric shock.

SCADA nodes The Supervisory control and data acquisition system (SCADA) of switchyard consists of Operator Stations, Engineer's Stations, Historical Storage, Computers and associated peripherals and the switchyard bay control systems interconnected through a high speed network . The system constitutes several operator work stations and engineer's work station with high resolution Color display monitors, touch screen, function key board, mouse, track ball and printers. Its features are: Monitoring of status of switchyard equipment like isolators, breakers, ground switches Issue of close/open commands to isolators, breakers Monitoring of system parameters like voltage, current, frequency, MW, MVAR, energy Time stamping of alarms, events, protective relay operations Presentation of information useful to operator in different forms Report generation Historical storage and retrieval Remote control and monitoring from Load dispatch centre through fibre optic/PLCC communication

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OHPC shall provide easement and rights of way to authorised personnel of OPTCL for the purpose of inspection, testing of relays, meters, CTs., PTs, etc. when required. Maintainance of Switchyard : Tests for operation time of the breaker. Operation & testing of isolator opening & closing. Checking of control circuit & healthiness of operating system of the breaker. Inspection of the CTs, PTs and bus bars for over heating, temperature rise etc.

Switchyard are to be kept neat & tidy. Minimum area surrounding the yard to be free from growth of scrubs and bushes to avoid any bush fire damaging the equipment.

The Interconnection Points between OHPC and OPTCL 132 KV / 66 KV /11KV / 0.4 KV system will be the take off points at 132 KV / 66 KV / 11KV switchyard gantry and 0.4 KV panel. Equipment like CT, LA etc., in the switchyard connected near the gantry, will be the responsibility of OHPC.

LOCATION OF INTER-CONNECTION POINTS i. 132 KV ALCO Feeder-I ii. 132 KV ALCO Feeder-II iii. 132 KV Budhipadar Feeder-I iv. 132 KV Budhipadar Feeder-II v. 132 KV Rairakhol Feeder. vi. 132 KV Sambalpur Feeder. vii. 132 KV Chiplima Tie-I Feeder viii. 132 KV Chiplima Tie-II Feeder.

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GENERATOR PROTECTION SCHEME

Functions Small (<10 MVA) Differential 95% Stator E/F 100% Stator E/F Interterm faults Back impedance Voltage controlled O/C Negative sequence Field failure Reverse Power Pole Slipping Overload Over voltage Under Frequency Dead machine Rotor earth fault Over fluxing Y Y N N Y Y N Y N Y Y Y N Y N Y

Steam & Gas turbines Medium (10-100 MVA) Y Y Y Y Y N Large (>100 MVA) Y Y Y Y Y N Small (<10 MVA) Y Y N Y N Y

Hydro Turbines Medium (10-100 MVA) Y Y Y Y Y N Large (>100 MVA) Y Y Y Y Y N

Y Y N N Y Y N Y Y

Y Y N Y Y Y Y Y Y

Y Y N Y Y Y N Y N

Y Y N Y Y Y N Y Y

Y Y Y Y Y Y Y Y Y

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PROTECTION SCHEMES GENERATOR PROTECTION

Class A Protections : This covers all electrical protections for fault within the generating unit in which generator field breaker, generator breaker and turbine should be tripped.

FAULT / INTERMEDIATE ACTION INITIATION OF AUX. RELAY RELAYS 87G87GT87UAT54G164G259GClass A 99GTTrip 64REF-Trip Generator CB 86 G 51UAT-Trip Exciter CB 50UAT-Trip Turbine 64R II STAGE-Trip UAT CB Rotor Over Voltage-Initiate LBB Excitation fail46G40G21GGT faultUAT faultClass B Protections : This covers all mechanical protections of the turbine in which turbine will be tripped first and following this generator will trip on reverse power / low forward protections.

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Faults Turbine Over SpeedGovernor failureTurbine Bearing temp. riseGuide bearing Temp. riseThrust bearing Temp. riseIntake gate closed / Inlet valve closedExcessive water pressureInside spiral casingStator temp. riseRotor temp. rise-

INTERMEDIATE AUX. RELAY

ACTION

-Trip Generator CB
Class A Trip 86 T

-Trip Exciter CB -Trip Turbine -Operate Emergency Closing of Guide apparatus. -Trip UAT CB -Initiate LBB -Close Intake gate / Inlet valve

Class C Protections : This covers electrical protection for faults in the system in which generator will be unloaded by tripping of generator breaker only. The unit will come to house load operation and the UAT will be in service. Various protections of this class are: i) ii) iii) iv) v) 220 KV (HV side of Generator Transformer) busbar protection. Generator Transformer HV side breaker pole discrepancy. Generator negative phase sequence protection. Generator Transformer over current / earth fault protection. Reverse power protection without turbine trip.

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RECENT VENTURES

Orissa government will upgrade the 5th and 6th units of the Hirakud hydro power projects at an estimated cost of Rs 297 crore in a bid to boost power production and generate more revenue. A high level meeting held under the chairmanship of Chief Secretary B K Patnaik decided to make international bidding for the upgradation of the power units at the earliest. The decision was taken as the equipment installed in these units became old and the power generation from these units were declining every year. The units which were installed in 1956 with installed capacity of 37.5 MW each were now generating 33 MW and it is likely to be reduced further. After the upgradation the power generation from these two units will increase 43 MW each and provide energy benefit of 218 MU. The 5th and 6th units of Burla hydro power project, each having capacity of 37.5 Mw, were installed 47 year ago and had frequent beak down complains. The renovation work aims at increasing the power generation capacity of the two units to 86 Mw, from the present 75 Mw, In the renovation work, we will replace the old machines with new ones and the entire process might take three years As such their modernization and up-rating has become necessary. With the proposed renovation, the capacity of each unit will be enhanced to 43 MW which will add 218 Million Units of energy benefit. Technical experts say it will take near about 38 months for installation of theses up-rated units involving an estimated cost of Rs296.83 Crorers. This will generate an additional revenue of around Rs 22 crore from these units. While the process for bidding requires eight months, another 30 months will be required for the upgradation of the two power units. Hirakud Hydro power project has seven units out of which four had already been upgraded. The work order involves supplying the machines and erecting them.

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BENEFITS OF HHEP PROJECT

In the upper drainage basin of the Mahanadi River, centered on the Chattisgarh Plain, periodic droughts contrast with the situation in the lower delta region where floods may damage crops. The dam was constructed to help alleviate these problems by creating a reservoir and controlling river flow through the drainage system. The dam regulates the flow of the Mahanadi River and produces hydroelectricity through several hydroelectric plants. The dam helps control floods in the Mahanadi delta and irrigates 75,000 square kilometres of land. Hydroelectricity is also generated. The Hirakud Dam regulates 83,400 km (32,200 mi) of Mahanadi's drainage. The reservoir has a storage capacity of 5.818 km with gross of 8.136 km. It drains an area of 133,090 km.. With successful irrigation provided by the dam, Sambalpur is called the rice bowl of Orissa. The project provides 1,556 km of kharif and 1,084 km of rabi irrigation in districts of Sambalpur, Bargarh, Bolangir, and Subarnpur. The water released by the power plant irrigates another 4360 km of CCA in Mahanadi delta. The dam can generate up to 307.5 MW of electrical power through its two power plants at Burla, on the dam's right bank and Chiplima, 22 km downstream from the dam. In addition, the project provides flood protection to 9500 km of delta area in district of Cuttack and Puri. Chiplima has gained prominence as the second hydroelectric project of the Hirakud Dam. A natural fall of 80 to 120 feet (25 to 40 m) in the river Mahanadi is used to generate electricity.

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DISADVANTAGES OF HHEP PROJECT

The power produced by the plant depends upon quantity of water which in turn is dependent upon the rainfall , so if the rainfall is in time and proper and the required amount of water can be collected, the plant will function satisfactorily otherwise not. The main purpose of the Hirakud Dam was to check the massive flood that was effecting a large part of coastal Orissa. But construction of the dam greatly affected the native of western part of Orissa. Nearly 150,000 people were affected by the Hirakud project. Nearly 22,000 family were displaced by the dam project. In the original estimate, an amount of Rs 12 crores was provided for payment of compensation to the affected people. After revision, the amount was reduced to Rs 9.5 crores and the total compensation paid to the people was, in reality, only Rs 3.32 crores. A large number of families were evacuated from their hearth and homes without compensation from 1956 onwards Hydro electric plants are generally situated away from the load centers. They require long transmission lines to deliver power. Therefore, the cost of transmission lines and losses in them will be more.

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CONCLUSION

Hydro electricity has been a reliable source of power supply since the day it came into force. Water being available as the natures free gift will continue to make hydroelectric power more easy and safer way of producing electricity. Though irregularities in rainfall become a major setback for the efficient power supply yet it has proved its mettle among the current breed of other sources of electricity.

HHEP is one of the first major multipurpose river valley project started after India's independence..

During our training period we learnt about different units of Burla Power House, maintainance and operations of Turbine, Alternators, its auxillaries ,Equipments and maintainance of Switchyard..

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THANK YOU

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