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Wapda internship report

The document is an internship report from the University of Engineering and Technology, Lahore, focusing on hydal operations and energy sources. It discusses conventional and non-conventional energy sources, the reliability of hydroelectric power over fossil fuels, and specific hydropower projects in Pakistan, including the Tarbela, Mangla, Warsak, and Ghazi Barotha hydel power stations. The report highlights Pakistan's significant hydropower potential and details the construction, specifications, and funding of various hydropower facilities.

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UNIVERSITY OF ENGINEERING AND TECHNOLOGY, LAHORE INTERNSHIP REPORT WAPDA-Hydal Operations Submitted To: General Manager (Hydal Operations) Mr.Taseer Iqbal Submitted By: Saboora Khatoon 2009-ME-140 Wardah Khalid 2009-ME-145 Faiza Rehman 2009-ME-147 Samavia Taseer 2009-ME-150 From 2nd July to 1st August
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2 INTRODUCTION TO ENERGY The capacity to do a work is energy…………….. We are greatly dependent upon energy. God gave us several forms of natural energy to help us live productively on earth. He gave man the intelligence to learn how to use different forms of energy in creative ways. Energy Sources The different things from which we get the energy are called as Energy Sources. There are two types of energy sources. 1. Conventional or Non-Renewable Energy Sources 2. Non-Conventional or Renewable Energy Sources 1. Conventional or Non-Renewable Energy Sources: The energy sources, which we are using from long time and which are in danger of exhausting, are called as Conventional OR Non-Renewable Energy Sources e. g. coal, petroleum products, nuclear fuels etc. 2. Non-Conventional or Renewable Energy Sources: These are the sources, which can be recovered and reused. i. e. they can be used again and again to generate energy because of the renewal of their energy. e.g. hydel, wind, geothermal etc.
3 Power and Energy  We can differentiate between power and energy as the utilization of power is energy.  We achieve power from generators in the form of mega watts, but this power when utilized for a time interval in any equipment, it is energy. Now, this energy gives the ability to do work.  The consumption of power for time is expressed in the form of energy. Our purpose is to generate power. Types of Power Generation We use conventional and non-conventional sources of energy for power generation. Thermal power generation is an expensive method. It needs a lot of auxiliaries and the system is overall complicated. Wind potential can be used for power generation but it requires greater restrictions. The selection of site and its climatic conditions are very important for wind, nuclear, geothermal power generation. Moreover, the drastic weather conditions cause the damage of heavy equipment which in run becomes a loss of lives and also capital. Keeping all the aspects in view, hydro-electric power plants are much more reliable and efficient than the fossil fuel fired plants.  Hydroelectric Power Hydro power is currently the world's largest renewable source of electricity, accounting for 6% of worldwide energy supply or about 15% of the world's electricity. Electricity produced from generators driven by water turbines that convert the energy in falling or fast-flowing water to mechanical energy. Water at a higher elevation flows downward through large pipes or tunnels (penstocks). The falling water rotates turbines, which drive the generators, which convert the turbines' mechanical energy into electricity. Advantages  Simple in construction  No Fuel consumption  No pollution  Low Running Cost  Less Maintenance  High efficiency with proper attendance of plant  Reutilization of water for Irrigation Disadvantages  High Capital or Initial cost i.e. of civil works, equipment etc  Power generation effects during dry season  High cost of transmission lines
4 HYDEL POTENTIAL IN PAKISTAN Taking a general over view of different locations in Pakistan, Pakistan WAPDA has traced out about 50,000 MW hydro-electric potential. But due to limited financial resources and political issues of the country, unfortunately only 6516 MW is the total installed capacity of HPP. There are 14 different Hydel power stations working under WAPDA in Pakistan. In 1960, with the co-operation of World Bank, a treaty was signed between India and Pakistan for water distribution. Salient Features of the Indus Basin Water Treaty Provisions regarding the Eastern Rivers: 1. All the waters of the Eastern Rivers shall be available for the unrestricted use of India. 2. Except for domestic and non-consumptive uses, Pakistan shall be under an obligation to let flow, and shall not permit any interference with, the waters of Sutlej Main and the Ravi Main in the reaches where these rivers flow in Pakistan and have not yet finally crossed into Pakistan. 3. All the waters, while flowing in Pakistan, of any tributary which, in its natural course joins the Sutlej Main or the Ravi Main after these rivers have finally crossed into Pakistan shall be available for the unrestricted use of Pakistan. Provisions regarding the Western Rivers: 1. Pakistan shall receive for unrestricted use all those waters of the western rivers. 2. India shall be under an obligation to let flow all the waters of the Western rivers, and shall not permit any interference with these waters. Provisions regarding the Eastern and Western Rivers: 1. Pakistan shall use its best endeavors to construct and bring into operation a system of works that will accomplish the replacement from the Western rivers (and other sources of ) the water supplies for irrigation canals in Pakistan, which on 15th August, 1947 were dependent on water supplies from the Eastern rivers. 2. The use of the natural channels of the rivers for the discharge of flood or other access waters shall be free and not subject to limitation by either party, or neither party shall have any claim against the other in respect of any damage caused by such use. 3. Each party declares its intention to prevent, as far as practicable, undue pollution of the waters and agrees to ensure that, before any sewage or industrial waste is allowed to flow into the rivers.
5 TARBELA HYDEL POWER STATION Tarbela Dam is one of the world’s largest earth and rock filled Dam and greatest water resources development project which was completed in 1976 as a component part of Indus Basin Project. The Dam is built on one of the World’s largest rivers – the Indus known as the “Abbasin” or the father of rivers. Project Project cost of Tarbela hydel power station was 16.417 billion Rupees and was funded by ADB/KFW. Specifications Main Spillway Capacity = 6, 50,000 cusecs Type = Earth and Rock fill Height = 485 ft (above river bed) Length = 9000 ft Total Capacity = 3478 MW Max. op. level = 1550 Min. op. level = 1378 Turbine (Francis-Vertical) UNITS 1-4 5-6 7-8 9-10 11-14 Rated Head ft. 378 378 378 378 385 Manufacturer Hitachi Japan DEW Canada DEW Canada DBS Canada DBS Canada Capacity /unit(MW) 175 175 175 175 432 Total installed capacity(MW) 700 350 350 350 1728 Commissioning JULY-1977 DEC-1982 DEC-1982 APR-1985 FEB-1993 Generator (Umbrella) UNITS 1-4 5-6 7-8 9-10 11-14 Output(MVA) 205.882 184.210 184.210 184.210 480 Output( P.F ) 0.85 0.95 0.95 0.95 0.90 Output(MW) 175 175 175 175 432 Rated Voltage(KV) 13.8 13.8 13.8 13.8 18.2 Manufacturer Hitachi Japan CGE Canada CGE Canada Hitachi Japan Siemens-ABB Germany Transformer UNITS 1-4 5-6 7-8 9-10 11-14 Capability(MVA/Phase) 79 71 71 71 160 Voltage Ratio 13.2/220 13.2/500 13.2/500 13.2/500 25.0/500 Manufacturer Jeumount- Scheider ASEA Canada Hitachi Japan Hitachi japan Jeumount- Scheider Ansaldo Italy
6 MANGLA HYDEL POWER STATION Location Mangla Dam Project was actually conceived in 1950's as a multipurpose project to be constructed at a place called Mangla on river Jhelum located about 30 km upstream of Jhelum city (120 km from Capital Islamabad). Project The initial investigation and its feasibility studies were completed in 1958. Later on the project was included in the Indus Basin Project. The construction of Mangla Dam was started in 1962 and completed in 1967.it was funded by USA,UK ,Australia, Germany, Newzeland, Pak &India IBRD world Bank ,CZECH-Pak barter, Credit Loan Marubini, Wapda&CZECH loan. Project cost was 3.455 billion rupees. Specifications Discharge = 8,70, 000 cusecs Total no. of units = 10 x 100 MW Total installed Capacity = 1000 MW Water Head = 296 ft Max./Min. op. level (ft) = 12426/1040 Turbine (Francis) UNITS 1~4 5~6 7~8 9~10 Output (BHP) 138000 138000 138000 138000 Rated Head (Ft. of Water) 295 295 295 295 Make Mitsubishi Japan CKD Blansko (Czech.) Escherwyse- ACEC Belgium SKODA (Czech.) Capacity/unit(MW) 100 100 100 100 Total installed capacity(MW) 400 200 200 200 Commissioning 1967-1969 MAR-1974 1981 1993-1994 Generator (umbrella) UNITS 1~4 5~6 7~8 9~10 Output (MVA) 125 125 125 125 Output (MW) 100 100 100 100 Output (P.F) 0.8 0.8 0.8 0.8 Output (K.V) 13.2 13.2 13.2 13.2 Rated Speed (RPM) 166.7 166.7 166.7 166.7 Make Hitachi Japan Skoda Czech. Hitachi Japan Skoda Czech. Transformer UNITS 1~4 5~6 7~8 9~10 Capability (MVA) 138 138 138 144 Voltage Ratio (KV) • 12.5 / 132 [Unit 1~2] • 12.5 / 220 [Unit 3~4] 12.5/220 12.5/220 12.5/220 Make Savigliano Italy [1&4] Skoda Czech. [2&3] Savigliano Italy Italtrafo [Unit-7] Skoda [Unit-8] Skoda Czech.
7 WARSAK HYDEL POWER STATION Location Warsak Hydro Electric Power Project is located on River Kabul at about 30 km from Peshawar in North-West Frontier Province of Pakistan. Project The project financed by Canadian Government was completed under COLOMBO PLAN in two phases. It was completed in 1960 at a total cost of Rs. 394.98 million in Phase 1. Two additional generating units each of 41.48 MW were added in 1980-81 at a cost of Rs. 106.25 million as second phase of the project.It was funded by PLAN & CIDA. Specifications Total installed Capacity = 242.96 MW Area = 4 Sq. miles Max. op. level (ft) = 1270 Min. op. level (ft) = 1270 Turbine (Francis-Vertical) UNITS 1-4 5-6 Output (BHP) 55,000 57,000 Net Head 144 ft 144 ft Speed 136.4 RPM 136.4 RPM Manufacturer Dominion Engg. Co. Canada Dominion Engg. Co. Canada commissioning JULY-1960 MARCH-1981 Generator (Umbrella) UNITS 1-4 5-6 Output(MW) 40 41.5 Output(P.F) 1.0 0.85 Rated Speed 136.3 RPM 136.3 RPM Manufacturer Canadian General Elec. Co. Ltd Canadian General Elec. Co. Ltd Transformer UNITS 1-4 5-6 Capacity 13.33/Phase 48.8 three Phase Voltage Ratio 11/132 KV 11/132 KV Manufacturer Saranti, Canada Westing house Switch yard No. of 132 KV feeder/breaker = 4 / 06 Scheme Layout = Double Bus bar/ One and half breaker system Tunnels/penstock = 6
8 GHAZI BAROTHA HYDEL POWER STATION Location Ghazi Barotha Hydropower Project is located on the Indus River downstream of Tarbela Dam. it reaches Indus River drops by 76 m in a distance of 63 km. Project This Project possesses the minimum of environmental and social impacts. Ghazi Barotha Hydropower Project consists of three main components. The Barrage, the Power Channel and the Power Complex.It was funded by World bank/ADB JAPAN Bank Int.Coop./KFW/Eurpean Invst Bank /Islamic Bank.Project cost was 94.733 billion rupees. Specifications Discharge Capacity = 1,600 cusics Total installed Capacity = 5 x 290 MW Max. op. level (ft) = 1096 Min. op. level (ft) = 1079 Turbine (Francis) Number of Units 1-4 5 Output (MW) 290 290 Rated Head (Feet) 226 226 Manufacturer M/S VOITH HYDRO GERMANY M/S VOITH HYDRO GERMANY Capacity/unit(MW) 290 290 Commissioning 7-2003 3-2004 Generator (Umbrella) Output (MVA) 322.2 Output (P.F) 0.9 LAGGING Rated speed (rpm) 100 Manufacturer M/S TOSHIBA CORPORATION JAPAN Transformer Capacity (MVA) 3X107.5 Voltage ratio (KV) LV=18 KV, H V=5153 KV Manufacturer SIEMENS ABB Switch yard No. of 500 KV feeder/breaker = 6 / 18 No. of 220 KV feeder/breaker = 2 / 6 Scheme Layout = Double Bus bar/ One and half breaker system Tunnels/penstock = 5
9 CHASHMA HYDEL POWER STATION Location It is located on the River Indus close to the right embank of Chashma Barrage.It is low head hydel power station utilizing available head of 4-13 meters. Project Its operation is dictated by the release downstream Chashma Reservoir being controlled by the Indus River System Authority (IRSA). The project cost is 21082 million rupees.It was funded by ADB,CITY Bank,Japan,Pakistan,French,Protocol,Suplementory credit Agricole indonsuez France. Specifications Total Capacity = 8 x 23 MW Generation voltage = 11 KV Max. op. level (ft) = 649 Min. op. level (ft) = 637 Turbine (Bulb) Type Fuji Japan Rotation Speed 21 ft Runner Diameter 21 ft Guide Vanes 16 Discharge unit 8829 cusecs Head available 13 m to 38 m Rated head 27.4 ft commissioning 2000-2001 Transformer Type GE Alsthon France Voltage 132 KV Rated Capacity 26 MVA Generator (Bulb) Type Fuji Japan Rated Capacity 23 MVA Power factor 0.9 Voltage 11 KV Switch yard No. of 132 KV feeder/breaker = 4 / 4 Scheme Layout = Double Bus bar/ Double breaker system
10 RASUL HYDEL POWER STATION Location It is first Hydel Power Station after creation of Pakistan. Hydel Power Station is situated on upper Jhelum Canal (UJC) 80 km downstream from its source i-e New Borg Escape ,Mangla. The power house is operated as base-load and it is connected to National Grid System through 132 KV and 66 KV transmission lines. Project. The cost of project is 20.33 Millions.It was funded by N.A. Specifications Total Capacity = 11 X 2 MW Generation Voltage = 11 KV Transformation Voltage = 132 KV Reservoir = River of Canal Installation = in 1952 Turbine (Kaplan) Type Kaplan Boving UK Discharge / unit 1812 cusecs Rated Head(ft) 85 Commissioning July-1952 Generator (Umbrella) Type Umbrella/British Thomson UK Output(MVA) 12.5 Output(P.F) 0.88 Output(KV) 11 Rated Speed 214 RPM Transformer Capacity 2*12.5 Voltage ratio 11/66 KV Transmission line 132 KV/2; 66 KV/2 Switch yard No. of 11 KV feeder/breaker = 2 / 4 No. of 66 KV feeder/breaker = 2 / 3 No. of 132 KV feeder/breaker = 2 / 3 Scheme Layout = Single Bus bar/ single breaker system Tunnels/penstock = 2
11 SHADIWAL HYDEL POWER STATION Location Shadiwal Hydel Power Station District Gujarat is situated at the tail of upper Jhelum Canal near Shadiwal town at a distance of 14 km from Gujarat which takes off from Jhelum River at Mangla and falls into Chanab River upstream of Khanki Head works after Shadiwal Power station. Project This project was completed through Colombo plan financed jointly by the government of Canada and Pakistan.Project cost was 0.044 billion rupees. Specifications Total capacity = 2 x 6.75 MW Generation voltage = 11 KV Transformation voltage = 132 KV Water head = 23 ft Manufacturer of turbine = Dominion Canada Manufacturer of generator = Umbrella /Canadian GEC Spillway gates = 6 Siphon spillway = 2 Turbine (Kaplan) Type Kaplan Dominion Canada Discharge /unit 3900 cusecs Commissioning JAN-1961 Generator (Umbrella) Output(MVA) 7.5 MVA Output(P.F) 0.9 Lagging Output(KV) 11 KV Rated Speed 83.3 RPM Transformer Capacity 4 x 5 Single Voltage Ratio 3.3/11 KV Manufacturer Pioneer Electric Ltd. Canada Transmission Line 132 KV/1 Switch yard No. of 11 KV feeder/breaker = 1 / 7 No. of 132 KV feeder/breaker = 1 / 1 Scheme Layout = Single Bus bar/ Single breaker system
12 NANDIPUR HYDEL POWER STATION Location It is situated on upper Chenab canal (UCC) near Nandipur village at a distance of about 10 km from Gujranwala-Sialkot road. Project Project cost was 0.062 billion rupees. It was funded by N.A. Specifications Total capacity = 3 x 4.6 MW Generation Voltage = 3.3 KV Transformation Voltage = 66 KV Water Head = 22 ft Manufacturer of turbine = Kaplan Litostroj Yugoslavia Manufacturer of generator = umbrella /Rade Koncer Yugoslavia Generator (Umbrella) Turbine (kaplan) Output 6500 BHP Discharge 3040 cusecs Head Water 22 ft Runaway Speed 280 RPM Rayed speed 107 RPM Power transformer Output 2*8500 KVA Voltage 11/66 KV Current 446/74.5 Amps Connection YD-5 Impedance 8.6% Switch yard No. of 66 KV feeder/breaker = 2 / 4 Scheme Layout = Double Bus bar/ Single breaker system Output 3*5750 KVA Power Factor 0.8 Rated Current 1010 Amps Voltage 3.3 KV No. of Poles 56 commissioning MAR-1963
13 CHICHCHOKI HYDEL POWER STATION Location Chichoki Hydel Power Station is located on Upper Chanab Canal near village Joyanwala about 20 Km from sheikhupura city. Project Power Station was commissioned on Aug 1959 the project cost is 30.55 million.It was funded by N.A. Specifications Total Capacity = 3 x 4.4 MW Generation voltage = 3.3 KV Transformation voltage = 66 KV Water head = 25 ft Manufacturer of turbine = Kaplan/Litostroj Yugosalavia Manufacturer of generator = Umbrella / Rade Koncer Yugosalavia Reservoir = Run of Canal Turbine (Kaplan) Type Kaplan Rated head 25 ft Discharge/unit 2700 cusecs Commissioning Aug-1959 Generator (Umbrella) Type Umbrella Output(MVA) 5.6 MVA Output(P.F) 0.8 Output(KV) 3.3 KV Rated Speed 107 RPM Transformer Capacity 2*15 Voltage Ratio 11/66 KV Transmission Line 11 KV/2 Switch yard No. of 66 KV feeder/breaker = 2 / 4 Scheme Layout = Double Bus bar/ Single breaker system
14 DARGAI HYDEL POWER STATION Location Dargai Hydel Power Station is located on Upper Swat Canal in Malakand agency near Dargai. Project The project was funded by N.A. The project cost is 30.86 Million. Specifications Total capacity = 4 x 5 MW Generation voltage = 11 KV Transformation voltage = 66 KV Reservoir = Run of Canal Manufacturer of turbine = SM smith USA Manufacturer of generator = Westings House Gross head station = 18.9 m Discharge/ unit = 15.8 m³/s Turbine (Francis) Type Kaplan Rated Head 243 ft Discharge/unit 240 cusecs commissioning Dec-1952 Generator (Umbrella) Output(MVA) 5.88 MVA Output(P.F) 0.85 Output(KV) 11 KV Rated Speed 500 RPM Transformer Capacity 2*15 ; 1*12.5 Voltage Ratio 11/132 KV ; 11/60 KV Transmission line 132 KV/2 ; 66 KV/1 Switch yard No. of 11 KV feeder/breaker = 1 / 7 No. of 132 KV feeder/breaker= 1 / 3 Scheme Layout = Double Bus bar/ Single breaker system Tunnels/penstock = 4
15 RENALA HYDEL POWER STATION Location The existing Renala Hydel Power Station is located on RD (160 to 686) near Renala town on Lower Bari Doab Canal off taking from Head Baloki. Project This was built in 1925 by Sir Ganga Ram for low head pumps for irrigation to fields.It was funded by Ganga Ram. Specifications Total Capacity = 5 x 0.22 MW Generation voltage = 3.3 KV Transformation voltage = 11 kV Turbine (Francis) Type Horizontal Francis Manufacturer Vicker England Speed 100 RPM BHP 385 hp Total Rated Discharge 74 cusecs Wicket Gates 16 Stay Vanes 16 Runner 4 Runner Blade 16 Commissioning Mar-1925 Transformer No. of Transformer 2 Nominal Rating 2 MVA High Voltage 11 KV Low Voltage 0.4 KV Generator (CEC.UK) Rated output 275 KVA Generation Voltage 33000 V No. of Poles 10 Rated Capacity 220 KV Switch yard No. of 11 KV feeder/breaker = 1 / 1 Scheme Layout = Double Bus bar/ Single breaker system
16 KURRAM GARHI HYDEL POWER STATION Location Khurram Ghari Hydel Power Station is located on river Khurram about 10 Km North West of Bannu city. Project The cost of the project is 4.07 Million. The project was funded by N.A. Specifications Total capacity = 4 x 1 MW Generation voltage = 3.3 KV Transformation voltage = 11 KV Water Head = 60 ft Manufacturer of turbine = Siemens Manufacturer of generator = Siemens Reservoir = Run of river Turbine (Siemens) Type Francis Rated Head 18.3 ft Discharge/unit 260 cusecs commissioning Feb-1958 Generator (Siemens) Output(MVA) 12.5 MVA Output(P.F) 0.85 Output(KV) 3.3 KV Rated Speed 428 RPM Transformer Voltage Ratio 3.3/11 KV Switch yard No. of 11 KV feeder/breaker = 1 / 10 No. of 66 KV breaker = 1 Scheme Layout = Single Bus bar/ Single breaker system Tunnels/penstock = 4
17 CHITRAL HYDEL POWER STATION Location Chitral Hydel Power Station is located on Ludko River Gram Chashma road, 7 KM East of Chitral town. Project Project cost was 19.47 million. It was funded by N.A. Specifications No. of units = 4 Capacity of each unit = 1-2 units (0.3 MW) & 3-4 units (0.2 MW) Total Capacity = 1 MW Generation voltage = 0.4 KV Water head = 110 ft Manufacturer of turbine = Ossberger W.G Manufacturer of generator = AEG W.G Turbine (Ossberger Germany) Type Kaplan Rated Head Unit 1-2(98 ft) & Unit 3-4(105 ft) Discharge/unit Unit 1-2(1050 Cfs) & Unit 3-4(1256 Cfs) Commissioning 1975 -1982 Generator (GMBH Germany) Output(MVA) 1.25 MVA Output(P.F) 0.8 Output(KV) 0.42 KV Rated Speed Unit 1-2(1500 RPM) & Unit 3-4(1000 RPM) Transformer Voltage Ratio 3.3/11 KV Manufacturer GEC Switch yard No. of 11 KV feeder/breaker = 2 / 2 Scheme Layout = Double Bus bar/ Single breaker system Tunnels/penstock = 2
18 KHAN KHWAR HYDROPOWER PROJECT Location The Project is located on Khan Khwar River, a tributary of Indus River near Besham District Shangla in N.W.F.P. at a distance of 245 Km from Islamabad. Specifications Design Discharge = 35 m³/s Gross Head = 252 m Headrace Tunnel =4.557 km Installed Capacity =72 MW Energy per annum =306 GWh NO. and types of unit =3(2*34+1*4)MW Francis Speed of Turbine =500 rpm Generator Speed 500 rpm Output 34 MW/40 MVA Turbine Discharge/unit 16.8 m³/s Discharge for Auxiliary unit 2 m³/s No. of unit 3 Type of unit Francis, Turgo Capacity of unit#1 34 Capacity of unit#2 34 Capacity of unit#3 4 Commissioning Feb 2011 Energy Output Installed capacity (2 Francis) 68 MW Auxiliary Capacity 4MW Switch yard No. of 11 KV feeder = 1 No. of 132 KV breaker = 5 Scheme layout = Single Bus bar/ Single breaker system
19 HYDROELECTRIC POWER PLANT SCHEME LAYOUT Hydroelectric power plants convert the hydraulic potential energy from water into electrical energy. Such plants are suitable were water with suitable head are available. The different parts of a hydroelectric power plant are  Catchment Area The areas from where water comes in the reservoir is called catchment area .e.g. mountains, rivers, lakes etc.  Reservoir The area where water is stored is called reservoir.  Dam Dams are structures built over rivers to stop the water flow and form a reservoir. The reservoir stores the water flowing down the river. This water is diverted to turbines in power stations. The dams collect water during the rainy season and stores it, thus allowing for a steady flow through the turbines throughout the year. Dams are also used for controlling floods and irrigation. The dams should be water-tight and should be able to withstand the pressure exerted by the water on it. There are different types of dams such as arch dams, gravity dams and buttress dams. The height of water in the dam is called head race.  Spillway A spillway is a way for spilling of water from dams. It is used to provide for the release of flood water from a dam. It is used to prevent over toping of the dams which could result in damage or failure of dams. There are two types of spillways: Controlled type & Uncontrolled type The uncontrolled types start releasing water upon water rising above a particular level. In case of the controlled type, regulation of flow is possible.  Penstock and Tunnel Penstocks are pipes which carry water from the reservoir to the turbines inside power station. They are usually made of steel and are equipped with gate systems. Water under high pressure flows through the penstock. A tunnel serves the same purpose as a penstock. It is used when an obstruction is present between the dam and power station such as a mountain.  Surge Tank Surge tanks are tanks connected to the water conductor system. It serves the purpose
20 of reducing water hammering in pipes which can cause damage to pipes. The sudden surge of water in penstock is taken by the surge tank, and when the water requirements increase, it supplies the collected water thereby regulating water flow and pressure inside the penstock.  Power Station Power station contains a turbine coupled to a generator. The water brought to the power station rotates the vanes of the turbine producing torque and rotation of turbine shaft. This rotational torque is transferred to the generator and is converted into electricity. The used water is released through the tail race. The difference between head race and tail race is called gross head and by subtracting the frictional losses we get the net head available to the turbine for generation of electricity.
21 SOURCES OF WATER AND SELECTION OF TURBINES Types of Reservoirs a- Run off River Plants b- Daily Storage Plant c- Seasonal Storage Plants d- Pump Storage Plants a. Run-of-river facilities use only the natural flow of the river to operate the turbine. E.g. Nandipur station. b. Daily storage plants store water from the river in a small pond that is passed through the turbine blades. This water storage is sufficient for a day use. i.e., at Ghazi Brotha station. c. Seasonal Storage plants use a dam to capture water in a reservoir. This stored water is released from the reservoir through turbines at the rate required to meet changing electricity needs or other needs such as flood control, fish passage, irrigation, navigation, and recreation. Mangla and Tarbela are large dams in Pakistan. d. Pump storage plants have specially designed turbines. These turbines have the ability to generate electricity the conventional way when water is delivered through penstocks to the turbines from a reservoir. They can also be reversed and used as pumps to lift water from the powerhouse back up into the reservoir where the water is stored for later use. Such type of plant is being constructed in Canada not available in Pakistan. Turbine A hydraulic turbine consists of a runner connected to a shaft for producing prime motive power, a mechanism for controlling water flow to the runner and water passages leading to the control mechanism and away from the runner. Fundamental Formula HpT = ( HxQxW)/550 = HQ/8.82 HpT= theoretical horse power W = weight of one cubic foot of water ( approximate,62.4 lb) Q = discharge of water H= Water head in feet
22 Synchronous Speed Hydraulic turbines are direct-connected to a-c generator, hence must operate at some speed nearest the best speed from a hydraulic and mechanical stand point The synchronous speed of a generator is a speed at which it is designed 𝑁 = 120𝑓 𝑃 Types of Hydraulic Turbines A. According to the type of flow of water The type of flow of water consider three axis 1. Axis along the shaft (Propeller and Kaplan turbines for 70 to 110 feet head) 2. Axis along the radius ( Francis Turbine for head of 800 feet) 3. Axis along the tangential flow. ( Pelton wheel for 1300 feet head and above ) B. According to Water Head 1- Up to 70 feet Propeller Type ( either fixed or adjustable ) 2- 70 ft to 110 ft Propeller Type or Francis Type 3- 110 ft to 800 ft Francis Type 4- 800 ft to 1300 ft Francis or Impulse type 5- More than 1300 ft Impulse ( Pelton wheel ) C. According to the action on fluid 1- Impulse Turbine 2- Reaction Turbine
23 1. Impulse Turbine A free jet of water discharging into an aerated space impinges on the buckets of the runner and is controlled by a needle- type nozzle .The power output is controlled either by actuating the needle in the centre of the nozzle or by deflecting the stream between nozzle and runner by means of a jet deflector. Types of Impulse Turbine a) Turgo turbine b) Cross flow turbine 2. Reaction Turbine These turbines work due to reaction of coming water on the water in which runner is submerged. Water enters in the spiral casing from the intake and passing through the stay/guide vanes it enters into the runner. The water enters under pressure and flows over the vanes. As the water flowing over the vanes, is under pressure, therefore the wheel of the turbine (runner) runs full and may be submerged below the tailrace level. The pressure head of water while flowing over the vanes is converted into velocity head and is finally reduced to the atmospheric pressure, before leaving the runner.Power is controlled by actuating the movable wicket gates either manually or by a motor or by a governor. Types of Reaction Turbine A- Depending upon the direction of the water flow 1. Radial flow turbines (Francis ) (Inward flow turbines and out ward flow turbines) 2. Axial flow turbines (Kaplan) (Movable and Fixed blade types) 3. Mixed flow turbines (Francis) B- Depending upon the water head 1. Francis (For medium head) 2. Kaplan (For low head)
24 COMPARISON OF IMPULSE AND REACTION TURBINES S.No. IMPULSE TURBINES REACTION TURBINES 1 The entire available energy of water is first converted into kinetic energy. The available energy of water is not converted from one form into other. 2 The water flows through the nozzles and impinges on the buckets which are used to the outer periphery of the wheel (runner). The water is guided by the guide vanes to flow over the moving blades. 3 The water impinges on the buckets with kinetic energy. The water glides over the moving blades with pressure energy. 4 The pressure of the flowing water remains unchanged and is equal to the atmospheric pressure. The pressure of flowing water is reduced after gliding over the blades. 5 It is not essential that the runner should run full .Moreover there should be free access of air between the vanes and the wheel ( runner.) It is essential that the runner should always run full and kept ful of power. 6 The water may be admitted over a part of the circumference or over the whole circumference of the wheel ( runner.) The water must be entered over the whole circumference of the runner. 7 It is possible to regulate the flow without loss. It is not possible to regulate the flow without loss.
25 FRANCIS TURBINE The basic components of Francis turbine are: 1) Runner Runner is usually made of Carbon steel for small outputs and of silicon steel or chrome steel for larger outputs. Basically it consists of two rings connected by blades (vanes). Profile of the blade is important thing and better design gives maximum output. This design changes from turbine to turbine. The water enters the turbine (runner) radially and leaves the runner axially in Francis turbines. It needs its annual maintenance because it remains under the pressure of water constantly. 2) Spiral Casing It is a tunnel moving all around the runner. As it move round the runner its diameter decreases gradually. The diameter is decreased to keep the pressure same so that there will be no jerk or sudden vibration .This casing is very large so it is divided into segments of suitable size for transportation. A great care is maintained in dispatching and receiving the segments and should be in sequence so there is no problem for transportation, handling and erecting. After erecting, alignment of the received pieces is made and then welded. After welding, X-ray tests are made of the welding. This welding is done by qualified welders. The spiral casing is made with hook type arrangement on around it. Then all the casing is imbedded in the concrete completely. The high pressure of the water will be balanced with concrete block around the casing. 3) Draft Tube Assembly It is very similar to spiral casing but it only takes the water, which is drained by runner. There are many shapes of draft tubes. In Mangla, the elbow shape tube is used. Its material is normal steel or alloy steel. Firstly it is designed, manufactured, dismantle, shifted to site, brought to site, erected on site, alignment is made and then welded. It is also brought in pieces or segments. Its assembly begins from the draft tube outlet. And followed to concrete block on all sides. All sides of the tube are provided hook type arrangement. The out lets are inverted funnel type. They are always dipped in water so that the water coming from runner will lose its remaining energy to overcome the thrust of water already there. 4) Draft Tube Cone It is erected in the last and after the concrete foundation; an opening (corridor) is made to go into the draft tube cone for the inspection of the runner. There are no. of small holes in the upper part of cone which have bushings in which the bottom neck of guide vane is housed.
26 5) Bottom Ring It is a ring placed at the top of draft tube cone. It has no. of holes. The bushes are housed in the holes in which the bottom neck of the guide vanes is placed. 6) Stay Ring / Stay Vanes When water enters to spiral casing, it has great pressure, it is not allowed to go into the blades of runner directly, and otherwise it will break all the things. So one ring is welded to the inner portion of spiral casing all around the diameter of casing. On this ring some curved spaces are made in to form of blade, these are called fixed vanes. Intensity of pressure of water is broken by the vanes, and is guided towards to guide vane. The reinforcement of the spiral casing is done by ring. 7) Inner & Outer Top Cover These are steel rings which are used to cover top side of the runner in turbine pit. 8) Stuffing Box When water enters to runner, it tries to go up along the shaft to maintain its level, so there should be something, which can stop this water; stuffing box is that arrangement which do this work. It is around the shaft. Firstly, there is a sleeve which is shrinking fitted to main shaft. After this, the carbon seals are fixed in form of segments around the sleeve. Around this carbon seals a steel ring is installed.. These seals are further reinforced by a steel spring which is kept in tension around the seals. All this arrangement is covered with semi-circular cover and is called stuffing box. Carbon is soft material as compared to sleeve material, so after wear & tear it can be replaced. Due to moving of shaft, heat is produced so cooling is very essential. The stuffing box is completely filled with water which has pressure more than the pressure of water coming from the runner 9) Main Guide Bearing In order to maintain the vertical alignment a bearing is fitted called main guide bearing . It has no. of pads which are fitted around the shaft, supported by shaft collar provided in the shaft. These pads are put together by a cover. These pads are completely filled with oil. Heat produced, is absorbed by the oil. This hot oil is cooled by the water which is provide in the form of jackets. There are copper tubes in the jacket in which water is coming, takes the heat from oil and goes back. 10) Wicket Gates, Servo Motors & Regulating Ring Wicket Gate is a solid piece which has two edges, one is face and other is tail. On tail its thickness is less, when it close, the face of other vane overlap the tail of other vane. So there is
27 no clearance for water. The weight of one guide vane is 2 tons. It is operated by the ring through flexible link mechanism. Servo motors are used to move a ring which is indirectly connected to guide vanes. These motors are oil operated. They produce a force which moves the regulating ring of which the lower portion is connected to the stopper head of guide vane by link mechanism. The pressure of oil required to operate the servomotor is 340Psi. When the ring moves anti-clock wise, the guide vanes will open and in clock wise it will close the guide vanes. The motors operate in this way that the force produced will be doubled, they do not cancel the force each other. 11) Irrigation Valve This valve serves two purposes. i. Irrigation purpose, when the irrigation demand is not fulfilled from Power house, then this valve is opened ii. For safety, It is used for the safety of tunnel from the water hammering when machine is tripped. This valve is operated by servomotors, which are connected two separate shafts, which move the sleeve. This sleeve covers the grooves and when this sleeve moves, these grooves are uncovered and valve opens. This valve opens within few seconds. The opening of the valve and opening of guide vanes are interconnected. When guide vanes are taking more water, then this valve discharges less water. This valve is direct extension of spiral casing. Cavitations Phenomenon, Its Effects And Remedies The water is conveyed to the turbine in pipes or conduits called penstocks. If the water pressure at any point reaches the vapor pressure, the vapor pockets or cavities are said to be formed. Hence the formation of vapor is called cavitations. When the pressure further increases the vapor pressure, a violent collapse takes place which is known as the water hammering. The pressure created may be so high that it causes pitting i.e. tearing off the surface of material. Remedies The cavitations can be avoided by the following methods. 1. By providing smooth curvatures for the flow of water. 2. By using tough and high resistive material. 3. By using steel line where there is a possibility of cavitations
28 AUXILIARY SYSTEMS OF UNIT 1. Cooling Water System 2. Lubrication System 3. Governor Oil System / Inlet Valve Oil system 4. Thrust Bearing oil Injection System 5. Brake System 6. Runner Air Aspiration System  Governor air system  Break air system  Stainer air system  General air compressor system  Power swing compressor system 7. High pressure oil injection system 8. Jacking oil system 9. Firefighting system 10. Drainage system 11. Dewatering system Cooling Water System The cooling is essential for every system in which heat is produced .Every material has its own specified designed temperature .When temperature of that part increases from that temperature, that wear & tear of that part occurs. The increase in normal rate of wear & tear decreases the life of that part. The cooling increases the life of that part. Lubrication System Lubrication is provided between any two moving or sliding parts to ensure easy movement and to reduce the friction. Friction creates heat and wear & tear of the relative parts. Grease Alvania EP-0 and Albania -2 are used in central grease system.
29 GOVERNORS Function Governors serve three basic purposes: a) Maintain a speed selected by the operator which is within the range of the governor. b) Prevent over-speed which may cause engine damage. c) Limit both high and low speeds. Types The four basic types of governors are as follows: 1. Mechanical Governor Mechanical governors, sometimes, referred to as centrifugal governors. Centrifugal flyweight style that relies on a set of rotating flyweights and a control spring; used since the inception of the diesel engine to control its speed. Power-assisted servo mechanical style that operates similar to the mechanical centrifugal flyweight but use engine oil under pressure to move the operating linkage. Hydraulic governor that relies on the movement of a pilot valve plunger to control pressurized oil flow to a power piston, which, in turn, moves the fuel control mechanism. 2. Pneumatic Governor Pneumatic governor that is responsive to the airflow (vacuum) in the intake manifold of an engine. A diaphragm within the governor housing is connected to the fuel control linkage that changes its setting with increases or decreases in the vacuum. 3. Electromechanical Governor Electromechanical governor uses a magnetic speed pickup sensor on an engine-driven component to monitor the rpm of the engine. The sensor sends a voltage signal to an electronic control unit that controls the current flow to a mechanical actuator connected to the fuel linkage. 4. Electronic Governor Electronic governor uses magnetic speed sensor to monitor the rpm of the engine. The sensor continuously feeds information back to the ECM (electronic control module). The ECM then computes all the information sent from all other engine sensors, such as the throttle
30 position sensor, turbocharger-boost sensor, engine oil pressure and temperature sensor, engine coolant sensor, and fuel temperature to limit engine speed. The governors, used on heavy-duty truck applications and construction equipment, fall into one of two basic categories: A. Limiting-speed governors sometimes referred to as minimum/maximum models since they are intended to control the idle and maximum speed settings of the engine. Normally there is no governor control in the intermediate range, being regulated by the position of the throttle linkage. B. Variable-speed or all range governors that are designed to control the speed of the engine regardless of the throttle setting. Other types of governors used on diesel engines are as follows: a. Constant-speed, intended to maintain the engine at a single speed from no load to full load. b. Load limiting, to limit the load applied to the engine at any given speed. It prevents overloading the engine at whatever speed it may be running. c. Load-control, used for adjusting to the amount of load applied at the engine to suit the speed at which it is set to run. d. Pressure regulating, used on an engine driving a pump to maintain a constant inlet or outlet pressure on the pump. At this time on heavy-duty truck and construction equipment applications, straight mechanically designed units dominate the governor used on non electronic fuel injection systems. Stability Stability is the ability to maintain a desired engine speed without fluctuating. Instability results in hunting or oscillating due to over correction. Excessive stability results in a dead-beat governor or one that does not correct sufficiently for load changes. Sensitivity Sensitivity is the percent of speed change required to produce a corrective movement of the fuel control mechanism. High governor sensitivity will help keep the engine operating at a constant speed.
31 PUMPS A pump is defined as ' A machine used to add energy to a liquid’. The flow of liquid is affected by friction, pipe size, liquid viscosity and the bends and fittings in the piping. To overcome flow problems, and to move liquids from place to place, against a higher pressure or to a higher elevation, energy must be added to the liquid. To add the required energy to liquids, we use ' PUMPS '. Pumps come in many types and sizes. The type depends on the function the pump is to perform and the size (and speed) depends on the amount (volume) of liquid to be moved in a given time. TYPES OF PUMP Most pumps fall into two main categories.  CENTRIFUGAL PUMPS  POSITIVE DISPLACEMENT PUMPS CENTRIFUGAL PUMPS Modern process plants use powerful centrifugal pumps, primarily because of the following factors: 1. The low initial cost. 2. Low maintenance costs. 3. Simple in operation. 4. Ability to operate under a wide variety of conditions. 5. Give a smooth, continuous flow, free from pulsation. Parts A centrifugal pump is built up of two main parts: 1. THE ROTOR (or Rotating Element). 2. THE CASING (or Housing or Body).
32 POSITIVE DISPLACEMENT PUMPS Positive displacement means that, when the pump piston or rotor moves, fluid moves and displaces the fluid ahead of it. Because of its operation, a positive displacement pump can build up a very high discharge pressure and, should a valve in the discharge system be closed for any reason, serious damage may result - the cylinder head, the casing or other downstream equipment may rupture or the driver may stall and burn out. A Positive Displacement pump must therefore be fitted with a safety relief system on the discharge side. Types of Positive Displacement Pump A. ROTARY PUMPS B. RECIPROCATING ( PISTON ) PUMPS ROTARY PUMPS In Rotary pumps, movement of liquid is achieved by mechanical displacement of liquid produced by rotation of a sealed arrangement of intermeshing rotating parts within the pump casing.
33 Rotary pumps have further many types. Gear pump is one of the most commonly used types. GEAR PUMP In this pump, intermeshing gears or rotors rotate in opposite directions, just like the gears in a vehicle or a watch mechanism. The pump rotors are housed in the casing or stator with a very small clearance between them and the casing. (The fluid being pumped will lubricate this small clearance and help prevent friction and therefore wear of the rotors and casing). Working The working of the gear pump can be explained as follows: 1. In this type of pump, only one of the rotors is driven. The intermeshing gears rotate the other rotor. As the rotors rotate, the liquid or gas, (this type of machine can also be used as a compressor), enters from the suction line and fills the spaces between the teeth of the gears and becomes trapped forming small 'Slugs' of fluid between the teeth. 2. The slugs are then carried round by the rotation of the teeth to the discharge side of the pump. 3. At this point, the gears mesh together and, as they do so, the fluid is displaced from each cavity by the intermeshing teeth. 4. Since the fluid cannot pass the points of near contact of the intermeshed teeth nor between the teeth and casing, it can only pass into the discharge line. 5. As the rotation continues, the teeth at the suction end are opened up again and the same amount of fluid will fill the spaces and the process repeated. The liquid at the discharge end is constantly being displaced (moved forward). Thus gear pumps compel or force a fixed volume of fluid to be displaced for each revolution of the rotors giving the 'Positive Displacement' action of the pump. Gear pumps are generally operated at high speed and thus give a fairly pulse-free discharge flow and pressure. Where these pumps are operated at slower speeds, as in pumping viscous liquids, the output tends to pulsate due to the meshing of teeth.
34 RECIPROCATING (PISTON) PUMPS A 'RECIPROCATING' pump is one with a forward and backward operating action. It is essentially a hand operated compressor and consists of a metal or plastic tube called a 'Cylinder' inside of which a hand-operated rod or 'Piston' is pushed back and forth. On the piston end, a special leather or rubber cup - shaped attachment is fixed.  When the piston is pushed forward, (this is called a 'Stroke'), the cup flexes against the cylinder walls giving a seal to prevent air passing to the other side. As the pump handle is pushed, air pressure builds up ahead of the cup and is forced (discharged) into the tire through the tire valve this also prevents air escaping when the pump is disconnected or when the piston is pulled back.  When the pump handle is pulled back, (called the 'Suction' stroke), the cup relaxes and the backward motion causes air to pass between it and the cylinder wall to replace the air pushed into the tire. This reciprocating action is repeated until the tire is at the required pressure. Because the air is expelled from the pump during the forward stroke only, the pump is known as a 'Single Acting Reciprocating Pump'. Double acting pumps are also available. Advantages  Reciprocating pumps will deliver fluid at high pressure (High Delivery Head).  They are 'Self-priming' - No need to fill the cylinders before starting. Disadvantages  Reciprocating pumps give a pulsating flow.  The suction stroke is difficult when pumping viscous liquids.  The cost of producing piston pumps is high.  They give low volume rates of flow compared to other types of pump.
35 HYDEL DEVELOPMENT This section of WAPDA was established in 2010 to deal with modernization and rehabilitation of old power stations and construction of new small power projects. This department was needed due to the fact that with the passage of time, there is always a demand of rehabilitation and maintenance of existing machinery. As some of our hydro electric plants are existing before the independence of the PAKISTAN like Renala(1925), Jabban(1936) and some after independence but still very old like Dargae(1952), Warsak(1960) etc. There were different problems faced during the generation process, hence WAPDA established this department for the development of these existing projects and also for construction of new projects but of small capacity and named it as “HYDEL DEVELOPMENT” section. The current duties of this department are as follows: Duties  Renovation of Mangla Power Station (Replacement of Generators)  Rehabilitation of Mangla training Center  Rehabilitation of Warsak Dam( Underground power house scheme with the increase incapability to 375 MW)  Reconstruction of Jabban Power House (Since Feb 2010 40% been completed)  Upgardation of Renala power station (1MW to 4MW by addition of 2 M/C of 1.5 MW capability each)  Construction of new power stations(Bonji, Daso, Basha, Harpo, Phunder)  Testing of new and existing electromechanical machinery  Study and checking of feasibility documents The brief detail of the following two current projects of this department is explained as:  Rehabilitation of Mangla hydel power station  Rehabilitation of Warsak hydel power station
36 REHABILITATION OF MANGLA HYDEL POWER STATION Mangla Dam Project completed in 1967 is located on River Jhelum at about 120 kM from Capital Islamabad. The Power House was completed in four stages, the initial phase comprising of four units of 100 MW each was completed in 1967~1969. The first extension of Units 5~6 (2X100 MW) was completed in 1974 while second extension comprising units 7~8(2X100 MW) was completed in 1981. The project attained its maximum capacity of 1000MW with the final extension of units 9&10(2X100 MW) in 1993-94. During high reservoir level period, Mangla is able to generate 1150 MW against the rated capacity of 1000MW due to permissible over loading of 15%. Since the reservoir capacity had reduced to 4.674 MAF from 5.88 MAF due to sediment deposition, raising of Mangla Dam by 30 ft. was taken in hand which has now completed. The Project will provide additional water storage of 2.88 MAF, increase water head by 30 ft and power generation of 644 GWh per annum and further flood alleviation. In the light of increase in aforesaid parameters, WAPDA intends to carry out a Feasibility Study for Up-gradation & Refurbishment of the old Generating Units and Allied Equipment of Mangla Power Station to ensure their optimized, reliable and sustainable operation in the Post Raised Mangla Dam Scenario. Electrical & Mechanical Equipment of the existing units after having spent 30 years or more of their useful lives have deteriorated due to aging effects resulting in reduction of efficiency and dependability. The intended Feasibility Study is aimed to assess the present operating conditions of existing Civil Structures & Plant Machinery, Study of various options of Refurbishment of Electrical & Mechanical Equipment and to recommend the most viable option for Up-gradation / Refurbishment of Power House Generating Units for achieving optimum benefits as a result of enhanced water availability and increased head after Mangla Dam Raising. Seven Consulting Firms/JVs were short-listed on the basis of their EOIs, invited by WAPDA for the above Task. Requests for Proposals (RFP) were issued to short-list Consulting Firms/JVs on 05-12-2009 with last date of submission as 17th February, 2010. Six Consulting Firms/JVs have submitted their Proposals upto the due date. Initial Technical Evaluation of these Proposals is in process. Total cost of the Project is roughly estimated to be US $ 300 to 500 million. However, better Cost Estimation of the project will be available after completion of the above study. USAID has shown interest to finance the subject Project.
37 REHABILITATION OF WARSAK HYDEL POWER STATION Warsak Hydel Power Station is located on River Kabul at 30 KM in North – West of Peshawar. The Project was completed under Colombo Plan under two phases and financed by Canadian government. The first phase completed in 1960 consisted of construction of Dam, irrigation tunnels and installation of four power generating units, each of 40 MW capacity with 132 KV transmission system which was completed in 1960. Two additional generating units each of 41.48 MW capacity were added in 1980-81 in the second phase. The total installed capacity of the station thus became nearly 243 MW. WAPDA intends to carry out a Feasibility Study for Rehabilitation, Up-gradation & Modernization of Electrical & Mechanical Equipment of Warsak Hydroelectric Power Station to ensure its reliable and sustainable operation at the total installed capacity of 243 MW. The Electrical & Mechanical Equipment of the existing units having spent 50 years (Units 1~4) and 30 years (Units 5~6) of their useful lives, have deteriorated due to aging effects resulting in reduction of reliability and dependability. The intended Feasibility Study is aimed to study and determine viable solutions and required Works for Rehabilitation, Up-gradation and Modernization of old E&M Equipment, recommend necessary remedial measures to overcome the defects in Civil Structures and to carry out Sedimentation Management Studies. Further, preparation of Detail Design, Tender Documents and PC-I for Warsak Rehabilitation Project (Phase-II) will also be a part of the required Consultancy Services. Seven Consulting Firms/Joint Ventures were short-listed on the basis of their EOIs, invited by WAPDA for the above Task. Requests for Proposals (RFP) have been issued to the short-listed Consulting Firms/JVs on 23-01-2010 with last date of submission of Proposals as 26th March, 2010. WAPDA approached Canadian High Commission Islamabad through EAD to seek Financial Assistance from CIDA as was done earlier for the first phase of Warsak Rehabilitation Project (1996~2006). But CIDA showed inability to provide any funding for the proposed Rehabilitation scheme. WAPDA then requested EAD on 22.12.2009 to approach JICA, KFW, ADB, IDB or any other Financing Agency to provide Funds for the Subject Project. Economic Affairs Division has forwarded above request of WAPDA to Asian Development Bank. In response ADB demanded a Concept Note of the Project from WAPDA which is being provided. Approximate cost of the Project is US $ 200 to 300 million.
38 Lecture By: Manzar Hussain, Chief Engineer Hydel Development WAPDA Outlines:  Concept Of Magnet  Electromagnetism Theory  Working Principle Of An AC Generator  Power Transmission  Electrical Circuit Elements  Prime Movers  Power Generation Methods  Types Of Motors  Types Of Turbines  Types Of Generators  Transmission System  Transformer  Switch Yard TRANSFORMER  Function: It is used to step up or step down the voltage.  Types on the basis of construction: Core Type & Shell Type  Components: 1. Outer Body 2. Fins for air cooling 3. Core 4. Windings 5. Bushes 6. Connections (star & delta arrangement) i. Low voltage side has star arrangement (4 connections) ii. High voltage side has delta arrangement (3 connections)  Dielectric: It is used for as a medium for insulation.  Tank: The outer tank of transformer is air tight to avoid moisture contents inside. This moisture will spoil the quality of oil. For this purpose, we use silica jel bags in the casing. It is porous material and a good dehydrating agent. When it absorbs moisture, it turns pink. This indication warns to replace the bag.
39  Oil: The tank is filled with oil. Oil is the heart of the transformer. The function of oil is to provide sufficient cooling and insulation in the two windings.  Breathers: Nitrogen bags in the large transformers act as breathers. They are used for breathing of transformer.  Buckles: When these operate, the transformer trips over.  Tapes: The connections have tolerance tapes of ±2.5% or ±5%. e.g., a 132 KV transformer can accept 128, 130, 134, 136 KV voltages. This tape changing may be automatic or by selector switch. Automatic tape changing is not available in small transformers and it is off load. Power & Distribution Transformers Small transformers that are used by distribution companies like LESCO to supply power to residential areas are called Distribution Transformers. They are usually step down transformers, usually step down the voltage from 11 KV to 220 V. Larger transformers in switch yard and grid station are called power transformers. They may be step up or step down. Cooling of Transformer i. Natural Cooling (By the fins provided on the outer surface of the tank) ii. Forced Cooling (Water is pumped into the tubes inside the tank. Hot water comes out and fresh water is induced into the tubes for cooling.) Rating of Transformer The rating of a transformer is done in Volt Ampere (VA) like 25 KVA, 50KVA, 138MVA. CT, VT & PT a. They are placed at lines and are very helpful in measuring current, voltage and power respectively. e.g. a line has a current of 1 KA, it is very difficult to measure that much amount of current directly. These transformers step down the current according to the ratio of the windings (like 100:1 or 1000:1), the current will be reduced to 1 A. Now, it is very easy to measure such a small amount. b. They are also for protective measures. CT is connected to the relays. Whenever there is a fault, the contactor opens the circuit so that whole line may not be damaged.
40 HYDRO PLANNING Hydro planning department deals with the planning of upcoming hydro electric projects of large capabilities. Planning of a project is quite lengthy process and according to rough estimate, about 10-12 years are required for the complete study of any project. What is a Project? “A project is a proposal for investment with the definite aim of producing a flow of output over a specified period of time” It lends itself to planning financing & implementation as a unit and it has a specific starting point and a specific ending point intended to accomplish a specific objective Project Cycle A project cycle depends on the following steps:  Identification  Formulation  Appraisal  Approval  Implementation  Evaluation 1. IDENTIFICATION The first and basic step of any project is to identify the resource potential area to be selected in the upcoming project and this is done by considering the following :  Resources Potential  Investment Opportunities  Socio-Economic Objectives Indicated In Plans  Local Needs
41  Directives  Results Of Surveys / Investigations / Research Works  Press Information Media  Removal Of Constraints  Supply-Shortage  Restoration / Renovation / Rehabilitation / Resettlement  Efficient Use Of Waste The results of surveys and investigations mainly help in the identification of site for the project. Different surveys are related to:  Geological Investigations  Hydrology  Civil Structure For the geological investigations GT Sheets are required. These sheets are basic drawings of geological analysis made by Pakistan Survey Department (PSD). These sheets tell us about the geological status and structures of the location. The important data to be obtained is the availability, flow and head of water which are taken by the fifty years back flow duration curves. (hydrology survey)
42 2. FORMULATION This step includes the study of the following aspects of the project:  Purpose / Objectives  Project Area  Location  Size  Costs  Funding  Management 3. APPRAISAL Appraisal is comparison of costs and benefits. Following are appraisal aspects:  Economic  Financial  Technical  Commercial  Institutional  Organizational  Managerial  Social  Environmental Importance of appraisal To convince yourself that the project costing is worth it. To convince the approving authority that the project being offered/proposed is worthy of implementation Measures of project worth  Benefit- cost ratio  Net present worth  Internal rate of return
43 4. APPROVAL Approval is re-appraisal for decision making. Assumptions of undertaking the appraisal  Life of project  Discount rate  Prices Aspects of approval  Availability of resources  Inter-sectoral and intra-sectoral priorities  Economic and social priorities  Political pressure 5. IMPLEMENTATION Conditions It is here that you will see the impact of how well you prepared the project. For implementation, we see the following aspects:  How far the prevailing conditions are conducive?  How skillfully the project is handled for execution?  How far the project suffers from planning deficiencies? Quality & quantity of human and material resources made available for execution of the project with the help of above study. 6. EVALUATION Evaluation is carried out when a part of the project is executed or completed to assess the magnitude of gap between promise and performance. Evaluation is the process of critically examining the areas of success and failure of projects.
44 FORMS: To remain well informed about a development project, Government of Pakistan designed different forms for the purpose of planning, monitoring and reporting during different stages of project cycle. These are:  PC-II PROFORMA  PC-I PROFORMA  PC-III PROFORMA  PC-IV PROFORMA  PC-V PROFORMA  PC-I and PC-II deal with identification and preparation of projects for implementation.  PC- III deals with the progress monitoring of projects under planning and implementation.  PC-IV and PC-V deal with projects after implementation. PC-II PROFORMA It deals with project proposal and is required for conducting surveys (identification of hydropower resources) and feasibility studies, in respect of large projects.  The objective of this is to get full justification for undertaking the project before large resources are tied up.  It should cover general description of the aims, objectives and coverage of the study. Previous studies in the same field should also be included.  Duration of study and commencement/completion months is also a necessary part.  It should contain cost estimate broken into local and foreign exchange expenditure.  The date on which cost estimate is prepared should also be written.  In case of foreign exchange involvement, firm commitment from sponsor may be indicated.
45 PC-I PROFORMA It is the basic form on which all projects are required to be drawn up and it is prepared after detailed feasibility study.  Its preparation is the pivotal phase of the project cycle because after its approval project implementation will be taken up.  Detailed design and drawings are not pre-requisite for the approval and preparation of PC-I.  PC-I Proforma comprises three parts: 1. Part a “project digest” 2. Part b “project description and financing” 3. Part c “project requirement” PC-III PROFORMA This proforma is designed to furnish information on the progress of on-going projects on quarterly basis and this is to be submitted during planning and implementation phase.  It is required to be submitted by the executing agencies/departments within 20 days of the closing of each quarter.  It shall include financial as well as physical progress of the subject project.  Information regarding bottlenecks experienced during the execution period shall also be incorporated. PC-IV PROFORMA This is the project completion report and it is to be furnished by every project director/executing agency only once, soon after a project is adjudged to be completed physically, whether or not the accounts of the project have been closed. The project completion report includes:  The full history of the project including financial and physical phasing.  Emphasising the risks taken and mistakes committed along with the remedial measures. adopted and experience gained.  History of the number of persons employed.
46  Suggestions about prevention of delays and cost escalation.  Comparison of planned performance with actual performance.  The reasons to achieve planned performance. PC-V PROFORMA This proforma is to be furnished on an annual basis for a period of five-years by the agencies responsible for operation and maintenance of the projects. PC-V proforma should include:  The review of cost, expenditure and financial results as estimated in completion report.  Reasons for variation in result for future guidance to planner and decision makers.  The performance of the persons involved in operation and maintenance.  Any difficulties experienced during operation should also be highlighted.  Future suggestion to avoid any type of mistake.
47 VISIT TO NANDIPUR POWER PLANT Visits are always useful for engineers. They allow them to visualize the technicalities of the projects. During our internship at WAPDA, we got an opportunity to visit Nandipur Power Plant. This plant is of significant importance since it is producing the same power as was estimated many years ago. We visited Nandipur power plant on 11 July, 2012. Resident Engineer Hafiz Muhammad Jamil received us with warm welcome and gave a comprehensive description about the plant. INTRODUCTION Gujranwala hydal power station Nandipur is situated at RD 44000 on upper Chenab canal near Nandipur village at distance of about 10km from Gujranwala on Gujranwala-Sialkot road. Upper Chenab canal takes-off from the river Chenab at Marala Head Works with full discharge capacity of 16000 cusecs. Nandipur Power Plant has the following specifications:  Capacity: The total installed capacity of Hydal power station Nandipur is 13.8MW at 0.8 power factor consisting of 3units each having a capacity of 4.6MW.  Discharge: Maximum discharge in the canal is available during summer and varies considerably during the whole year. The designed head ranges from 19.8 ft to 24.4 ft.  Transmission: The power house operates as base load connected to National Grid System through 66KV Gujranwala and Daska transmission lines. There is one 11KV feeder supplying power WAPDA colony HPS Nandipur.
48 STATION DATA Unit # Date of commissioning Capacity (MW) Head (ft) Discharge (cusecs) UNIT#1 22-03-1963 4.6 22 3040 UNIT#2 26-03-1963 4.6 22 3040 UNIT#3 17-03-1963 4.6 22 3040 TOTAL 13.8 22 9120 Salient Features:  Maximum Discharge= 10028 Cfs  Absolute minimum Discharge= 1800Cfs  Design water head= Max. =24.4 ft Min.=19.8ft  Total cost of project= Rs. 56.224 million  Type of turbine= Kaplan turbine  Cost Benefit Ratio= 1/1.26  Name of consultant= M/s . Engro Project of Yugoslavia  Source of funding= Barter Major Components: The major components of the power plant are:  Turbines  Generators  Transformers  Switchyard Other areas present there are: control room, model of the plant, inlet gates and TSR.
49 TURBINE A hydraulic turbine produces prime motive power by rotating the runner connected to a shaft, a mechanism for controlling water flow to the runner and water passages leading to the control mechanism. In Nandipur power house, Kaplan turbines with four numbers of blades have been installed to obtain maximum power at low head and high discharge rate available at Upper Chenab Canal. Technical Data:  Output= 6500 BHP  Design Discharge=3040 Cusecs  Head= 22 ft  Rate Speed= 107 rpm  Runway speed=280 rpm  Made by= M/S TTTOVI ZAVODI YOGOSALAVIA GENERATOR In electricity generation, an electric generator is a device that converts mechanical energy to electrical energy. A generator forces electric charge (usually carried by electrons) to flow through an external electrical circuit. The rotor installed in Nandipur HPS has 56 poles as per designed speed of 107 rpm by the basic relation N=120xf/p. Technical Data:  Output= 3×5750 KVA  Power factor= 0.8  Rated current = 1010 Amp  Voltage=3.3 KV  Number of Poles=56  Made By= M/S RADE KONCAR YUGOSALAVIA
50 POWER TRANSFORMER A transformer is a device that transfers electrical energy from one circuit to another through inductively coupled conductors—the transformer's coils. Transformers are essential for high-voltage electric power transmission, which makes long- distance transmission economically practical. Nandipur switchyard has two 66KV and one 11KV transformer Technical Data:  Output= 2×8500 KVA  Voltages= 11/66 KV  Current= 446/ 74.5 Amp  Connection =YD-5  Impedance= 8.6 %  Made By= M/S RADE KONCAR YUGOSALAVIA SWITCHYARD A switchyard is essentially a hub for electrical power sources. For instance, a switchyard will exist at a generating station to coordinate the exchange of power between the generators and the transmission lines in the area. A switchyard will also exist when high voltage lines need to be converted to lower voltage for distribution to consumers. 66KV Air Blast Circuit Breaker:  Rated current=800 amp  Rated pressure =14 kg/cm2  Voltage= 66KV  Made By= MERLIN GERIN GRENOBLE, France No. of Transmission Lines:  To Gujranwala Grid (132KV)  To Daska Grid (66KV)
51 Other components observed with brief details are as below:  In control room, there were electronically controlled systems and relays, maintaining the generation and transmition in the station.  At the back of generating units, there were inlet gates, installed to control the inflow of water from canal to the turbine generating unit.  TSR machine was installed to remove the daily trash coming with canal water flow. TSR was working similar to a manually operated crane.  In order to lessen the heat losses, cooling system was installed. These were oil water cooled pipes.  A complete designed model of power house was also shown, revealing the details of the generation scheme. Unit # 1 was placed there in disassembled form due to the damage of one blade of Kaplan turbine. Model of Nandipur generating unit
52 VISIT TO IRRIGATION COLONY NANDIPUR After visiting the Nandipur power plant, we visited the Irrigation Colony Nandipur and there we saw the models of different existing and upcoming hydal projects. The specifications of the models present there as a civil structures are of extreme importance as these are used to check the feasibility of the planned projects by using the real material present at the sites of these dams and by creating the real topology of that area. So the models are not mere models, these are also the important testing structures. There were many models present there. The models that we observed were:  Bhasha Hydropower Project  Bunji Hydropower Project (River Indus)  Neelum Jehlum Hydropower Project Model Of Bunji:
53 Model Of Bhasha: Model Of Neelam Jehlum:
54 VISIT TO POWER TRANSFORMER SHOP KOT LAKHPAT “Power Transformer Engineering Services Units” is WAPDA workshop working on repairing of power transformers at Kot Lakhpat. We visited this workshop on 12 July, 2012. Mr. Bashir Ahmad , a supervisor of the repairing section told us about the various transformers brought there for repairing and brief us about the working of different sections. Power transformers refer to those transformers used between the generator and the distribution circuits, and these are usually rated at 220 kVA and above. Power transformers are available for step-up operation, primarily used at the generator and referred to as generator step-up (GSU) transformers, and for step-down operation, mainly used to feed distribution circuits Functions of a Transformer The purpose of a power transformer in Switch-Mode Power Supplies is to transfer power efficiently and instantaneously from an external electrical source to an external load. In doing so, the transformer also provides important additional capabilities:  The primary to secondary turns ratio can be established to efficiently accommodate widely different input/output voltage levels.  Multiple secondaries with different numbers of turns can be used to achieve multiple outputs at different voltage levels.  Separate primary and secondary windings facilitate high voltage input/output isolation, especially important for safety in off-line applications. Locating the fault and finding the solutions is much harder job than making a new thing, WAPDA workshop is of special importance from the point of view of providing repairing to the damages. Defected Power transformers from all over the Pakistan are forwarded to this workshop for the purpose of repairing. There are four sections in this workshop: 1) Repair Section 2) Testing Section 3) Winding section
55 4) Insulation Repair Section Power transformers from all around the Pakistan are brought here to repair. First of all, transformers are opened and windings are separated from the shell. Different tests are performed in order to check the fault in core, lamination and windings etc. After finding the faults, these are recovered by the help of other sections e.g. new windings provided by the winding section are installed if required, oil is changed often and then it is passed through VPD (Vapor Phase Drying) Plant for the absorption of moisture. In this section:  Two cranes of capacity 100 ton each are available, for more than 100 ton weight coupled cranes are used.  Currently they are working on a Power transformer of 250 MVA. It was damaged because of stress stain forces on windings.
56 Separation of windings for repairing Testing Section This section is working in collaboration with PEL (Pak Electron Limited).Power transformers of capacity 1013MW, 2026MW and 40 MW are tested here after repairing to check the expected accurate working of transformers before finalizing the repair procedure. Following Quality tests are performed in this section:  Insulation resistance  Turn ratio  DC winding resistance  Capacitance and dissipation factor  No load losses  Power frequency tests  Induce over voltage with partial discharge Oil Test Lab:  Dielectric test  Acidity test  Moisture analysis  Interfacial tension  Viscosity  Flash point  Dissolved gas analysis  Oxygen stability  Tangent-Delta test
57 Winding Section This section deals with the making of new windings for transformers and also the repairing of old windings for transformers. The windings which are damaged due to over heating or short circuiting are repaired in this section and this is the special achievement of this workshop that they are reusing the damaged copper which saves much of the cost.
58 Insulation Section The section is serving the duties of preparing the insulations for the transformers. The insulation for transformers is basically made by highly compressed wood sheets. Due to compression the wood proves to be an excellent insulator. This section also deals with the transformer oil which is a very important insulation component for the power transformers. Finally after the complete removal of damages by installing new windings, changing insulation sheets or some other processes, the secondary and primary windings are assembled together with the core present in between the winding rings and connections (delta and star) are made manually.
59 The four sections are performing their duties side by side to repair the transformers successfully and this workshop proves itself not only economically beneficial for WAPDA but also the only skillful transformer repairing workshop in Pakistan. That’s why Power transformers from all around the Pakistan are brought here for the purpose of repairing. The following image shows the transformers were present there on 12th July in repairing process;
60 VISIT TO SHALAMAR RECLAMATION SHOP WAPDA has three transformer workshops for the repair and reclamation of distribution transformers. These workshops are present in:  LAHORE(SHALAMAR)  SAKHAR  NOSHERA We visited the Shalamar Reclamation Workshop on 13th July, 2012. This workshop is the biggest among the three and was built in 1977. Mr. Saleem Shams guided us about the manufacturing, repairing and testing of distribution transformers. Distribution transformers are used to convert higher voltage (usually 11-22-33kV) of the electric distribution system, to a lower voltage (250 or 433V) needed at the customers end with frequency identical before and after the transformation. With given secondary voltage, distribution transformer is usually the last in the chain of electrical energy supply to households and industrial enterprises. It is basically a static device constructed with two or more windings used to transfer alternating current electric power by electromagnetic induction from one circuit to another at the same frequency but with different values of voltage and current. Construction There are 3 main parts in the distribution transformer: 1. Coils/winding – where incoming alternate current (through primary winding) generates magnetic flux, which in turn develop a magnetic field feeding back a secondary winding.  The low current, high voltage primaries are wound from enamel coated copper wire.  The high current, low voltage secondaries are wound using a thick ribbon of aluminum or copper insulated with resin-impregnated paper.
61 2. Magnetic core – allowing transfer of magnetic field generated by primary winding to secondary winding by principle of magnetic induction.  Core is made from laminations of sheet steel stacked and either glued together with resin or banded together with steel straps. 3. Tank – serving as a mechanical package to protect active parts, as a holding vessel for transformer oil used for cooling and insulation and bushing (plus auxiliary equipment where applicable)  The entire assembly is baked to cure the resin then submerged in a large (usually gray) powder coated steel tank which is then filled with high purity mineral oil, which is inert and non-conductive.
62 The above mentioned parts are manufactured and repaired in this workshop. The different sections are performing the following duties:  Winding section is performing their duties of repairing and manufacturing of new windings. Actually, the insulation of copper wires by covering them with the three layers of special Press Pond paper is done in this section.  After the proper insulation of the copper wires, windings of the transformer are constructed with sufficient turns in each winding to limit the no-load or exciting current. The voltages induced in each turn of the primary and secondary winding coils will be approximately equal, and the voltage induced in each winding will be equal to the voltage per turn multiplied by the number of turns. These windings are then checked for correct or desired turn ratio by completing the loop through the TTR machine. TTR machine Connection with poles  The core is then made up by arranging the steel plates of specific design in particular positions as per the core design. Then the windings are installed with the core plates in between them.  Finally the connections of windings are made with the poles of transformer by the star and delta arrangements.  After baking the whole assembly, it is submerged in the oil filled tank and passed through IRON and COPPER losses test before finalizing the manufacturing process.
63 STANDARDS  IRON and COPPER losses Capacity of transformer IRON losses with 15% COPPER losses with 15% 25KVA 141W 736W 50KVA 201W 1346W 100KVA 356W 2323W 200KVA 570W 3922W  Quantity of oil used in transformers: Capacity of transformer Qty of oil in liters 25KVA 80 50KVA 120 100KVA 180 200KVA 300  Weight of the paper covered copper strip used in L.T winding: Capacity of transformer Size Weight in KG 25KVA 3x4 15 50KVA 5x4 25 100KVA 5x8 35 200KVA 5x8 55
64  Weight of the enameled copper wire used in H.T winding: Capacity of transformer Size Weight in KG 25KVA 0.6 25 50KVA 0.8 35 100KVA 1.1 55 200KVA 1.5 80 Sample Tests The Quality up Gradation tests performed are: 1. Windings Resistance Test 2. No Load Test 3. Full Load Test 4. Induced Voltage Test 5. Separate Source Over Voltage Withstand Test 6. Turn Ratio Test 7. Air Pressure Test 8. Bird Protection Test 9. Tin Coating and other Allied Test on Connector 10. Visual and Dimensional 11. Oil test of transformer Transformer Oil Transformer working totally depends upon insulation. Mineral oil is used as the transformer oil which helps dissipate heat and protects the transformer from moisture, which will float on the surface of the oil. This workshop has a separate oil section and is working successfully in improving the quality of transformer oil by processing it through the following tanks.  Agitator Tank (6hr)  Cleansing Tank (Neutralization using NaOH)  Filter Press  Decantation Tank (12-13hr)
65 The oil quality tests standards as per IEC-296 are; Specific gravity at 20°C <0.895/cm3 Acidity Neutralization 0.03ma KOH/g of oil Viscosity at 20°C < 40°C Flash Point >140°C Pour point(Freezing Point) <-30°C Moisture contents <30ppm Dielectric Strength >30KV Tangent Delta <0.005 Corrosive sulphur Non-corrosive The above standard values are achieved at any cost for the efficient and deigned performance of the transformer.
66 FINANCE DEPARTMENT The finance e department deals with all the financing and managing of finance related activities for the distribution of money, funds and investments required for the smooth running of current and upcoming projects. This also deals with how to take taxes and preparation of balance sheets, income statements and other related issues. In WAPDA Finance department basically deals with the following 2 sectors:  Operations and Maintenance  Development Finance department is working according to WAPDA ACT introduced in 1958. This department is purely based on law of economics which includes cost benefit analysis. The projects are processed on the basis of DEBT EQUITY RATIO which is 80:20 respectively. In this ratio Debt consists of GOP Grants, GOP Loans, Donor Agencies and WAPDA owned sources while equity is SELF FINANCING. Regarding the costs every project is approved from the GOP. If cost of a project exceeds after a delay then approval is required once again from GOP. According to GENERATION LICENSE 2004, NEPRA issues licenses to generation, transmission and distribution sector. Restructuring of WAPDA WAPDA was restructured into 14 companies and residual WAPDA in 1998. SECP (Security Exchange Commission of Pakistan) approves the registration of new companies. These registered companies use: CO (company) at the end of their names. There are 3 types of companies:  Public Limited  Private Limited  Guarantee Limited (STOCK EXCHANGE OF PAKISTAN) 14 COMPANIES THAT WERE RESTRUCTURED INTO:  4 generation companies (GENCOS)  9 distribution (DISCOS)  1 NTDC
67 GENCOS 1. JAMSHORO POWER COMPANY Limited (JPCL) GENCO I 2. Central Power Generation Company Limited (CPGCL) GENCO II 3. Northern Power Generation Company Limited (NPGCL) GENCO III 4. Lakhra Power Generation Company Limited (LPGCL) GENCO IV DISCOS  TESCO: Tribal Electric Supply Company  PESCO: Peshawar Electric Supply Company  IESCO: Islamabad Electric Supply Company  LESCO: Lahore Electric Supply Company  FESCO: Faisalabad Electric Supply Company  GEPCO: Gujranwala Electric Supply Company  MEPCO: Multan Electric Supply Company  SEPCO: Sakhar Electric Supply Company  HESCO: Hyderabad Electric Supply Company  QESCO: Quetta Electric Supply Company  KESCO: Karachi Electric Supply Company CPPA Central Power Purchase agency purchases energy from all energy generating sources of Pakistan. Then sales the energy to DISCOS and DISCOS further distribute the energy to the consumers at a diversified tariff which is decided by NAPRA. All generation sources sale their energy to CPPA at the estimated price. After that CPPA sale that energy to DISCOS and NEPRA decides the most appropriate tariff for the DISCOS. Calculation of Revenue 1. Operation and Maintenance 2. Depreciation 3. NHP (Net Hydal Profit) 4. WUC (Water Usage Charges)
68 5. ROA (Return on Assets) VISIT TO AC PLANT IN WAPDA HOUSE Our first meeting was with XEN, AC Plant in 311-WAPDA house. The discussion was primarily about the HVAC systems. There are two basic HVAC systems A. Vapor Absorption System B. Vapor Compression System In WAPDA house, Vapor Absorption Cycle is used in the Plant for the purpose of building air- conditioning. Air-Conditioning of Large Buildings To condition the larger buildings, it is economical to use AC plant instead of small window units. In a large building of seven storeys and a basement with less or more 800 rooms, like in WAPDA House, it is very expensive to have separate ducts for each unit. Moreover, the building would have over-fixture view. To have a comfortable environment in the building, we prefer to have an AC plant.
69 Absorption Chiller Systems The chiller systems are of three types basically: 1. Water Cooled System a) Smaller units b) Multi-chiller c) Multiple cooling towers d) Compact size e) Instant cooling f) Less running expenditures 2. Air Cooled System a) Comparatively large units b) Multi-chiller with multiple circuits c) Comparatively large cooling towers d) Size depends upon the size of the building e) Delay cooling f) High operating costs because of chemicals 3. Gas Absorption System a) Bigger Units (1 or may be 2 units as per requirement) b) Large cooling towers c) Large space required d) Slow cooling (at least half an hour is required for proper air-conditioning after the running on of the plant) e) Consumption of gas and chemicals f) High operating cost g) Needs a boiler h) Efficient for conditioning of large buildings
70 Working Principle of Absorption Cycle HIGH PRESSURE SECTION Concentrator and Condenser Steam or hot water moving through the concentrator tube causes the LiBr to boil. The refrigerant, water is liberated from the LiBr as it boils. The refrigerant vapor then passes through an eliminator section that separates the concentrator from the condenser. The eliminators remove droplets of LiBr from the vapor as it passes to the condenser. Water flowing through the condenser tubes cools the refrigerant vapor as it passes into the condenser .this causes the vapor to condense. The condensed refrigerant falls to condenser pan and is directed into the evaporator section through several pipes which terminate at an orifice. As the condensed refrigerant passes through the orifice into the lower pressure evaporator section, a portion flashes to vapor, causing the temperature of the remaining liquid refrigerant to drop. LOW PRESSURE SECTION Evaporator and Absorber The heat from the system chilled water is used to vaporize the refrigerant at approximately 40 F in the evaporator section. As the refrigerant changes state, heat is removed from the system water. The resulting water vapor is then drawn into the relatively lower pressure absorber section and is absorbed into an aqueous solution of LiBr. Cooling water is circulated through the absorber tube bundle in order to remove the heat of dilution from the LiBr solution. The LiBr that is sprayed over the absorber tubes absorbs the refrigerant water vapors and then becomes diluted, reducing its ability to absorb. Therefore, it is necessary to return the dilute solution to the concentrator to reclaim the refrigerant. SOLUTION HEAT EXCHANGER Dilute Solution is pumped to the concentrator, but first passes through a heat exchanger. The heat exchanger’s function is to efficiently exchange heat between the hot concentrated and cool dilute solution. During operation, the heat exchanger transfers heat between the cool dilute LiBr solution from the absorber and the hot concentrated solution being returned from
71 the concentrator to the absorber spray trees. Dilute solution passes through the tubes of the heat exchanger and the strong solution through the shell side around the tube. The heat exchanger is very important to the overall efficiency of the absorption cycle. Crystallization During normal operation, the absorber solution concentration adjusted automatically by the machine as needed to provide proper evaporator leaving water temperature. The condensable are present in the absorber, the machine provide the evaporator water temperature. As a result, the machine will continue to increase solution concentrations in order to correct this condition. Eventually, the concentrations increase until the solution crystallizes. Normal solution flow in the heat exchanger is then disrupted and corrective action is required. Periodic machine purging is required to prevent this condition. Purge System The purge system consists of pick-up tubes and a purge chamber which are located within the absorber. The chamber is an enclosure which isolates the section of absorber tubes. It is connected to vacuum pump through a manual shut off valve mounted on the outside of the machine. Purge Pump It is a mechanical, rotary, oil sealed, vane type, low volume unit of two-stage construction. It is capable of operating with very low suction pressures. The pump compresses the non- condensable gases as they are removed from the purge chamber. The compressed gas is then discharge to the atmosphere. AC PLANT- GENERAL INFORMATION The Trane Single Stage Absorption Cold Generator® is designed to use 12 or 14 psig steam, or hot water up to 270 F. Working Fluids  Lithium Bromide as an absorbent It is used because it has excellent affinity for water vapor, release refrigerant vapor at relatively low temperature and has a very high boiling point.  Water as refrigerant
72 It is an excellent refrigerant because it boils easily at a low evaporation pressure, has a relatively high refrigeration effect. Components Each machine has four internal sections: A. Concentrators B. Condensers C. Evaporators D. Absorber Additional components include: 1. Heat Exchanger 2. Electric Control Panel 3. Pneumatic Control Panel 4. Operating Valves 5. Solution Pump 6. Purge Pump Technical Data I. Boilers: 2 (Fire Tube Boilers) II. Chillers: 2 III. No. of chilled pumps: 6 IV. No. of booster pumps: 3 V. Refrigerant: Water VI. Absorbent: Lithium Bromide VII. Capacity: 750 tons VIII. Fuel for boiler: gas/ furnace Oil IX. Gas Pressure: 12 psi X. No. Of Cooling Towers: 8 XI. Length of cooling tower: 14 ft XII. Total no. of AHUs (Air Handling Unit) : 38 a. Filters b. Damper c. Cooling coil d. Blower
73 Boiler Chiller Honey Comb structure in Cooling Tower Fan in cooling tower Nozzles in Cooling Tower
74 ELEVATOR IN WAPDA HOUSE WAPDA House is a multi-storey building with eight floors and basement. For comfortable movement inside the building, it has a good lifting system. The system has been installed in 1965 when WAPDA House was erected. There are two control rooms, one is three cars side and the other is four cars side. There are eight cars in the elevator section. These cars move in a well. Seven cars are used for persons and the eighth one is the service lift. The parts which were shown on opening the elevator section are: i. counter balance ii. beam iii. pulleys iv. ropes v. motor (for opening & closing of door) vi. car/cabin The control room has: i. relay system ii. selector switch iii. differential gear iv. rack & pinion v. sheave (a wheel on which there are six V shape grooves are mend for ropes) vi. ropes Technical Data Load = 3500 lbs Ultimate strength per rope = 22,000 lbs Length of rope = 139-140 ft Speed = 300ft/min System Requirement for operation = 400 V, 114 Amp
75 Nomenclature WAPDA: Water And Power Development Authority PEPCO: Pakistan Electric Power Company NTDC: National Transmission And Dispatch Company DISCO: Distribution Company TESCO: Tribal Electric Supply Company PESCO: Peshawar Electric Supply Company IESCO: Islamabad Electric Supply Company LESCO: Lahore Electric Supply Company FESCO: Faisalabad Electric Supply Company GEPCO: Gujranwala Electric Supply Company MEPCO: Multan Electric Supply Company SEPCO: Sakhar Electric Supply Company HESCO: Hyderabad Electric Supply Company QESCO: Quetta Electric Supply Company KESCO: Karachi Electric Supply Company GENCO: Generation Company IPPs: Independent Power Producers KAPCO: Kot Addu Power Company NEPRAH: National Electric Power Regularity Authority IRSA: Indus River System Authority NPCC: National Power Control Center CPPA: Central Power Purchase Analysis SECP: Security and Exchange Commission of Pakistan IRR: Internal Rate of Return EPP: Energy Purchase Price CPP: Capacity Purchase Price RSO: Residual Furnace Oil HSD: High Speed Diesel

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Wapda internship report

  • 1.
    UNIVERSITY OF ENGINEERINGAND TECHNOLOGY, LAHORE INTERNSHIP REPORT WAPDA-Hydal Operations Submitted To: General Manager (Hydal Operations) Mr.Taseer Iqbal Submitted By: Saboora Khatoon 2009-ME-140 Wardah Khalid 2009-ME-145 Faiza Rehman 2009-ME-147 Samavia Taseer 2009-ME-150 From 2nd July to 1st August
  • 2.
  • 3.
    2 INTRODUCTION TO ENERGY Thecapacity to do a work is energy…………….. We are greatly dependent upon energy. God gave us several forms of natural energy to help us live productively on earth. He gave man the intelligence to learn how to use different forms of energy in creative ways. Energy Sources The different things from which we get the energy are called as Energy Sources. There are two types of energy sources. 1. Conventional or Non-Renewable Energy Sources 2. Non-Conventional or Renewable Energy Sources 1. Conventional or Non-Renewable Energy Sources: The energy sources, which we are using from long time and which are in danger of exhausting, are called as Conventional OR Non-Renewable Energy Sources e. g. coal, petroleum products, nuclear fuels etc. 2. Non-Conventional or Renewable Energy Sources: These are the sources, which can be recovered and reused. i. e. they can be used again and again to generate energy because of the renewal of their energy. e.g. hydel, wind, geothermal etc.
  • 4.
    3 Power and Energy We can differentiate between power and energy as the utilization of power is energy.  We achieve power from generators in the form of mega watts, but this power when utilized for a time interval in any equipment, it is energy. Now, this energy gives the ability to do work.  The consumption of power for time is expressed in the form of energy. Our purpose is to generate power. Types of Power Generation We use conventional and non-conventional sources of energy for power generation. Thermal power generation is an expensive method. It needs a lot of auxiliaries and the system is overall complicated. Wind potential can be used for power generation but it requires greater restrictions. The selection of site and its climatic conditions are very important for wind, nuclear, geothermal power generation. Moreover, the drastic weather conditions cause the damage of heavy equipment which in run becomes a loss of lives and also capital. Keeping all the aspects in view, hydro-electric power plants are much more reliable and efficient than the fossil fuel fired plants.  Hydroelectric Power Hydro power is currently the world's largest renewable source of electricity, accounting for 6% of worldwide energy supply or about 15% of the world's electricity. Electricity produced from generators driven by water turbines that convert the energy in falling or fast-flowing water to mechanical energy. Water at a higher elevation flows downward through large pipes or tunnels (penstocks). The falling water rotates turbines, which drive the generators, which convert the turbines' mechanical energy into electricity. Advantages  Simple in construction  No Fuel consumption  No pollution  Low Running Cost  Less Maintenance  High efficiency with proper attendance of plant  Reutilization of water for Irrigation Disadvantages  High Capital or Initial cost i.e. of civil works, equipment etc  Power generation effects during dry season  High cost of transmission lines
  • 5.
    4 HYDEL POTENTIAL INPAKISTAN Taking a general over view of different locations in Pakistan, Pakistan WAPDA has traced out about 50,000 MW hydro-electric potential. But due to limited financial resources and political issues of the country, unfortunately only 6516 MW is the total installed capacity of HPP. There are 14 different Hydel power stations working under WAPDA in Pakistan. In 1960, with the co-operation of World Bank, a treaty was signed between India and Pakistan for water distribution. Salient Features of the Indus Basin Water Treaty Provisions regarding the Eastern Rivers: 1. All the waters of the Eastern Rivers shall be available for the unrestricted use of India. 2. Except for domestic and non-consumptive uses, Pakistan shall be under an obligation to let flow, and shall not permit any interference with, the waters of Sutlej Main and the Ravi Main in the reaches where these rivers flow in Pakistan and have not yet finally crossed into Pakistan. 3. All the waters, while flowing in Pakistan, of any tributary which, in its natural course joins the Sutlej Main or the Ravi Main after these rivers have finally crossed into Pakistan shall be available for the unrestricted use of Pakistan. Provisions regarding the Western Rivers: 1. Pakistan shall receive for unrestricted use all those waters of the western rivers. 2. India shall be under an obligation to let flow all the waters of the Western rivers, and shall not permit any interference with these waters. Provisions regarding the Eastern and Western Rivers: 1. Pakistan shall use its best endeavors to construct and bring into operation a system of works that will accomplish the replacement from the Western rivers (and other sources of ) the water supplies for irrigation canals in Pakistan, which on 15th August, 1947 were dependent on water supplies from the Eastern rivers. 2. The use of the natural channels of the rivers for the discharge of flood or other access waters shall be free and not subject to limitation by either party, or neither party shall have any claim against the other in respect of any damage caused by such use. 3. Each party declares its intention to prevent, as far as practicable, undue pollution of the waters and agrees to ensure that, before any sewage or industrial waste is allowed to flow into the rivers.
  • 6.
    5 TARBELA HYDEL POWERSTATION Tarbela Dam is one of the world’s largest earth and rock filled Dam and greatest water resources development project which was completed in 1976 as a component part of Indus Basin Project. The Dam is built on one of the World’s largest rivers – the Indus known as the “Abbasin” or the father of rivers. Project Project cost of Tarbela hydel power station was 16.417 billion Rupees and was funded by ADB/KFW. Specifications Main Spillway Capacity = 6, 50,000 cusecs Type = Earth and Rock fill Height = 485 ft (above river bed) Length = 9000 ft Total Capacity = 3478 MW Max. op. level = 1550 Min. op. level = 1378 Turbine (Francis-Vertical) UNITS 1-4 5-6 7-8 9-10 11-14 Rated Head ft. 378 378 378 378 385 Manufacturer Hitachi Japan DEW Canada DEW Canada DBS Canada DBS Canada Capacity /unit(MW) 175 175 175 175 432 Total installed capacity(MW) 700 350 350 350 1728 Commissioning JULY-1977 DEC-1982 DEC-1982 APR-1985 FEB-1993 Generator (Umbrella) UNITS 1-4 5-6 7-8 9-10 11-14 Output(MVA) 205.882 184.210 184.210 184.210 480 Output( P.F ) 0.85 0.95 0.95 0.95 0.90 Output(MW) 175 175 175 175 432 Rated Voltage(KV) 13.8 13.8 13.8 13.8 18.2 Manufacturer Hitachi Japan CGE Canada CGE Canada Hitachi Japan Siemens-ABB Germany Transformer UNITS 1-4 5-6 7-8 9-10 11-14 Capability(MVA/Phase) 79 71 71 71 160 Voltage Ratio 13.2/220 13.2/500 13.2/500 13.2/500 25.0/500 Manufacturer Jeumount- Scheider ASEA Canada Hitachi Japan Hitachi japan Jeumount- Scheider Ansaldo Italy
  • 7.
    6 MANGLA HYDEL POWERSTATION Location Mangla Dam Project was actually conceived in 1950's as a multipurpose project to be constructed at a place called Mangla on river Jhelum located about 30 km upstream of Jhelum city (120 km from Capital Islamabad). Project The initial investigation and its feasibility studies were completed in 1958. Later on the project was included in the Indus Basin Project. The construction of Mangla Dam was started in 1962 and completed in 1967.it was funded by USA,UK ,Australia, Germany, Newzeland, Pak &India IBRD world Bank ,CZECH-Pak barter, Credit Loan Marubini, Wapda&CZECH loan. Project cost was 3.455 billion rupees. Specifications Discharge = 8,70, 000 cusecs Total no. of units = 10 x 100 MW Total installed Capacity = 1000 MW Water Head = 296 ft Max./Min. op. level (ft) = 12426/1040 Turbine (Francis) UNITS 1~4 5~6 7~8 9~10 Output (BHP) 138000 138000 138000 138000 Rated Head (Ft. of Water) 295 295 295 295 Make Mitsubishi Japan CKD Blansko (Czech.) Escherwyse- ACEC Belgium SKODA (Czech.) Capacity/unit(MW) 100 100 100 100 Total installed capacity(MW) 400 200 200 200 Commissioning 1967-1969 MAR-1974 1981 1993-1994 Generator (umbrella) UNITS 1~4 5~6 7~8 9~10 Output (MVA) 125 125 125 125 Output (MW) 100 100 100 100 Output (P.F) 0.8 0.8 0.8 0.8 Output (K.V) 13.2 13.2 13.2 13.2 Rated Speed (RPM) 166.7 166.7 166.7 166.7 Make Hitachi Japan Skoda Czech. Hitachi Japan Skoda Czech. Transformer UNITS 1~4 5~6 7~8 9~10 Capability (MVA) 138 138 138 144 Voltage Ratio (KV) • 12.5 / 132 [Unit 1~2] • 12.5 / 220 [Unit 3~4] 12.5/220 12.5/220 12.5/220 Make Savigliano Italy [1&4] Skoda Czech. [2&3] Savigliano Italy Italtrafo [Unit-7] Skoda [Unit-8] Skoda Czech.
  • 8.
    7 WARSAK HYDEL POWERSTATION Location Warsak Hydro Electric Power Project is located on River Kabul at about 30 km from Peshawar in North-West Frontier Province of Pakistan. Project The project financed by Canadian Government was completed under COLOMBO PLAN in two phases. It was completed in 1960 at a total cost of Rs. 394.98 million in Phase 1. Two additional generating units each of 41.48 MW were added in 1980-81 at a cost of Rs. 106.25 million as second phase of the project.It was funded by PLAN & CIDA. Specifications Total installed Capacity = 242.96 MW Area = 4 Sq. miles Max. op. level (ft) = 1270 Min. op. level (ft) = 1270 Turbine (Francis-Vertical) UNITS 1-4 5-6 Output (BHP) 55,000 57,000 Net Head 144 ft 144 ft Speed 136.4 RPM 136.4 RPM Manufacturer Dominion Engg. Co. Canada Dominion Engg. Co. Canada commissioning JULY-1960 MARCH-1981 Generator (Umbrella) UNITS 1-4 5-6 Output(MW) 40 41.5 Output(P.F) 1.0 0.85 Rated Speed 136.3 RPM 136.3 RPM Manufacturer Canadian General Elec. Co. Ltd Canadian General Elec. Co. Ltd Transformer UNITS 1-4 5-6 Capacity 13.33/Phase 48.8 three Phase Voltage Ratio 11/132 KV 11/132 KV Manufacturer Saranti, Canada Westing house Switch yard No. of 132 KV feeder/breaker = 4 / 06 Scheme Layout = Double Bus bar/ One and half breaker system Tunnels/penstock = 6
  • 9.
    8 GHAZI BAROTHA HYDELPOWER STATION Location Ghazi Barotha Hydropower Project is located on the Indus River downstream of Tarbela Dam. it reaches Indus River drops by 76 m in a distance of 63 km. Project This Project possesses the minimum of environmental and social impacts. Ghazi Barotha Hydropower Project consists of three main components. The Barrage, the Power Channel and the Power Complex.It was funded by World bank/ADB JAPAN Bank Int.Coop./KFW/Eurpean Invst Bank /Islamic Bank.Project cost was 94.733 billion rupees. Specifications Discharge Capacity = 1,600 cusics Total installed Capacity = 5 x 290 MW Max. op. level (ft) = 1096 Min. op. level (ft) = 1079 Turbine (Francis) Number of Units 1-4 5 Output (MW) 290 290 Rated Head (Feet) 226 226 Manufacturer M/S VOITH HYDRO GERMANY M/S VOITH HYDRO GERMANY Capacity/unit(MW) 290 290 Commissioning 7-2003 3-2004 Generator (Umbrella) Output (MVA) 322.2 Output (P.F) 0.9 LAGGING Rated speed (rpm) 100 Manufacturer M/S TOSHIBA CORPORATION JAPAN Transformer Capacity (MVA) 3X107.5 Voltage ratio (KV) LV=18 KV, H V=5153 KV Manufacturer SIEMENS ABB Switch yard No. of 500 KV feeder/breaker = 6 / 18 No. of 220 KV feeder/breaker = 2 / 6 Scheme Layout = Double Bus bar/ One and half breaker system Tunnels/penstock = 5
  • 10.
    9 CHASHMA HYDEL POWERSTATION Location It is located on the River Indus close to the right embank of Chashma Barrage.It is low head hydel power station utilizing available head of 4-13 meters. Project Its operation is dictated by the release downstream Chashma Reservoir being controlled by the Indus River System Authority (IRSA). The project cost is 21082 million rupees.It was funded by ADB,CITY Bank,Japan,Pakistan,French,Protocol,Suplementory credit Agricole indonsuez France. Specifications Total Capacity = 8 x 23 MW Generation voltage = 11 KV Max. op. level (ft) = 649 Min. op. level (ft) = 637 Turbine (Bulb) Type Fuji Japan Rotation Speed 21 ft Runner Diameter 21 ft Guide Vanes 16 Discharge unit 8829 cusecs Head available 13 m to 38 m Rated head 27.4 ft commissioning 2000-2001 Transformer Type GE Alsthon France Voltage 132 KV Rated Capacity 26 MVA Generator (Bulb) Type Fuji Japan Rated Capacity 23 MVA Power factor 0.9 Voltage 11 KV Switch yard No. of 132 KV feeder/breaker = 4 / 4 Scheme Layout = Double Bus bar/ Double breaker system
  • 11.
    10 RASUL HYDEL POWERSTATION Location It is first Hydel Power Station after creation of Pakistan. Hydel Power Station is situated on upper Jhelum Canal (UJC) 80 km downstream from its source i-e New Borg Escape ,Mangla. The power house is operated as base-load and it is connected to National Grid System through 132 KV and 66 KV transmission lines. Project. The cost of project is 20.33 Millions.It was funded by N.A. Specifications Total Capacity = 11 X 2 MW Generation Voltage = 11 KV Transformation Voltage = 132 KV Reservoir = River of Canal Installation = in 1952 Turbine (Kaplan) Type Kaplan Boving UK Discharge / unit 1812 cusecs Rated Head(ft) 85 Commissioning July-1952 Generator (Umbrella) Type Umbrella/British Thomson UK Output(MVA) 12.5 Output(P.F) 0.88 Output(KV) 11 Rated Speed 214 RPM Transformer Capacity 2*12.5 Voltage ratio 11/66 KV Transmission line 132 KV/2; 66 KV/2 Switch yard No. of 11 KV feeder/breaker = 2 / 4 No. of 66 KV feeder/breaker = 2 / 3 No. of 132 KV feeder/breaker = 2 / 3 Scheme Layout = Single Bus bar/ single breaker system Tunnels/penstock = 2
  • 12.
    11 SHADIWAL HYDEL POWERSTATION Location Shadiwal Hydel Power Station District Gujarat is situated at the tail of upper Jhelum Canal near Shadiwal town at a distance of 14 km from Gujarat which takes off from Jhelum River at Mangla and falls into Chanab River upstream of Khanki Head works after Shadiwal Power station. Project This project was completed through Colombo plan financed jointly by the government of Canada and Pakistan.Project cost was 0.044 billion rupees. Specifications Total capacity = 2 x 6.75 MW Generation voltage = 11 KV Transformation voltage = 132 KV Water head = 23 ft Manufacturer of turbine = Dominion Canada Manufacturer of generator = Umbrella /Canadian GEC Spillway gates = 6 Siphon spillway = 2 Turbine (Kaplan) Type Kaplan Dominion Canada Discharge /unit 3900 cusecs Commissioning JAN-1961 Generator (Umbrella) Output(MVA) 7.5 MVA Output(P.F) 0.9 Lagging Output(KV) 11 KV Rated Speed 83.3 RPM Transformer Capacity 4 x 5 Single Voltage Ratio 3.3/11 KV Manufacturer Pioneer Electric Ltd. Canada Transmission Line 132 KV/1 Switch yard No. of 11 KV feeder/breaker = 1 / 7 No. of 132 KV feeder/breaker = 1 / 1 Scheme Layout = Single Bus bar/ Single breaker system
  • 13.
    12 NANDIPUR HYDEL POWERSTATION Location It is situated on upper Chenab canal (UCC) near Nandipur village at a distance of about 10 km from Gujranwala-Sialkot road. Project Project cost was 0.062 billion rupees. It was funded by N.A. Specifications Total capacity = 3 x 4.6 MW Generation Voltage = 3.3 KV Transformation Voltage = 66 KV Water Head = 22 ft Manufacturer of turbine = Kaplan Litostroj Yugoslavia Manufacturer of generator = umbrella /Rade Koncer Yugoslavia Generator (Umbrella) Turbine (kaplan) Output 6500 BHP Discharge 3040 cusecs Head Water 22 ft Runaway Speed 280 RPM Rayed speed 107 RPM Power transformer Output 2*8500 KVA Voltage 11/66 KV Current 446/74.5 Amps Connection YD-5 Impedance 8.6% Switch yard No. of 66 KV feeder/breaker = 2 / 4 Scheme Layout = Double Bus bar/ Single breaker system Output 3*5750 KVA Power Factor 0.8 Rated Current 1010 Amps Voltage 3.3 KV No. of Poles 56 commissioning MAR-1963
  • 14.
    13 CHICHCHOKI HYDEL POWERSTATION Location Chichoki Hydel Power Station is located on Upper Chanab Canal near village Joyanwala about 20 Km from sheikhupura city. Project Power Station was commissioned on Aug 1959 the project cost is 30.55 million.It was funded by N.A. Specifications Total Capacity = 3 x 4.4 MW Generation voltage = 3.3 KV Transformation voltage = 66 KV Water head = 25 ft Manufacturer of turbine = Kaplan/Litostroj Yugosalavia Manufacturer of generator = Umbrella / Rade Koncer Yugosalavia Reservoir = Run of Canal Turbine (Kaplan) Type Kaplan Rated head 25 ft Discharge/unit 2700 cusecs Commissioning Aug-1959 Generator (Umbrella) Type Umbrella Output(MVA) 5.6 MVA Output(P.F) 0.8 Output(KV) 3.3 KV Rated Speed 107 RPM Transformer Capacity 2*15 Voltage Ratio 11/66 KV Transmission Line 11 KV/2 Switch yard No. of 66 KV feeder/breaker = 2 / 4 Scheme Layout = Double Bus bar/ Single breaker system
  • 15.
    14 DARGAI HYDEL POWERSTATION Location Dargai Hydel Power Station is located on Upper Swat Canal in Malakand agency near Dargai. Project The project was funded by N.A. The project cost is 30.86 Million. Specifications Total capacity = 4 x 5 MW Generation voltage = 11 KV Transformation voltage = 66 KV Reservoir = Run of Canal Manufacturer of turbine = SM smith USA Manufacturer of generator = Westings House Gross head station = 18.9 m Discharge/ unit = 15.8 m³/s Turbine (Francis) Type Kaplan Rated Head 243 ft Discharge/unit 240 cusecs commissioning Dec-1952 Generator (Umbrella) Output(MVA) 5.88 MVA Output(P.F) 0.85 Output(KV) 11 KV Rated Speed 500 RPM Transformer Capacity 2*15 ; 1*12.5 Voltage Ratio 11/132 KV ; 11/60 KV Transmission line 132 KV/2 ; 66 KV/1 Switch yard No. of 11 KV feeder/breaker = 1 / 7 No. of 132 KV feeder/breaker= 1 / 3 Scheme Layout = Double Bus bar/ Single breaker system Tunnels/penstock = 4
  • 16.
    15 RENALA HYDEL POWERSTATION Location The existing Renala Hydel Power Station is located on RD (160 to 686) near Renala town on Lower Bari Doab Canal off taking from Head Baloki. Project This was built in 1925 by Sir Ganga Ram for low head pumps for irrigation to fields.It was funded by Ganga Ram. Specifications Total Capacity = 5 x 0.22 MW Generation voltage = 3.3 KV Transformation voltage = 11 kV Turbine (Francis) Type Horizontal Francis Manufacturer Vicker England Speed 100 RPM BHP 385 hp Total Rated Discharge 74 cusecs Wicket Gates 16 Stay Vanes 16 Runner 4 Runner Blade 16 Commissioning Mar-1925 Transformer No. of Transformer 2 Nominal Rating 2 MVA High Voltage 11 KV Low Voltage 0.4 KV Generator (CEC.UK) Rated output 275 KVA Generation Voltage 33000 V No. of Poles 10 Rated Capacity 220 KV Switch yard No. of 11 KV feeder/breaker = 1 / 1 Scheme Layout = Double Bus bar/ Single breaker system
  • 17.
    16 KURRAM GARHI HYDELPOWER STATION Location Khurram Ghari Hydel Power Station is located on river Khurram about 10 Km North West of Bannu city. Project The cost of the project is 4.07 Million. The project was funded by N.A. Specifications Total capacity = 4 x 1 MW Generation voltage = 3.3 KV Transformation voltage = 11 KV Water Head = 60 ft Manufacturer of turbine = Siemens Manufacturer of generator = Siemens Reservoir = Run of river Turbine (Siemens) Type Francis Rated Head 18.3 ft Discharge/unit 260 cusecs commissioning Feb-1958 Generator (Siemens) Output(MVA) 12.5 MVA Output(P.F) 0.85 Output(KV) 3.3 KV Rated Speed 428 RPM Transformer Voltage Ratio 3.3/11 KV Switch yard No. of 11 KV feeder/breaker = 1 / 10 No. of 66 KV breaker = 1 Scheme Layout = Single Bus bar/ Single breaker system Tunnels/penstock = 4
  • 18.
    17 CHITRAL HYDEL POWERSTATION Location Chitral Hydel Power Station is located on Ludko River Gram Chashma road, 7 KM East of Chitral town. Project Project cost was 19.47 million. It was funded by N.A. Specifications No. of units = 4 Capacity of each unit = 1-2 units (0.3 MW) & 3-4 units (0.2 MW) Total Capacity = 1 MW Generation voltage = 0.4 KV Water head = 110 ft Manufacturer of turbine = Ossberger W.G Manufacturer of generator = AEG W.G Turbine (Ossberger Germany) Type Kaplan Rated Head Unit 1-2(98 ft) & Unit 3-4(105 ft) Discharge/unit Unit 1-2(1050 Cfs) & Unit 3-4(1256 Cfs) Commissioning 1975 -1982 Generator (GMBH Germany) Output(MVA) 1.25 MVA Output(P.F) 0.8 Output(KV) 0.42 KV Rated Speed Unit 1-2(1500 RPM) & Unit 3-4(1000 RPM) Transformer Voltage Ratio 3.3/11 KV Manufacturer GEC Switch yard No. of 11 KV feeder/breaker = 2 / 2 Scheme Layout = Double Bus bar/ Single breaker system Tunnels/penstock = 2
  • 19.
    18 KHAN KHWAR HYDROPOWERPROJECT Location The Project is located on Khan Khwar River, a tributary of Indus River near Besham District Shangla in N.W.F.P. at a distance of 245 Km from Islamabad. Specifications Design Discharge = 35 m³/s Gross Head = 252 m Headrace Tunnel =4.557 km Installed Capacity =72 MW Energy per annum =306 GWh NO. and types of unit =3(2*34+1*4)MW Francis Speed of Turbine =500 rpm Generator Speed 500 rpm Output 34 MW/40 MVA Turbine Discharge/unit 16.8 m³/s Discharge for Auxiliary unit 2 m³/s No. of unit 3 Type of unit Francis, Turgo Capacity of unit#1 34 Capacity of unit#2 34 Capacity of unit#3 4 Commissioning Feb 2011 Energy Output Installed capacity (2 Francis) 68 MW Auxiliary Capacity 4MW Switch yard No. of 11 KV feeder = 1 No. of 132 KV breaker = 5 Scheme layout = Single Bus bar/ Single breaker system
  • 20.
    19 HYDROELECTRIC POWER PLANTSCHEME LAYOUT Hydroelectric power plants convert the hydraulic potential energy from water into electrical energy. Such plants are suitable were water with suitable head are available. The different parts of a hydroelectric power plant are  Catchment Area The areas from where water comes in the reservoir is called catchment area .e.g. mountains, rivers, lakes etc.  Reservoir The area where water is stored is called reservoir.  Dam Dams are structures built over rivers to stop the water flow and form a reservoir. The reservoir stores the water flowing down the river. This water is diverted to turbines in power stations. The dams collect water during the rainy season and stores it, thus allowing for a steady flow through the turbines throughout the year. Dams are also used for controlling floods and irrigation. The dams should be water-tight and should be able to withstand the pressure exerted by the water on it. There are different types of dams such as arch dams, gravity dams and buttress dams. The height of water in the dam is called head race.  Spillway A spillway is a way for spilling of water from dams. It is used to provide for the release of flood water from a dam. It is used to prevent over toping of the dams which could result in damage or failure of dams. There are two types of spillways: Controlled type & Uncontrolled type The uncontrolled types start releasing water upon water rising above a particular level. In case of the controlled type, regulation of flow is possible.  Penstock and Tunnel Penstocks are pipes which carry water from the reservoir to the turbines inside power station. They are usually made of steel and are equipped with gate systems. Water under high pressure flows through the penstock. A tunnel serves the same purpose as a penstock. It is used when an obstruction is present between the dam and power station such as a mountain.  Surge Tank Surge tanks are tanks connected to the water conductor system. It serves the purpose
  • 21.
    20 of reducing waterhammering in pipes which can cause damage to pipes. The sudden surge of water in penstock is taken by the surge tank, and when the water requirements increase, it supplies the collected water thereby regulating water flow and pressure inside the penstock.  Power Station Power station contains a turbine coupled to a generator. The water brought to the power station rotates the vanes of the turbine producing torque and rotation of turbine shaft. This rotational torque is transferred to the generator and is converted into electricity. The used water is released through the tail race. The difference between head race and tail race is called gross head and by subtracting the frictional losses we get the net head available to the turbine for generation of electricity.
  • 22.
    21 SOURCES OF WATERAND SELECTION OF TURBINES Types of Reservoirs a- Run off River Plants b- Daily Storage Plant c- Seasonal Storage Plants d- Pump Storage Plants a. Run-of-river facilities use only the natural flow of the river to operate the turbine. E.g. Nandipur station. b. Daily storage plants store water from the river in a small pond that is passed through the turbine blades. This water storage is sufficient for a day use. i.e., at Ghazi Brotha station. c. Seasonal Storage plants use a dam to capture water in a reservoir. This stored water is released from the reservoir through turbines at the rate required to meet changing electricity needs or other needs such as flood control, fish passage, irrigation, navigation, and recreation. Mangla and Tarbela are large dams in Pakistan. d. Pump storage plants have specially designed turbines. These turbines have the ability to generate electricity the conventional way when water is delivered through penstocks to the turbines from a reservoir. They can also be reversed and used as pumps to lift water from the powerhouse back up into the reservoir where the water is stored for later use. Such type of plant is being constructed in Canada not available in Pakistan. Turbine A hydraulic turbine consists of a runner connected to a shaft for producing prime motive power, a mechanism for controlling water flow to the runner and water passages leading to the control mechanism and away from the runner. Fundamental Formula HpT = ( HxQxW)/550 = HQ/8.82 HpT= theoretical horse power W = weight of one cubic foot of water ( approximate,62.4 lb) Q = discharge of water H= Water head in feet
  • 23.
    22 Synchronous Speed Hydraulic turbinesare direct-connected to a-c generator, hence must operate at some speed nearest the best speed from a hydraulic and mechanical stand point The synchronous speed of a generator is a speed at which it is designed 𝑁 = 120𝑓 𝑃 Types of Hydraulic Turbines A. According to the type of flow of water The type of flow of water consider three axis 1. Axis along the shaft (Propeller and Kaplan turbines for 70 to 110 feet head) 2. Axis along the radius ( Francis Turbine for head of 800 feet) 3. Axis along the tangential flow. ( Pelton wheel for 1300 feet head and above ) B. According to Water Head 1- Up to 70 feet Propeller Type ( either fixed or adjustable ) 2- 70 ft to 110 ft Propeller Type or Francis Type 3- 110 ft to 800 ft Francis Type 4- 800 ft to 1300 ft Francis or Impulse type 5- More than 1300 ft Impulse ( Pelton wheel ) C. According to the action on fluid 1- Impulse Turbine 2- Reaction Turbine
  • 24.
    23 1. Impulse Turbine Afree jet of water discharging into an aerated space impinges on the buckets of the runner and is controlled by a needle- type nozzle .The power output is controlled either by actuating the needle in the centre of the nozzle or by deflecting the stream between nozzle and runner by means of a jet deflector. Types of Impulse Turbine a) Turgo turbine b) Cross flow turbine 2. Reaction Turbine These turbines work due to reaction of coming water on the water in which runner is submerged. Water enters in the spiral casing from the intake and passing through the stay/guide vanes it enters into the runner. The water enters under pressure and flows over the vanes. As the water flowing over the vanes, is under pressure, therefore the wheel of the turbine (runner) runs full and may be submerged below the tailrace level. The pressure head of water while flowing over the vanes is converted into velocity head and is finally reduced to the atmospheric pressure, before leaving the runner.Power is controlled by actuating the movable wicket gates either manually or by a motor or by a governor. Types of Reaction Turbine A- Depending upon the direction of the water flow 1. Radial flow turbines (Francis ) (Inward flow turbines and out ward flow turbines) 2. Axial flow turbines (Kaplan) (Movable and Fixed blade types) 3. Mixed flow turbines (Francis) B- Depending upon the water head 1. Francis (For medium head) 2. Kaplan (For low head)
  • 25.
    24 COMPARISON OF IMPULSEAND REACTION TURBINES S.No. IMPULSE TURBINES REACTION TURBINES 1 The entire available energy of water is first converted into kinetic energy. The available energy of water is not converted from one form into other. 2 The water flows through the nozzles and impinges on the buckets which are used to the outer periphery of the wheel (runner). The water is guided by the guide vanes to flow over the moving blades. 3 The water impinges on the buckets with kinetic energy. The water glides over the moving blades with pressure energy. 4 The pressure of the flowing water remains unchanged and is equal to the atmospheric pressure. The pressure of flowing water is reduced after gliding over the blades. 5 It is not essential that the runner should run full .Moreover there should be free access of air between the vanes and the wheel ( runner.) It is essential that the runner should always run full and kept ful of power. 6 The water may be admitted over a part of the circumference or over the whole circumference of the wheel ( runner.) The water must be entered over the whole circumference of the runner. 7 It is possible to regulate the flow without loss. It is not possible to regulate the flow without loss.
  • 26.
    25 FRANCIS TURBINE The basiccomponents of Francis turbine are: 1) Runner Runner is usually made of Carbon steel for small outputs and of silicon steel or chrome steel for larger outputs. Basically it consists of two rings connected by blades (vanes). Profile of the blade is important thing and better design gives maximum output. This design changes from turbine to turbine. The water enters the turbine (runner) radially and leaves the runner axially in Francis turbines. It needs its annual maintenance because it remains under the pressure of water constantly. 2) Spiral Casing It is a tunnel moving all around the runner. As it move round the runner its diameter decreases gradually. The diameter is decreased to keep the pressure same so that there will be no jerk or sudden vibration .This casing is very large so it is divided into segments of suitable size for transportation. A great care is maintained in dispatching and receiving the segments and should be in sequence so there is no problem for transportation, handling and erecting. After erecting, alignment of the received pieces is made and then welded. After welding, X-ray tests are made of the welding. This welding is done by qualified welders. The spiral casing is made with hook type arrangement on around it. Then all the casing is imbedded in the concrete completely. The high pressure of the water will be balanced with concrete block around the casing. 3) Draft Tube Assembly It is very similar to spiral casing but it only takes the water, which is drained by runner. There are many shapes of draft tubes. In Mangla, the elbow shape tube is used. Its material is normal steel or alloy steel. Firstly it is designed, manufactured, dismantle, shifted to site, brought to site, erected on site, alignment is made and then welded. It is also brought in pieces or segments. Its assembly begins from the draft tube outlet. And followed to concrete block on all sides. All sides of the tube are provided hook type arrangement. The out lets are inverted funnel type. They are always dipped in water so that the water coming from runner will lose its remaining energy to overcome the thrust of water already there. 4) Draft Tube Cone It is erected in the last and after the concrete foundation; an opening (corridor) is made to go into the draft tube cone for the inspection of the runner. There are no. of small holes in the upper part of cone which have bushings in which the bottom neck of guide vane is housed.
  • 27.
    26 5) Bottom Ring Itis a ring placed at the top of draft tube cone. It has no. of holes. The bushes are housed in the holes in which the bottom neck of the guide vanes is placed. 6) Stay Ring / Stay Vanes When water enters to spiral casing, it has great pressure, it is not allowed to go into the blades of runner directly, and otherwise it will break all the things. So one ring is welded to the inner portion of spiral casing all around the diameter of casing. On this ring some curved spaces are made in to form of blade, these are called fixed vanes. Intensity of pressure of water is broken by the vanes, and is guided towards to guide vane. The reinforcement of the spiral casing is done by ring. 7) Inner & Outer Top Cover These are steel rings which are used to cover top side of the runner in turbine pit. 8) Stuffing Box When water enters to runner, it tries to go up along the shaft to maintain its level, so there should be something, which can stop this water; stuffing box is that arrangement which do this work. It is around the shaft. Firstly, there is a sleeve which is shrinking fitted to main shaft. After this, the carbon seals are fixed in form of segments around the sleeve. Around this carbon seals a steel ring is installed.. These seals are further reinforced by a steel spring which is kept in tension around the seals. All this arrangement is covered with semi-circular cover and is called stuffing box. Carbon is soft material as compared to sleeve material, so after wear & tear it can be replaced. Due to moving of shaft, heat is produced so cooling is very essential. The stuffing box is completely filled with water which has pressure more than the pressure of water coming from the runner 9) Main Guide Bearing In order to maintain the vertical alignment a bearing is fitted called main guide bearing . It has no. of pads which are fitted around the shaft, supported by shaft collar provided in the shaft. These pads are put together by a cover. These pads are completely filled with oil. Heat produced, is absorbed by the oil. This hot oil is cooled by the water which is provide in the form of jackets. There are copper tubes in the jacket in which water is coming, takes the heat from oil and goes back. 10) Wicket Gates, Servo Motors & Regulating Ring Wicket Gate is a solid piece which has two edges, one is face and other is tail. On tail its thickness is less, when it close, the face of other vane overlap the tail of other vane. So there is
  • 28.
    27 no clearance forwater. The weight of one guide vane is 2 tons. It is operated by the ring through flexible link mechanism. Servo motors are used to move a ring which is indirectly connected to guide vanes. These motors are oil operated. They produce a force which moves the regulating ring of which the lower portion is connected to the stopper head of guide vane by link mechanism. The pressure of oil required to operate the servomotor is 340Psi. When the ring moves anti-clock wise, the guide vanes will open and in clock wise it will close the guide vanes. The motors operate in this way that the force produced will be doubled, they do not cancel the force each other. 11) Irrigation Valve This valve serves two purposes. i. Irrigation purpose, when the irrigation demand is not fulfilled from Power house, then this valve is opened ii. For safety, It is used for the safety of tunnel from the water hammering when machine is tripped. This valve is operated by servomotors, which are connected two separate shafts, which move the sleeve. This sleeve covers the grooves and when this sleeve moves, these grooves are uncovered and valve opens. This valve opens within few seconds. The opening of the valve and opening of guide vanes are interconnected. When guide vanes are taking more water, then this valve discharges less water. This valve is direct extension of spiral casing. Cavitations Phenomenon, Its Effects And Remedies The water is conveyed to the turbine in pipes or conduits called penstocks. If the water pressure at any point reaches the vapor pressure, the vapor pockets or cavities are said to be formed. Hence the formation of vapor is called cavitations. When the pressure further increases the vapor pressure, a violent collapse takes place which is known as the water hammering. The pressure created may be so high that it causes pitting i.e. tearing off the surface of material. Remedies The cavitations can be avoided by the following methods. 1. By providing smooth curvatures for the flow of water. 2. By using tough and high resistive material. 3. By using steel line where there is a possibility of cavitations
  • 29.
    28 AUXILIARY SYSTEMS OFUNIT 1. Cooling Water System 2. Lubrication System 3. Governor Oil System / Inlet Valve Oil system 4. Thrust Bearing oil Injection System 5. Brake System 6. Runner Air Aspiration System  Governor air system  Break air system  Stainer air system  General air compressor system  Power swing compressor system 7. High pressure oil injection system 8. Jacking oil system 9. Firefighting system 10. Drainage system 11. Dewatering system Cooling Water System The cooling is essential for every system in which heat is produced .Every material has its own specified designed temperature .When temperature of that part increases from that temperature, that wear & tear of that part occurs. The increase in normal rate of wear & tear decreases the life of that part. The cooling increases the life of that part. Lubrication System Lubrication is provided between any two moving or sliding parts to ensure easy movement and to reduce the friction. Friction creates heat and wear & tear of the relative parts. Grease Alvania EP-0 and Albania -2 are used in central grease system.
  • 30.
    29 GOVERNORS Function Governors serve threebasic purposes: a) Maintain a speed selected by the operator which is within the range of the governor. b) Prevent over-speed which may cause engine damage. c) Limit both high and low speeds. Types The four basic types of governors are as follows: 1. Mechanical Governor Mechanical governors, sometimes, referred to as centrifugal governors. Centrifugal flyweight style that relies on a set of rotating flyweights and a control spring; used since the inception of the diesel engine to control its speed. Power-assisted servo mechanical style that operates similar to the mechanical centrifugal flyweight but use engine oil under pressure to move the operating linkage. Hydraulic governor that relies on the movement of a pilot valve plunger to control pressurized oil flow to a power piston, which, in turn, moves the fuel control mechanism. 2. Pneumatic Governor Pneumatic governor that is responsive to the airflow (vacuum) in the intake manifold of an engine. A diaphragm within the governor housing is connected to the fuel control linkage that changes its setting with increases or decreases in the vacuum. 3. Electromechanical Governor Electromechanical governor uses a magnetic speed pickup sensor on an engine-driven component to monitor the rpm of the engine. The sensor sends a voltage signal to an electronic control unit that controls the current flow to a mechanical actuator connected to the fuel linkage. 4. Electronic Governor Electronic governor uses magnetic speed sensor to monitor the rpm of the engine. The sensor continuously feeds information back to the ECM (electronic control module). The ECM then computes all the information sent from all other engine sensors, such as the throttle
  • 31.
    30 position sensor, turbocharger-boostsensor, engine oil pressure and temperature sensor, engine coolant sensor, and fuel temperature to limit engine speed. The governors, used on heavy-duty truck applications and construction equipment, fall into one of two basic categories: A. Limiting-speed governors sometimes referred to as minimum/maximum models since they are intended to control the idle and maximum speed settings of the engine. Normally there is no governor control in the intermediate range, being regulated by the position of the throttle linkage. B. Variable-speed or all range governors that are designed to control the speed of the engine regardless of the throttle setting. Other types of governors used on diesel engines are as follows: a. Constant-speed, intended to maintain the engine at a single speed from no load to full load. b. Load limiting, to limit the load applied to the engine at any given speed. It prevents overloading the engine at whatever speed it may be running. c. Load-control, used for adjusting to the amount of load applied at the engine to suit the speed at which it is set to run. d. Pressure regulating, used on an engine driving a pump to maintain a constant inlet or outlet pressure on the pump. At this time on heavy-duty truck and construction equipment applications, straight mechanically designed units dominate the governor used on non electronic fuel injection systems. Stability Stability is the ability to maintain a desired engine speed without fluctuating. Instability results in hunting or oscillating due to over correction. Excessive stability results in a dead-beat governor or one that does not correct sufficiently for load changes. Sensitivity Sensitivity is the percent of speed change required to produce a corrective movement of the fuel control mechanism. High governor sensitivity will help keep the engine operating at a constant speed.
  • 32.
    31 PUMPS A pump isdefined as ' A machine used to add energy to a liquid’. The flow of liquid is affected by friction, pipe size, liquid viscosity and the bends and fittings in the piping. To overcome flow problems, and to move liquids from place to place, against a higher pressure or to a higher elevation, energy must be added to the liquid. To add the required energy to liquids, we use ' PUMPS '. Pumps come in many types and sizes. The type depends on the function the pump is to perform and the size (and speed) depends on the amount (volume) of liquid to be moved in a given time. TYPES OF PUMP Most pumps fall into two main categories.  CENTRIFUGAL PUMPS  POSITIVE DISPLACEMENT PUMPS CENTRIFUGAL PUMPS Modern process plants use powerful centrifugal pumps, primarily because of the following factors: 1. The low initial cost. 2. Low maintenance costs. 3. Simple in operation. 4. Ability to operate under a wide variety of conditions. 5. Give a smooth, continuous flow, free from pulsation. Parts A centrifugal pump is built up of two main parts: 1. THE ROTOR (or Rotating Element). 2. THE CASING (or Housing or Body).
  • 33.
    32 POSITIVE DISPLACEMENT PUMPS Positivedisplacement means that, when the pump piston or rotor moves, fluid moves and displaces the fluid ahead of it. Because of its operation, a positive displacement pump can build up a very high discharge pressure and, should a valve in the discharge system be closed for any reason, serious damage may result - the cylinder head, the casing or other downstream equipment may rupture or the driver may stall and burn out. A Positive Displacement pump must therefore be fitted with a safety relief system on the discharge side. Types of Positive Displacement Pump A. ROTARY PUMPS B. RECIPROCATING ( PISTON ) PUMPS ROTARY PUMPS In Rotary pumps, movement of liquid is achieved by mechanical displacement of liquid produced by rotation of a sealed arrangement of intermeshing rotating parts within the pump casing.
  • 34.
    33 Rotary pumps havefurther many types. Gear pump is one of the most commonly used types. GEAR PUMP In this pump, intermeshing gears or rotors rotate in opposite directions, just like the gears in a vehicle or a watch mechanism. The pump rotors are housed in the casing or stator with a very small clearance between them and the casing. (The fluid being pumped will lubricate this small clearance and help prevent friction and therefore wear of the rotors and casing). Working The working of the gear pump can be explained as follows: 1. In this type of pump, only one of the rotors is driven. The intermeshing gears rotate the other rotor. As the rotors rotate, the liquid or gas, (this type of machine can also be used as a compressor), enters from the suction line and fills the spaces between the teeth of the gears and becomes trapped forming small 'Slugs' of fluid between the teeth. 2. The slugs are then carried round by the rotation of the teeth to the discharge side of the pump. 3. At this point, the gears mesh together and, as they do so, the fluid is displaced from each cavity by the intermeshing teeth. 4. Since the fluid cannot pass the points of near contact of the intermeshed teeth nor between the teeth and casing, it can only pass into the discharge line. 5. As the rotation continues, the teeth at the suction end are opened up again and the same amount of fluid will fill the spaces and the process repeated. The liquid at the discharge end is constantly being displaced (moved forward). Thus gear pumps compel or force a fixed volume of fluid to be displaced for each revolution of the rotors giving the 'Positive Displacement' action of the pump. Gear pumps are generally operated at high speed and thus give a fairly pulse-free discharge flow and pressure. Where these pumps are operated at slower speeds, as in pumping viscous liquids, the output tends to pulsate due to the meshing of teeth.
  • 35.
    34 RECIPROCATING (PISTON) PUMPS A'RECIPROCATING' pump is one with a forward and backward operating action. It is essentially a hand operated compressor and consists of a metal or plastic tube called a 'Cylinder' inside of which a hand-operated rod or 'Piston' is pushed back and forth. On the piston end, a special leather or rubber cup - shaped attachment is fixed.  When the piston is pushed forward, (this is called a 'Stroke'), the cup flexes against the cylinder walls giving a seal to prevent air passing to the other side. As the pump handle is pushed, air pressure builds up ahead of the cup and is forced (discharged) into the tire through the tire valve this also prevents air escaping when the pump is disconnected or when the piston is pulled back.  When the pump handle is pulled back, (called the 'Suction' stroke), the cup relaxes and the backward motion causes air to pass between it and the cylinder wall to replace the air pushed into the tire. This reciprocating action is repeated until the tire is at the required pressure. Because the air is expelled from the pump during the forward stroke only, the pump is known as a 'Single Acting Reciprocating Pump'. Double acting pumps are also available. Advantages  Reciprocating pumps will deliver fluid at high pressure (High Delivery Head).  They are 'Self-priming' - No need to fill the cylinders before starting. Disadvantages  Reciprocating pumps give a pulsating flow.  The suction stroke is difficult when pumping viscous liquids.  The cost of producing piston pumps is high.  They give low volume rates of flow compared to other types of pump.
  • 36.
    35 HYDEL DEVELOPMENT This sectionof WAPDA was established in 2010 to deal with modernization and rehabilitation of old power stations and construction of new small power projects. This department was needed due to the fact that with the passage of time, there is always a demand of rehabilitation and maintenance of existing machinery. As some of our hydro electric plants are existing before the independence of the PAKISTAN like Renala(1925), Jabban(1936) and some after independence but still very old like Dargae(1952), Warsak(1960) etc. There were different problems faced during the generation process, hence WAPDA established this department for the development of these existing projects and also for construction of new projects but of small capacity and named it as “HYDEL DEVELOPMENT” section. The current duties of this department are as follows: Duties  Renovation of Mangla Power Station (Replacement of Generators)  Rehabilitation of Mangla training Center  Rehabilitation of Warsak Dam( Underground power house scheme with the increase incapability to 375 MW)  Reconstruction of Jabban Power House (Since Feb 2010 40% been completed)  Upgardation of Renala power station (1MW to 4MW by addition of 2 M/C of 1.5 MW capability each)  Construction of new power stations(Bonji, Daso, Basha, Harpo, Phunder)  Testing of new and existing electromechanical machinery  Study and checking of feasibility documents The brief detail of the following two current projects of this department is explained as:  Rehabilitation of Mangla hydel power station  Rehabilitation of Warsak hydel power station
  • 37.
    36 REHABILITATION OF MANGLAHYDEL POWER STATION Mangla Dam Project completed in 1967 is located on River Jhelum at about 120 kM from Capital Islamabad. The Power House was completed in four stages, the initial phase comprising of four units of 100 MW each was completed in 1967~1969. The first extension of Units 5~6 (2X100 MW) was completed in 1974 while second extension comprising units 7~8(2X100 MW) was completed in 1981. The project attained its maximum capacity of 1000MW with the final extension of units 9&10(2X100 MW) in 1993-94. During high reservoir level period, Mangla is able to generate 1150 MW against the rated capacity of 1000MW due to permissible over loading of 15%. Since the reservoir capacity had reduced to 4.674 MAF from 5.88 MAF due to sediment deposition, raising of Mangla Dam by 30 ft. was taken in hand which has now completed. The Project will provide additional water storage of 2.88 MAF, increase water head by 30 ft and power generation of 644 GWh per annum and further flood alleviation. In the light of increase in aforesaid parameters, WAPDA intends to carry out a Feasibility Study for Up-gradation & Refurbishment of the old Generating Units and Allied Equipment of Mangla Power Station to ensure their optimized, reliable and sustainable operation in the Post Raised Mangla Dam Scenario. Electrical & Mechanical Equipment of the existing units after having spent 30 years or more of their useful lives have deteriorated due to aging effects resulting in reduction of efficiency and dependability. The intended Feasibility Study is aimed to assess the present operating conditions of existing Civil Structures & Plant Machinery, Study of various options of Refurbishment of Electrical & Mechanical Equipment and to recommend the most viable option for Up-gradation / Refurbishment of Power House Generating Units for achieving optimum benefits as a result of enhanced water availability and increased head after Mangla Dam Raising. Seven Consulting Firms/JVs were short-listed on the basis of their EOIs, invited by WAPDA for the above Task. Requests for Proposals (RFP) were issued to short-list Consulting Firms/JVs on 05-12-2009 with last date of submission as 17th February, 2010. Six Consulting Firms/JVs have submitted their Proposals upto the due date. Initial Technical Evaluation of these Proposals is in process. Total cost of the Project is roughly estimated to be US $ 300 to 500 million. However, better Cost Estimation of the project will be available after completion of the above study. USAID has shown interest to finance the subject Project.
  • 38.
    37 REHABILITATION OF WARSAKHYDEL POWER STATION Warsak Hydel Power Station is located on River Kabul at 30 KM in North – West of Peshawar. The Project was completed under Colombo Plan under two phases and financed by Canadian government. The first phase completed in 1960 consisted of construction of Dam, irrigation tunnels and installation of four power generating units, each of 40 MW capacity with 132 KV transmission system which was completed in 1960. Two additional generating units each of 41.48 MW capacity were added in 1980-81 in the second phase. The total installed capacity of the station thus became nearly 243 MW. WAPDA intends to carry out a Feasibility Study for Rehabilitation, Up-gradation & Modernization of Electrical & Mechanical Equipment of Warsak Hydroelectric Power Station to ensure its reliable and sustainable operation at the total installed capacity of 243 MW. The Electrical & Mechanical Equipment of the existing units having spent 50 years (Units 1~4) and 30 years (Units 5~6) of their useful lives, have deteriorated due to aging effects resulting in reduction of reliability and dependability. The intended Feasibility Study is aimed to study and determine viable solutions and required Works for Rehabilitation, Up-gradation and Modernization of old E&M Equipment, recommend necessary remedial measures to overcome the defects in Civil Structures and to carry out Sedimentation Management Studies. Further, preparation of Detail Design, Tender Documents and PC-I for Warsak Rehabilitation Project (Phase-II) will also be a part of the required Consultancy Services. Seven Consulting Firms/Joint Ventures were short-listed on the basis of their EOIs, invited by WAPDA for the above Task. Requests for Proposals (RFP) have been issued to the short-listed Consulting Firms/JVs on 23-01-2010 with last date of submission of Proposals as 26th March, 2010. WAPDA approached Canadian High Commission Islamabad through EAD to seek Financial Assistance from CIDA as was done earlier for the first phase of Warsak Rehabilitation Project (1996~2006). But CIDA showed inability to provide any funding for the proposed Rehabilitation scheme. WAPDA then requested EAD on 22.12.2009 to approach JICA, KFW, ADB, IDB or any other Financing Agency to provide Funds for the Subject Project. Economic Affairs Division has forwarded above request of WAPDA to Asian Development Bank. In response ADB demanded a Concept Note of the Project from WAPDA which is being provided. Approximate cost of the Project is US $ 200 to 300 million.
  • 39.
    38 Lecture By: ManzarHussain, Chief Engineer Hydel Development WAPDA Outlines:  Concept Of Magnet  Electromagnetism Theory  Working Principle Of An AC Generator  Power Transmission  Electrical Circuit Elements  Prime Movers  Power Generation Methods  Types Of Motors  Types Of Turbines  Types Of Generators  Transmission System  Transformer  Switch Yard TRANSFORMER  Function: It is used to step up or step down the voltage.  Types on the basis of construction: Core Type & Shell Type  Components: 1. Outer Body 2. Fins for air cooling 3. Core 4. Windings 5. Bushes 6. Connections (star & delta arrangement) i. Low voltage side has star arrangement (4 connections) ii. High voltage side has delta arrangement (3 connections)  Dielectric: It is used for as a medium for insulation.  Tank: The outer tank of transformer is air tight to avoid moisture contents inside. This moisture will spoil the quality of oil. For this purpose, we use silica jel bags in the casing. It is porous material and a good dehydrating agent. When it absorbs moisture, it turns pink. This indication warns to replace the bag.
  • 40.
    39  Oil: Thetank is filled with oil. Oil is the heart of the transformer. The function of oil is to provide sufficient cooling and insulation in the two windings.  Breathers: Nitrogen bags in the large transformers act as breathers. They are used for breathing of transformer.  Buckles: When these operate, the transformer trips over.  Tapes: The connections have tolerance tapes of ±2.5% or ±5%. e.g., a 132 KV transformer can accept 128, 130, 134, 136 KV voltages. This tape changing may be automatic or by selector switch. Automatic tape changing is not available in small transformers and it is off load. Power & Distribution Transformers Small transformers that are used by distribution companies like LESCO to supply power to residential areas are called Distribution Transformers. They are usually step down transformers, usually step down the voltage from 11 KV to 220 V. Larger transformers in switch yard and grid station are called power transformers. They may be step up or step down. Cooling of Transformer i. Natural Cooling (By the fins provided on the outer surface of the tank) ii. Forced Cooling (Water is pumped into the tubes inside the tank. Hot water comes out and fresh water is induced into the tubes for cooling.) Rating of Transformer The rating of a transformer is done in Volt Ampere (VA) like 25 KVA, 50KVA, 138MVA. CT, VT & PT a. They are placed at lines and are very helpful in measuring current, voltage and power respectively. e.g. a line has a current of 1 KA, it is very difficult to measure that much amount of current directly. These transformers step down the current according to the ratio of the windings (like 100:1 or 1000:1), the current will be reduced to 1 A. Now, it is very easy to measure such a small amount. b. They are also for protective measures. CT is connected to the relays. Whenever there is a fault, the contactor opens the circuit so that whole line may not be damaged.
  • 41.
    40 HYDRO PLANNING Hydro planningdepartment deals with the planning of upcoming hydro electric projects of large capabilities. Planning of a project is quite lengthy process and according to rough estimate, about 10-12 years are required for the complete study of any project. What is a Project? “A project is a proposal for investment with the definite aim of producing a flow of output over a specified period of time” It lends itself to planning financing & implementation as a unit and it has a specific starting point and a specific ending point intended to accomplish a specific objective Project Cycle A project cycle depends on the following steps:  Identification  Formulation  Appraisal  Approval  Implementation  Evaluation 1. IDENTIFICATION The first and basic step of any project is to identify the resource potential area to be selected in the upcoming project and this is done by considering the following :  Resources Potential  Investment Opportunities  Socio-Economic Objectives Indicated In Plans  Local Needs
  • 42.
    41  Directives  ResultsOf Surveys / Investigations / Research Works  Press Information Media  Removal Of Constraints  Supply-Shortage  Restoration / Renovation / Rehabilitation / Resettlement  Efficient Use Of Waste The results of surveys and investigations mainly help in the identification of site for the project. Different surveys are related to:  Geological Investigations  Hydrology  Civil Structure For the geological investigations GT Sheets are required. These sheets are basic drawings of geological analysis made by Pakistan Survey Department (PSD). These sheets tell us about the geological status and structures of the location. The important data to be obtained is the availability, flow and head of water which are taken by the fifty years back flow duration curves. (hydrology survey)
  • 43.
    42 2. FORMULATION This stepincludes the study of the following aspects of the project:  Purpose / Objectives  Project Area  Location  Size  Costs  Funding  Management 3. APPRAISAL Appraisal is comparison of costs and benefits. Following are appraisal aspects:  Economic  Financial  Technical  Commercial  Institutional  Organizational  Managerial  Social  Environmental Importance of appraisal To convince yourself that the project costing is worth it. To convince the approving authority that the project being offered/proposed is worthy of implementation Measures of project worth  Benefit- cost ratio  Net present worth  Internal rate of return
  • 44.
    43 4. APPROVAL Approval isre-appraisal for decision making. Assumptions of undertaking the appraisal  Life of project  Discount rate  Prices Aspects of approval  Availability of resources  Inter-sectoral and intra-sectoral priorities  Economic and social priorities  Political pressure 5. IMPLEMENTATION Conditions It is here that you will see the impact of how well you prepared the project. For implementation, we see the following aspects:  How far the prevailing conditions are conducive?  How skillfully the project is handled for execution?  How far the project suffers from planning deficiencies? Quality & quantity of human and material resources made available for execution of the project with the help of above study. 6. EVALUATION Evaluation is carried out when a part of the project is executed or completed to assess the magnitude of gap between promise and performance. Evaluation is the process of critically examining the areas of success and failure of projects.
  • 45.
    44 FORMS: To remain wellinformed about a development project, Government of Pakistan designed different forms for the purpose of planning, monitoring and reporting during different stages of project cycle. These are:  PC-II PROFORMA  PC-I PROFORMA  PC-III PROFORMA  PC-IV PROFORMA  PC-V PROFORMA  PC-I and PC-II deal with identification and preparation of projects for implementation.  PC- III deals with the progress monitoring of projects under planning and implementation.  PC-IV and PC-V deal with projects after implementation. PC-II PROFORMA It deals with project proposal and is required for conducting surveys (identification of hydropower resources) and feasibility studies, in respect of large projects.  The objective of this is to get full justification for undertaking the project before large resources are tied up.  It should cover general description of the aims, objectives and coverage of the study. Previous studies in the same field should also be included.  Duration of study and commencement/completion months is also a necessary part.  It should contain cost estimate broken into local and foreign exchange expenditure.  The date on which cost estimate is prepared should also be written.  In case of foreign exchange involvement, firm commitment from sponsor may be indicated.
  • 46.
    45 PC-I PROFORMA It isthe basic form on which all projects are required to be drawn up and it is prepared after detailed feasibility study.  Its preparation is the pivotal phase of the project cycle because after its approval project implementation will be taken up.  Detailed design and drawings are not pre-requisite for the approval and preparation of PC-I.  PC-I Proforma comprises three parts: 1. Part a “project digest” 2. Part b “project description and financing” 3. Part c “project requirement” PC-III PROFORMA This proforma is designed to furnish information on the progress of on-going projects on quarterly basis and this is to be submitted during planning and implementation phase.  It is required to be submitted by the executing agencies/departments within 20 days of the closing of each quarter.  It shall include financial as well as physical progress of the subject project.  Information regarding bottlenecks experienced during the execution period shall also be incorporated. PC-IV PROFORMA This is the project completion report and it is to be furnished by every project director/executing agency only once, soon after a project is adjudged to be completed physically, whether or not the accounts of the project have been closed. The project completion report includes:  The full history of the project including financial and physical phasing.  Emphasising the risks taken and mistakes committed along with the remedial measures. adopted and experience gained.  History of the number of persons employed.
  • 47.
    46  Suggestions aboutprevention of delays and cost escalation.  Comparison of planned performance with actual performance.  The reasons to achieve planned performance. PC-V PROFORMA This proforma is to be furnished on an annual basis for a period of five-years by the agencies responsible for operation and maintenance of the projects. PC-V proforma should include:  The review of cost, expenditure and financial results as estimated in completion report.  Reasons for variation in result for future guidance to planner and decision makers.  The performance of the persons involved in operation and maintenance.  Any difficulties experienced during operation should also be highlighted.  Future suggestion to avoid any type of mistake.
  • 48.
    47 VISIT TO NANDIPURPOWER PLANT Visits are always useful for engineers. They allow them to visualize the technicalities of the projects. During our internship at WAPDA, we got an opportunity to visit Nandipur Power Plant. This plant is of significant importance since it is producing the same power as was estimated many years ago. We visited Nandipur power plant on 11 July, 2012. Resident Engineer Hafiz Muhammad Jamil received us with warm welcome and gave a comprehensive description about the plant. INTRODUCTION Gujranwala hydal power station Nandipur is situated at RD 44000 on upper Chenab canal near Nandipur village at distance of about 10km from Gujranwala on Gujranwala-Sialkot road. Upper Chenab canal takes-off from the river Chenab at Marala Head Works with full discharge capacity of 16000 cusecs. Nandipur Power Plant has the following specifications:  Capacity: The total installed capacity of Hydal power station Nandipur is 13.8MW at 0.8 power factor consisting of 3units each having a capacity of 4.6MW.  Discharge: Maximum discharge in the canal is available during summer and varies considerably during the whole year. The designed head ranges from 19.8 ft to 24.4 ft.  Transmission: The power house operates as base load connected to National Grid System through 66KV Gujranwala and Daska transmission lines. There is one 11KV feeder supplying power WAPDA colony HPS Nandipur.
  • 49.
    48 STATION DATA Unit #Date of commissioning Capacity (MW) Head (ft) Discharge (cusecs) UNIT#1 22-03-1963 4.6 22 3040 UNIT#2 26-03-1963 4.6 22 3040 UNIT#3 17-03-1963 4.6 22 3040 TOTAL 13.8 22 9120 Salient Features:  Maximum Discharge= 10028 Cfs  Absolute minimum Discharge= 1800Cfs  Design water head= Max. =24.4 ft Min.=19.8ft  Total cost of project= Rs. 56.224 million  Type of turbine= Kaplan turbine  Cost Benefit Ratio= 1/1.26  Name of consultant= M/s . Engro Project of Yugoslavia  Source of funding= Barter Major Components: The major components of the power plant are:  Turbines  Generators  Transformers  Switchyard Other areas present there are: control room, model of the plant, inlet gates and TSR.
  • 50.
    49 TURBINE A hydraulic turbineproduces prime motive power by rotating the runner connected to a shaft, a mechanism for controlling water flow to the runner and water passages leading to the control mechanism. In Nandipur power house, Kaplan turbines with four numbers of blades have been installed to obtain maximum power at low head and high discharge rate available at Upper Chenab Canal. Technical Data:  Output= 6500 BHP  Design Discharge=3040 Cusecs  Head= 22 ft  Rate Speed= 107 rpm  Runway speed=280 rpm  Made by= M/S TTTOVI ZAVODI YOGOSALAVIA GENERATOR In electricity generation, an electric generator is a device that converts mechanical energy to electrical energy. A generator forces electric charge (usually carried by electrons) to flow through an external electrical circuit. The rotor installed in Nandipur HPS has 56 poles as per designed speed of 107 rpm by the basic relation N=120xf/p. Technical Data:  Output= 3×5750 KVA  Power factor= 0.8  Rated current = 1010 Amp  Voltage=3.3 KV  Number of Poles=56  Made By= M/S RADE KONCAR YUGOSALAVIA
  • 51.
    50 POWER TRANSFORMER A transformeris a device that transfers electrical energy from one circuit to another through inductively coupled conductors—the transformer's coils. Transformers are essential for high-voltage electric power transmission, which makes long- distance transmission economically practical. Nandipur switchyard has two 66KV and one 11KV transformer Technical Data:  Output= 2×8500 KVA  Voltages= 11/66 KV  Current= 446/ 74.5 Amp  Connection =YD-5  Impedance= 8.6 %  Made By= M/S RADE KONCAR YUGOSALAVIA SWITCHYARD A switchyard is essentially a hub for electrical power sources. For instance, a switchyard will exist at a generating station to coordinate the exchange of power between the generators and the transmission lines in the area. A switchyard will also exist when high voltage lines need to be converted to lower voltage for distribution to consumers. 66KV Air Blast Circuit Breaker:  Rated current=800 amp  Rated pressure =14 kg/cm2  Voltage= 66KV  Made By= MERLIN GERIN GRENOBLE, France No. of Transmission Lines:  To Gujranwala Grid (132KV)  To Daska Grid (66KV)
  • 52.
    51 Other components observedwith brief details are as below:  In control room, there were electronically controlled systems and relays, maintaining the generation and transmition in the station.  At the back of generating units, there were inlet gates, installed to control the inflow of water from canal to the turbine generating unit.  TSR machine was installed to remove the daily trash coming with canal water flow. TSR was working similar to a manually operated crane.  In order to lessen the heat losses, cooling system was installed. These were oil water cooled pipes.  A complete designed model of power house was also shown, revealing the details of the generation scheme. Unit # 1 was placed there in disassembled form due to the damage of one blade of Kaplan turbine. Model of Nandipur generating unit
  • 53.
    52 VISIT TO IRRIGATIONCOLONY NANDIPUR After visiting the Nandipur power plant, we visited the Irrigation Colony Nandipur and there we saw the models of different existing and upcoming hydal projects. The specifications of the models present there as a civil structures are of extreme importance as these are used to check the feasibility of the planned projects by using the real material present at the sites of these dams and by creating the real topology of that area. So the models are not mere models, these are also the important testing structures. There were many models present there. The models that we observed were:  Bhasha Hydropower Project  Bunji Hydropower Project (River Indus)  Neelum Jehlum Hydropower Project Model Of Bunji:
  • 54.
    53 Model Of Bhasha: ModelOf Neelam Jehlum:
  • 55.
    54 VISIT TO POWERTRANSFORMER SHOP KOT LAKHPAT “Power Transformer Engineering Services Units” is WAPDA workshop working on repairing of power transformers at Kot Lakhpat. We visited this workshop on 12 July, 2012. Mr. Bashir Ahmad , a supervisor of the repairing section told us about the various transformers brought there for repairing and brief us about the working of different sections. Power transformers refer to those transformers used between the generator and the distribution circuits, and these are usually rated at 220 kVA and above. Power transformers are available for step-up operation, primarily used at the generator and referred to as generator step-up (GSU) transformers, and for step-down operation, mainly used to feed distribution circuits Functions of a Transformer The purpose of a power transformer in Switch-Mode Power Supplies is to transfer power efficiently and instantaneously from an external electrical source to an external load. In doing so, the transformer also provides important additional capabilities:  The primary to secondary turns ratio can be established to efficiently accommodate widely different input/output voltage levels.  Multiple secondaries with different numbers of turns can be used to achieve multiple outputs at different voltage levels.  Separate primary and secondary windings facilitate high voltage input/output isolation, especially important for safety in off-line applications. Locating the fault and finding the solutions is much harder job than making a new thing, WAPDA workshop is of special importance from the point of view of providing repairing to the damages. Defected Power transformers from all over the Pakistan are forwarded to this workshop for the purpose of repairing. There are four sections in this workshop: 1) Repair Section 2) Testing Section 3) Winding section
  • 56.
    55 4) Insulation Repair Section Powertransformers from all around the Pakistan are brought here to repair. First of all, transformers are opened and windings are separated from the shell. Different tests are performed in order to check the fault in core, lamination and windings etc. After finding the faults, these are recovered by the help of other sections e.g. new windings provided by the winding section are installed if required, oil is changed often and then it is passed through VPD (Vapor Phase Drying) Plant for the absorption of moisture. In this section:  Two cranes of capacity 100 ton each are available, for more than 100 ton weight coupled cranes are used.  Currently they are working on a Power transformer of 250 MVA. It was damaged because of stress stain forces on windings.
  • 57.
    56 Separation of windingsfor repairing Testing Section This section is working in collaboration with PEL (Pak Electron Limited).Power transformers of capacity 1013MW, 2026MW and 40 MW are tested here after repairing to check the expected accurate working of transformers before finalizing the repair procedure. Following Quality tests are performed in this section:  Insulation resistance  Turn ratio  DC winding resistance  Capacitance and dissipation factor  No load losses  Power frequency tests  Induce over voltage with partial discharge Oil Test Lab:  Dielectric test  Acidity test  Moisture analysis  Interfacial tension  Viscosity  Flash point  Dissolved gas analysis  Oxygen stability  Tangent-Delta test
  • 58.
    57 Winding Section This sectiondeals with the making of new windings for transformers and also the repairing of old windings for transformers. The windings which are damaged due to over heating or short circuiting are repaired in this section and this is the special achievement of this workshop that they are reusing the damaged copper which saves much of the cost.
  • 59.
    58 Insulation Section The sectionis serving the duties of preparing the insulations for the transformers. The insulation for transformers is basically made by highly compressed wood sheets. Due to compression the wood proves to be an excellent insulator. This section also deals with the transformer oil which is a very important insulation component for the power transformers. Finally after the complete removal of damages by installing new windings, changing insulation sheets or some other processes, the secondary and primary windings are assembled together with the core present in between the winding rings and connections (delta and star) are made manually.
  • 60.
    59 The four sectionsare performing their duties side by side to repair the transformers successfully and this workshop proves itself not only economically beneficial for WAPDA but also the only skillful transformer repairing workshop in Pakistan. That’s why Power transformers from all around the Pakistan are brought here for the purpose of repairing. The following image shows the transformers were present there on 12th July in repairing process;
  • 61.
    60 VISIT TO SHALAMARRECLAMATION SHOP WAPDA has three transformer workshops for the repair and reclamation of distribution transformers. These workshops are present in:  LAHORE(SHALAMAR)  SAKHAR  NOSHERA We visited the Shalamar Reclamation Workshop on 13th July, 2012. This workshop is the biggest among the three and was built in 1977. Mr. Saleem Shams guided us about the manufacturing, repairing and testing of distribution transformers. Distribution transformers are used to convert higher voltage (usually 11-22-33kV) of the electric distribution system, to a lower voltage (250 or 433V) needed at the customers end with frequency identical before and after the transformation. With given secondary voltage, distribution transformer is usually the last in the chain of electrical energy supply to households and industrial enterprises. It is basically a static device constructed with two or more windings used to transfer alternating current electric power by electromagnetic induction from one circuit to another at the same frequency but with different values of voltage and current. Construction There are 3 main parts in the distribution transformer: 1. Coils/winding – where incoming alternate current (through primary winding) generates magnetic flux, which in turn develop a magnetic field feeding back a secondary winding.  The low current, high voltage primaries are wound from enamel coated copper wire.  The high current, low voltage secondaries are wound using a thick ribbon of aluminum or copper insulated with resin-impregnated paper.
  • 62.
    61 2. Magnetic core– allowing transfer of magnetic field generated by primary winding to secondary winding by principle of magnetic induction.  Core is made from laminations of sheet steel stacked and either glued together with resin or banded together with steel straps. 3. Tank – serving as a mechanical package to protect active parts, as a holding vessel for transformer oil used for cooling and insulation and bushing (plus auxiliary equipment where applicable)  The entire assembly is baked to cure the resin then submerged in a large (usually gray) powder coated steel tank which is then filled with high purity mineral oil, which is inert and non-conductive.
  • 63.
    62 The above mentionedparts are manufactured and repaired in this workshop. The different sections are performing the following duties:  Winding section is performing their duties of repairing and manufacturing of new windings. Actually, the insulation of copper wires by covering them with the three layers of special Press Pond paper is done in this section.  After the proper insulation of the copper wires, windings of the transformer are constructed with sufficient turns in each winding to limit the no-load or exciting current. The voltages induced in each turn of the primary and secondary winding coils will be approximately equal, and the voltage induced in each winding will be equal to the voltage per turn multiplied by the number of turns. These windings are then checked for correct or desired turn ratio by completing the loop through the TTR machine. TTR machine Connection with poles  The core is then made up by arranging the steel plates of specific design in particular positions as per the core design. Then the windings are installed with the core plates in between them.  Finally the connections of windings are made with the poles of transformer by the star and delta arrangements.  After baking the whole assembly, it is submerged in the oil filled tank and passed through IRON and COPPER losses test before finalizing the manufacturing process.
  • 64.
    63 STANDARDS  IRON andCOPPER losses Capacity of transformer IRON losses with 15% COPPER losses with 15% 25KVA 141W 736W 50KVA 201W 1346W 100KVA 356W 2323W 200KVA 570W 3922W  Quantity of oil used in transformers: Capacity of transformer Qty of oil in liters 25KVA 80 50KVA 120 100KVA 180 200KVA 300  Weight of the paper covered copper strip used in L.T winding: Capacity of transformer Size Weight in KG 25KVA 3x4 15 50KVA 5x4 25 100KVA 5x8 35 200KVA 5x8 55
  • 65.
    64  Weight ofthe enameled copper wire used in H.T winding: Capacity of transformer Size Weight in KG 25KVA 0.6 25 50KVA 0.8 35 100KVA 1.1 55 200KVA 1.5 80 Sample Tests The Quality up Gradation tests performed are: 1. Windings Resistance Test 2. No Load Test 3. Full Load Test 4. Induced Voltage Test 5. Separate Source Over Voltage Withstand Test 6. Turn Ratio Test 7. Air Pressure Test 8. Bird Protection Test 9. Tin Coating and other Allied Test on Connector 10. Visual and Dimensional 11. Oil test of transformer Transformer Oil Transformer working totally depends upon insulation. Mineral oil is used as the transformer oil which helps dissipate heat and protects the transformer from moisture, which will float on the surface of the oil. This workshop has a separate oil section and is working successfully in improving the quality of transformer oil by processing it through the following tanks.  Agitator Tank (6hr)  Cleansing Tank (Neutralization using NaOH)  Filter Press  Decantation Tank (12-13hr)
  • 66.
    65 The oil qualitytests standards as per IEC-296 are; Specific gravity at 20°C <0.895/cm3 Acidity Neutralization 0.03ma KOH/g of oil Viscosity at 20°C < 40°C Flash Point >140°C Pour point(Freezing Point) <-30°C Moisture contents <30ppm Dielectric Strength >30KV Tangent Delta <0.005 Corrosive sulphur Non-corrosive The above standard values are achieved at any cost for the efficient and deigned performance of the transformer.
  • 67.
    66 FINANCE DEPARTMENT The financee department deals with all the financing and managing of finance related activities for the distribution of money, funds and investments required for the smooth running of current and upcoming projects. This also deals with how to take taxes and preparation of balance sheets, income statements and other related issues. In WAPDA Finance department basically deals with the following 2 sectors:  Operations and Maintenance  Development Finance department is working according to WAPDA ACT introduced in 1958. This department is purely based on law of economics which includes cost benefit analysis. The projects are processed on the basis of DEBT EQUITY RATIO which is 80:20 respectively. In this ratio Debt consists of GOP Grants, GOP Loans, Donor Agencies and WAPDA owned sources while equity is SELF FINANCING. Regarding the costs every project is approved from the GOP. If cost of a project exceeds after a delay then approval is required once again from GOP. According to GENERATION LICENSE 2004, NEPRA issues licenses to generation, transmission and distribution sector. Restructuring of WAPDA WAPDA was restructured into 14 companies and residual WAPDA in 1998. SECP (Security Exchange Commission of Pakistan) approves the registration of new companies. These registered companies use: CO (company) at the end of their names. There are 3 types of companies:  Public Limited  Private Limited  Guarantee Limited (STOCK EXCHANGE OF PAKISTAN) 14 COMPANIES THAT WERE RESTRUCTURED INTO:  4 generation companies (GENCOS)  9 distribution (DISCOS)  1 NTDC
  • 68.
    67 GENCOS 1. JAMSHORO POWERCOMPANY Limited (JPCL) GENCO I 2. Central Power Generation Company Limited (CPGCL) GENCO II 3. Northern Power Generation Company Limited (NPGCL) GENCO III 4. Lakhra Power Generation Company Limited (LPGCL) GENCO IV DISCOS  TESCO: Tribal Electric Supply Company  PESCO: Peshawar Electric Supply Company  IESCO: Islamabad Electric Supply Company  LESCO: Lahore Electric Supply Company  FESCO: Faisalabad Electric Supply Company  GEPCO: Gujranwala Electric Supply Company  MEPCO: Multan Electric Supply Company  SEPCO: Sakhar Electric Supply Company  HESCO: Hyderabad Electric Supply Company  QESCO: Quetta Electric Supply Company  KESCO: Karachi Electric Supply Company CPPA Central Power Purchase agency purchases energy from all energy generating sources of Pakistan. Then sales the energy to DISCOS and DISCOS further distribute the energy to the consumers at a diversified tariff which is decided by NAPRA. All generation sources sale their energy to CPPA at the estimated price. After that CPPA sale that energy to DISCOS and NEPRA decides the most appropriate tariff for the DISCOS. Calculation of Revenue 1. Operation and Maintenance 2. Depreciation 3. NHP (Net Hydal Profit) 4. WUC (Water Usage Charges)
  • 69.
    68 5. ROA (Returnon Assets) VISIT TO AC PLANT IN WAPDA HOUSE Our first meeting was with XEN, AC Plant in 311-WAPDA house. The discussion was primarily about the HVAC systems. There are two basic HVAC systems A. Vapor Absorption System B. Vapor Compression System In WAPDA house, Vapor Absorption Cycle is used in the Plant for the purpose of building air- conditioning. Air-Conditioning of Large Buildings To condition the larger buildings, it is economical to use AC plant instead of small window units. In a large building of seven storeys and a basement with less or more 800 rooms, like in WAPDA House, it is very expensive to have separate ducts for each unit. Moreover, the building would have over-fixture view. To have a comfortable environment in the building, we prefer to have an AC plant.
  • 70.
    69 Absorption Chiller Systems Thechiller systems are of three types basically: 1. Water Cooled System a) Smaller units b) Multi-chiller c) Multiple cooling towers d) Compact size e) Instant cooling f) Less running expenditures 2. Air Cooled System a) Comparatively large units b) Multi-chiller with multiple circuits c) Comparatively large cooling towers d) Size depends upon the size of the building e) Delay cooling f) High operating costs because of chemicals 3. Gas Absorption System a) Bigger Units (1 or may be 2 units as per requirement) b) Large cooling towers c) Large space required d) Slow cooling (at least half an hour is required for proper air-conditioning after the running on of the plant) e) Consumption of gas and chemicals f) High operating cost g) Needs a boiler h) Efficient for conditioning of large buildings
  • 71.
    70 Working Principle ofAbsorption Cycle HIGH PRESSURE SECTION Concentrator and Condenser Steam or hot water moving through the concentrator tube causes the LiBr to boil. The refrigerant, water is liberated from the LiBr as it boils. The refrigerant vapor then passes through an eliminator section that separates the concentrator from the condenser. The eliminators remove droplets of LiBr from the vapor as it passes to the condenser. Water flowing through the condenser tubes cools the refrigerant vapor as it passes into the condenser .this causes the vapor to condense. The condensed refrigerant falls to condenser pan and is directed into the evaporator section through several pipes which terminate at an orifice. As the condensed refrigerant passes through the orifice into the lower pressure evaporator section, a portion flashes to vapor, causing the temperature of the remaining liquid refrigerant to drop. LOW PRESSURE SECTION Evaporator and Absorber The heat from the system chilled water is used to vaporize the refrigerant at approximately 40 F in the evaporator section. As the refrigerant changes state, heat is removed from the system water. The resulting water vapor is then drawn into the relatively lower pressure absorber section and is absorbed into an aqueous solution of LiBr. Cooling water is circulated through the absorber tube bundle in order to remove the heat of dilution from the LiBr solution. The LiBr that is sprayed over the absorber tubes absorbs the refrigerant water vapors and then becomes diluted, reducing its ability to absorb. Therefore, it is necessary to return the dilute solution to the concentrator to reclaim the refrigerant. SOLUTION HEAT EXCHANGER Dilute Solution is pumped to the concentrator, but first passes through a heat exchanger. The heat exchanger’s function is to efficiently exchange heat between the hot concentrated and cool dilute solution. During operation, the heat exchanger transfers heat between the cool dilute LiBr solution from the absorber and the hot concentrated solution being returned from
  • 72.
    71 the concentrator tothe absorber spray trees. Dilute solution passes through the tubes of the heat exchanger and the strong solution through the shell side around the tube. The heat exchanger is very important to the overall efficiency of the absorption cycle. Crystallization During normal operation, the absorber solution concentration adjusted automatically by the machine as needed to provide proper evaporator leaving water temperature. The condensable are present in the absorber, the machine provide the evaporator water temperature. As a result, the machine will continue to increase solution concentrations in order to correct this condition. Eventually, the concentrations increase until the solution crystallizes. Normal solution flow in the heat exchanger is then disrupted and corrective action is required. Periodic machine purging is required to prevent this condition. Purge System The purge system consists of pick-up tubes and a purge chamber which are located within the absorber. The chamber is an enclosure which isolates the section of absorber tubes. It is connected to vacuum pump through a manual shut off valve mounted on the outside of the machine. Purge Pump It is a mechanical, rotary, oil sealed, vane type, low volume unit of two-stage construction. It is capable of operating with very low suction pressures. The pump compresses the non- condensable gases as they are removed from the purge chamber. The compressed gas is then discharge to the atmosphere. AC PLANT- GENERAL INFORMATION The Trane Single Stage Absorption Cold Generator® is designed to use 12 or 14 psig steam, or hot water up to 270 F. Working Fluids  Lithium Bromide as an absorbent It is used because it has excellent affinity for water vapor, release refrigerant vapor at relatively low temperature and has a very high boiling point.  Water as refrigerant
  • 73.
    72 It is anexcellent refrigerant because it boils easily at a low evaporation pressure, has a relatively high refrigeration effect. Components Each machine has four internal sections: A. Concentrators B. Condensers C. Evaporators D. Absorber Additional components include: 1. Heat Exchanger 2. Electric Control Panel 3. Pneumatic Control Panel 4. Operating Valves 5. Solution Pump 6. Purge Pump Technical Data I. Boilers: 2 (Fire Tube Boilers) II. Chillers: 2 III. No. of chilled pumps: 6 IV. No. of booster pumps: 3 V. Refrigerant: Water VI. Absorbent: Lithium Bromide VII. Capacity: 750 tons VIII. Fuel for boiler: gas/ furnace Oil IX. Gas Pressure: 12 psi X. No. Of Cooling Towers: 8 XI. Length of cooling tower: 14 ft XII. Total no. of AHUs (Air Handling Unit) : 38 a. Filters b. Damper c. Cooling coil d. Blower
  • 74.
    73 Boiler Chiller Honey Combstructure in Cooling Tower Fan in cooling tower Nozzles in Cooling Tower
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    74 ELEVATOR IN WAPDAHOUSE WAPDA House is a multi-storey building with eight floors and basement. For comfortable movement inside the building, it has a good lifting system. The system has been installed in 1965 when WAPDA House was erected. There are two control rooms, one is three cars side and the other is four cars side. There are eight cars in the elevator section. These cars move in a well. Seven cars are used for persons and the eighth one is the service lift. The parts which were shown on opening the elevator section are: i. counter balance ii. beam iii. pulleys iv. ropes v. motor (for opening & closing of door) vi. car/cabin The control room has: i. relay system ii. selector switch iii. differential gear iv. rack & pinion v. sheave (a wheel on which there are six V shape grooves are mend for ropes) vi. ropes Technical Data Load = 3500 lbs Ultimate strength per rope = 22,000 lbs Length of rope = 139-140 ft Speed = 300ft/min System Requirement for operation = 400 V, 114 Amp
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    75 Nomenclature WAPDA: Water AndPower Development Authority PEPCO: Pakistan Electric Power Company NTDC: National Transmission And Dispatch Company DISCO: Distribution Company TESCO: Tribal Electric Supply Company PESCO: Peshawar Electric Supply Company IESCO: Islamabad Electric Supply Company LESCO: Lahore Electric Supply Company FESCO: Faisalabad Electric Supply Company GEPCO: Gujranwala Electric Supply Company MEPCO: Multan Electric Supply Company SEPCO: Sakhar Electric Supply Company HESCO: Hyderabad Electric Supply Company QESCO: Quetta Electric Supply Company KESCO: Karachi Electric Supply Company GENCO: Generation Company IPPs: Independent Power Producers KAPCO: Kot Addu Power Company NEPRAH: National Electric Power Regularity Authority IRSA: Indus River System Authority NPCC: National Power Control Center CPPA: Central Power Purchase Analysis SECP: Security and Exchange Commission of Pakistan IRR: Internal Rate of Return EPP: Energy Purchase Price CPP: Capacity Purchase Price RSO: Residual Furnace Oil HSD: High Speed Diesel