2x15 MW BHPS-II MPPGCL SILPARA

GENERAL INFORMATION FOR

ENGINEERS TRAINEE
 INTRODUCTION

BANSAGAR TONS H.E. PROJECT

Power House Installed Capacity Location Year of Commissioning

01- P.H. No. I 3x105 M.W. Sirmour November. 1991

02- P.H. No. II 2x15 M.W. Silpara August 2002

03- P.H. No. III 3x20 M.W. Deolond July 2001

04- P.H. No. IV 2x10 M.W. Jhinna August 2006

Bansagar Tons Multipurpose Hydel Project complex is located in Shahdol,

Rewa and Satna Districts of M.P. envisages utilization of water of Sone, Tons
and Beehar river by diversion through a Power Channel on the top of the
escarpment parallel to Tons river thus availing a net head of 175m. down stream
of Chachai falls for generation of power in Power House I. The Tons waters are
diverted to Beehar reservoir through 24Km. Long Link canal . The Sone
waters[M.P’s share of 2 MAF, out of which 1.48 MAF is reserved for Irrigation
and 0.52 MAF for power generation in the final phase of development] is being
diverted through a 36.57 Km. Long CWC canal.
The installed capacity of P.H. I is 3x105 M.W. Similarly the installed
capacity of P.H. II is 2x15 M.W. The generation of power from these power
houses is being done around the year as per availability of water in Bansagar dam.
The power house III is situated at the toe of Bansagar Dam. The installed
capacity of this Power House is 3x20 M.W. The generation power from this
Power House is being done as per requirement of water for Bihar State.
The Power House IV is situated at the toe of Jhinna head regulator. The
installed capacity of P.H. IV is 2x10 M.W.

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 2x15 MW BHPS-II Silpara

This power house is located in Rewa- Shahdol Road about 7 Km from Rewa City.
This power house accommodates two vertical KAPLAN generating units of
15MW each designed and manufactured by M/s Bharat Heavy Electricals Ltd. The
generating unit consists of Vertical Kaplan type turbine, coupled with 3
phase,50Hz 15 MW generator, also designed & manufactured by BHEL. Each
Penstock of dia 6000mm feeds the water to turbine. The main auxiliaries of TG
set are as under-
(a) Brake & Jack System (b)Air Compressors (c) Air receivers (d) H.S. system (e)
Co2 system (f) Neutral grounding system (g) Centralized Grease Lubrication
system (h) Pressure receiver with PP set (i) Digital Voltage regulation system (j)
Electro Hydraulic Governor System (k) Temperature Measurement system (l)
Hydro mechanical cubicle (m) Cooling water system (n) Drainage & Dewatering
system (o) Space Heaters

DISCRIPTION OF TURBINE
Vertical shaft Kaplan type machine consists of draft tube, spiral casing and stay
ring, guide apparatus, shaft, runner guide bearing, shaft seal, oil tubes, oil header
and auxiliaries.

Technical Parameters

Capacity-2x17 MW, Type-Vertical Kaplan, Maximum net head-21.4 M

Minimum net head-19.6 M, Rated Speed-166.7 rpm, Direction of rotation-
Clockwise, Rated discharge- 92.5 Cusec, No. of Guide Vanes-24,

Draft Tube- The draft tube is constructed of welded steel and consists of a cone
and elbow liner. The draft tube elbow liner has been provided in segments, welded
together at site extending up to down stream from vertical center line of the
turbine. The outer portion of the steel liner has adequately been ribbed and
provided with means for anchoring the liner to surrounding concrete.

Runner Envelope- It is machined stainless steel shell of cylindrical spherical and

conical section to ensure minimum clearance and to reduce leakage at all positions
of runner blade openings. It supports pivot ring and it is heavily ribbed and
anchored in the concrete to reduce the vibrations.
Spiral Casing & Stay Ring- The Spiral Casing & Stay Ring are fabricated from
steel plates. The spiral casing is of logarithmic form of cross section for
maintaining constant velocity through out its passage.
Guide Apparatus- Guide Apparatus regulates the flow of water with change in
load and also serves as a closing devise. It includes top cover, pivot ring,
regulating ring, guide vanes and turning mechanism. Two servomotors fixed
inside the pit liner actuate the regulating ring, which in turn operates the guide
vanes through regulating gear. The guide vane lever and strap, which form a part
of regulating gear are assembled together by a shear pin. The pin gets shared-off
when the guide vane passage is blocked, thus protecting the guide vane and
regulating gear against further damage. Two servomotors are provided for turning
the regulating ring during regulation of load on turbine and closing/opening of the
guide apparatus.

Runner- The turbine runner comprises of four number cast stainless steel blades
(13% Cr,4% Ni). Blade operating mechanism consists of a powerful oil pressure
servomotor built in runner hub in which piston moves up and down. Runner
blades are coupled to the piston by means of connecting links and spider which is
in turn bolted to the piston rod which moves up and down in the bushes provided
in the runner hub casting. Oil enters the servomotor from the oil header at the top
of generator and passes through oil tubes located in the central portion of main
shaft.

Shaft- It is of forged steel with integral flanges at both ends for coupling to the
generator shaft and runner. The shaft is bored for its full length to ascertain its
soundness and to accommodate the runner blade servomotor oil tubes.

Shaft Sealing- The shaft sealing prevents leakage of water through clearance
between top cover and shaft sleeve. It is located below turbine guide bearing and
is fastened on top cover by studs. The sealing elements consists of three layers of
sealing rings made of rubber sheet. The sealing rings are retained in position
against the rotating shaft sleeve, by bottom cover plate, distance ring, intermediate
ring and top cover plate. The isolating seal is applied when the turbine is
stationary, by supplying compressed air to sealing with nozzle. When the turbine
is in operation, this seal is held clear of the shaft.

Guide Bearing- The guide bearing is of pivoted pad type with self contained oil
bath lubrication. It consists of eight babbit lined pads arranged along the outer
circumference of skirt of the shaft. Each pad is adjustable by means of studs. In
stationary condition, the pads are kept immersed in oil sump. Rotation of shaft
induces centrifugal force, due to which oil flows through the holes in shaft collar
and rises along the journal surface, thus lubricating the pads. Temperature of guide
bearing pads is monitored by a set of resistance detectors (RTDs) and
thermometers.
Runner Aeration Valve- 250NB runner aeration valve located near down stream
wall on top cover and is connected through pipe lines to inner surface of top cover.
This remain closed against rubber valve seat due to spring pressure. When ever the
pressure above the runner is below atmospheric, the valve allows the air to pass
through.

Compressed Air System- Air system consists of two H.P. compressor motor set.
The H.P. compressors are three stage compressors with air cooled intercoolers
between the stages. Compressed air from H.P. receiver is used in governor for
pressurizing oil. Compressed air from L.P. receiver is used in brake and Jack panel
and to shaft seal and also used for flushing at the cooling water tapping and DT
drain pipe.

Drainage-Dewatering system- Drainage-Dewatering system has been provided

to remove water from turbine water passage via pits to tail race through header.
Also seepage water collected in pits is removed through this system.

Cooling Water System- Cooling Water System is used for (i) Cooling water for
generator bearings (ii) Cooling water for generator coolers (iii) water for shaft
seal.
Cooling water for the above requirement is tapped from spiral inlet pipe and is
passed through strainer. Three booster pumps are provided for stepping up the
pressure of water.

CGL System – To facilitate grease lubrication of every moving parts of turbine a

Centralized Grease System has been provided. This system is completely
automatic with an adjustable timer for repeating grease cycle. From this system
greasing can be done even when the machine is running.

Intake Gate- Two nos. Intake gates has been provided to control the flow of
water to the turbine. Every gate is operated by one no. Hydraulic Cylinder. A
power pack unit for each gate generates the hydraulic pressure. There is a back up
battery for emergency closure of gates incase of total power failure.
The gates are complete with wheels, sill beam, side and top seal paths, wheel
track, bottom and side rubber seals, top rubber seal, side guide & guide shoes.
Draft Tube Gates- There are 4 nos. sliding type DT gates. The gates are complete
with thrust pad, sill beam, side and top seal paths, track for thrust pad, bottom and
side rubber seals, top rubber seal, side guide, spring loaded guide shoes and
filling valves. Latches have been provided at each opening for DT gates. An
automatic engaging and disengaging type lifting beam has been provided for
lifting and lowering the DT gate by a gantry crane.
STARTING PROCEDURE: -

1) DT Gate should be in open condition.

2) CHARGE the Governor & put on AUTO mode. Please check the Oil
Level & Pressure. Please RESET all the relays at relay panel and
also ensure resetting of ESV from HMC & GCP panel by closing
 GOV motorized valve (HMC control oil pressure should be ‘0’
Kg/Cm2). Then normalize the Governor by opening the Motorized
Valve.
3) After ensuring above clearance should be given for opening of
PENSTOCK GATE. Open the PENSTOCK GATE.
4) After opening of Penstock Gate, please open the MAIN LATING
VALVE of penstock and SUCTION VALVE of CW header of
corresponding Unit side, and open the MOTORIZED VALVE of
respective Unit, than CW PUMP should be selected for running,
Please open the Inlet & outlet valve of selected CW Pump. Please
start the selected CW PUMP.
5) After running of CW pump, pressure & flow in CW line should be
checked & it should be normal.
6) Apply Shaft Water sealing, check for normal Shaft Seal Pressure.
7) Machine Brakes should be in removed condition, please ensure.
8) Start HS Lub oil pump, machine will start rolling, ensure creeping of
the machine.
9) Put Governor control on AUTO MODE, & Give Start command to
the GOVERNOR, Machine will spin at 50 Hz. If OLG MOTOR of
HMC is OUT raise the Turbine Speed upto 50 HZ from HMC
WHEEL.
10) After ensuring the normal Turbine Speed, Close the FIELD
BREAKER and make EXCITATION ON.
11) Ensure the Generator Voltage within limit (11KV +/- 5%), otherwise
adjust ( raise / lower the Generator Voltage) and make it NORMAL.
12) After above put the SYNCHRONIZATION SELECTOR SWITCH on
AUTO POSITION and simultaneously put the SYNCHROSCOPE
ON/OFF SWITCH in ON position.
13) Wait for the AUTO SYNCHRONIZATION of machine and after
Synchronization, gradually raise the Load of Machine to desired
value.

STOPPING OF MACHINES

1) Governor must be on AUTO mode – Reduce the load gradually to desired

minimum level, then open the 11 KV Generator Circuit (GCB). Machine will
stop the Generation and remain spinning at 50 Hz. Please check.
2) Make the Excitation OFF and open the Field Breaker. Decrease the Guide
Vane Limiter to Minimum (0 %) position, speed of the machine will decrease.
3) Start the HS pump at 15 Hz and apply the Air Brakes at 10 Hz.
4) After stand-still of machine stop the HS pump.
5) After sufficient time CW pumps can be stopped, and penstock gate can be
lowered.
 MADHYA PRADESH POWER GENERATING CO. LTD.
SALIENT FEATURES

2X15MW THPII SILPARA

1) Installed capacity - 2X15 MW

2) Make & Type of M/C -BHEL ,Kaplan Turbine
3) Water requirement for full load - 185 M3 / sec.
4) Maximum head - 21.50 Mtr
5) Rated speed (rpm) -166.67 rpm
6) Generated voltage - 11 KV
7) Generator capacity -17.6 MW
8) Generator Transformers -2X20 MVA - (11 / 132 KV)
9) Auxiliary Transformers -2X1000 KVA – (11 KV / 415 V)
10) Excitation Transformers - 2 Nos, 11 KV / 190 V
11) No. of rotor poles -36 Poles
12) No of guide vans - 24 Nos
13) Station Supply -From AT-I & AT-II (415 Volts)
14) Air Compressors - 2 Nos 15 KW Capacity
(50 Kg/Cm2 )
i) HP air 40 Kg/Cm2 used in Governor
ii) LP air 6.5 Kg/Cm2 to
7.5 Kg/Cm2 used in
Brakes, Shaft sealing,
Dewatering Pit &
Service air
15) CW System 3X45 KW Cooling Water pumps,
CW Inlet Pressure – 2.1 Kg/Cm2
CW Outlet Pressure – 6 Kg/Cm2
16) Governor -2X22 KW Capacity pumps in each unit
- Oil Pressure -37 Kg/Cm2 to 40 Kg/Cm2
- PP Set – 02 Nos,
- HMC – 02 Nos
- EHG – 02 Nos
17) CO2 Generator Fire Fighting System - Common for both the units
18) HS Lub Oil Pumps - 15 KW Capacity (01 for each unit)
19) Drainage Pumps -2X9.3 KW
20) Dewatering Pumps -2X125 KW
21) Top cover Drain Pumps -2X0.75 KW in each unit
22) Switchyard - Only 02 bays – Directly connected to
nearby 220KV / 132 KV Substations
23) EOT Crane -75 MT / 15 MT Capacity hook,
Make – M/S WMI Mumbai

24) Various PH Building Floors -Draft Tube drain Floor – 274 Mtr,
Draft Tube Gallery – 281.4 Mtr,
CW Floor – 284 Mtr,
Machine Centre – 288 Mtr,
Turbine Floor – 292 Mtr,
Generator Floor – 297 Mtr,
Intake Gate Floor – 317 Mtr
25) Control Supply - 220 Volt DC (300 AH),
24 Volt DC (136 AH), &
UPS 230 Volts AC 05 KVA capacity,
26) Circuit Breakers - 132 KV – SF6 Breaker,
Make – BHEL,
-11 KV – Vacuum Breaker, Make –
BHEL (used for M/C Synchronization)
27) Penstock / Intake Gate - Hydraulically operated by oil
Pressure – 100 Kg/Cm2
28) Draft Tube Gates - 2 Nos .for each unit, electrically
operated.
 DETAILS OF TURBINE 2X15 MW SILPARA

1. Capacity – 2X17 MW
2. Type – Vertical Kaplan
3. Max net head – 21.4 M
4. Min net head – 19.6 M
5. Rated net head – 21.3 M
6. Rated output – 17.85 MW
7. Rated Speed – 166.7 rpm
8. Runaway speed on cam – 350 rpm
9. Runaway speed off cam – 410 rpm
10.Direction of rotation – Clockwise
11.Rated Discharge – 92.5 Cusec
12.Nos of Guide vanes – 24
13.Runner tip diameter – 3900 mm
14.Turbine Shaft diameter – 530 mm
15.Servomotor Diameter – 300 mm
16.Max GV opening – 360 mm
17.STATION AUXILIARIES –
a) CW Booster pump –
i) Make – Kirloskar UP 150/38A, Horz Split, Single Suction double entry

Centrifugal pump

ii) Head – 40 M
iii) Discharge – 4500 LPM
iv) Motor Rating – 45 KW, 1500 rpm, 3 phase, 415 V, 50 HZ, Sq cage
SPDP Crompton Greaves make C200L
b) Compressors –
i) Working Pressure – 50 Kg/Cm2
ii) Nos of Stages - 3
iii) Type – SP20 600/Var800 ELGI make Reciprocating Type
iv) Speed – 1250 rpm
v) FAD – 1 CubM/Min
vi) Cooling – Air Cooled
i) Motor – 20 HP,415 V TEFC sq cage induction Crompton
Greaves
c) Dewatering Pump –
i) Operating Head – 25 MWC
ii) Discharge – 17000 LPM
iii) Nos of Stages – 2
iv) Type – Jyoti make 450T3A4 Ver Turbine Pump
 v) Motor – 125 KW, 415 V, 50 Hz, 3 ph
vi) Type – Vertical hollow Shaft Jyoti make
d) Drainage Pump –
i) Operating Head – 25 MWC
ii) Discharge – 1000 LPM
iii) Nos of Stages – 3
iv) Type – Jyoti 300 T2XA4 Pump oil lubricated
v) Motor – 7.5 KW, 415 V, 50 Hz, 3 ph
vi) Type – Vertical hollow shaft drip proof, Jyoti make CVD 160B
e) Top Cover Drainage Pump –
i) Operating head – 13 M
ii) Discharge – 210 LPM
iii) Type – Kirloskar KOS 116 M, 1 HP, 2900 rpm, 220 V,1 ph,
f) CGL System –
i) Grease pump type – Plunger type
ii) Output – 300 cc/min
iii) Pressure (max) – 250 Kg/Cm2
iv) Motor Rating – 1.5 HP,
v) Container Capacity – 140 L
vi) Grease Type – Servogem-2 or equi
18.The turbine shall not be operated with tail water level (TWL) lower than EL
291.1 M
Net Head (M) Turbine Output (max) KW Turbine Output (min) KW
21.4 17850 6450
21.3 17850 6450
19.6 15000 5850
 DETAILS OF GENERATOR 2X15 MW SILPARA

1. Rated Power – 15 MW / 17.65 MVA

2. Max continuous Rating – 17 MW / 20 MVA
3. Rated Voltage – 11000 V (+/-) 5%
4. Rated power factor – 0.85 lagging
5. Rated Frequency – 50 Hz (+/-) 3 %
6. Rated Speed – 166.7 rpm
7. Nos of poles – 36
8. Direction of Rotation – Clockwise from top
9. Short Circuit Ratio – 1.05
10.Air gap at pole centre – 15 mm
11.Stator Resistence / phase at 20oC – 0.032 Ohm
12.Stator Winding Connection – Star
13.Field Winding Resistence at 20oC – 0.10 Ohm
14.Excitation at No Load – 530 A
15.Excitation at full load, 11 KV, 0.85 pf (lag) – 975 A
16.Excitation at max load, 11 KV, 0.85 pf (lag) – 1050 A
17.Excitation equipment rating – 1200 A, 167 V, 200 KW
18.Thrust bearing –
a) Thrust Bearing Type – Spring Mattress
b) Nos of pads – 12
c) Nos. of spring / pad – 31 (Total – 332)
d) Bearing Dimensions – ID-800mm OD-1610mm
e) Total load on bearing – 340 MT
f) Grade of Oil – Servoprime 57 or equi
g) Qty of oil – 4500 L
h) Max permissible temp alarm/trip – 75/85oC
i) Normal operating temp – 70oC
19.Guide Bearing –
a) Type of bearing – Segmental pad type
b) Nos of pads / Size – 12 Nos / 215mmX215mm
c) Diameter of Guide Bearing – 1610 mm
d) Max permissible temp alarm/trip – 75/85oC
e) Normal operating temp – 70oC
20.Cooling Water System –
a) No. of air coolers -06
b) No. of air coolers -06
 c) Cooling water quantity of air coolers- 1800 LPM
d) Cooling water quantity of oil coolers- 660 LPM
e) Maximum safe working pressure - 07 Kg/cm2
21. Brake/Jack Units-
a) No. of Units -04
b)Brake Material -Ferodo Grade
c) Brake Pad size -245x245 mm2
d) Safe wearing depth of pad -20 mm
e) Jacking oil Pressure required -72 kg/cm2
f) Brake application speed -55 RPM
e) Rotor Jack Limit -14 mm.
22. SLIPRINGS-
a) No. of brushes per ring -10 (Total 20)
b) Brush Grade -EGO
c) Brush size -25.4x38.1x50.8 mm
d) Brush spring load -1.8 Kgf
23. Anti- Condensation Heaters-
a) Rated capacity of each Heater Unit -3000 Watts
b)Voltage supply -415 V. AC, 3 Phase, 50 Hz.
c) No. of Heaters -03
d) Total heater capacity -09 KW