Guide lines for operation of Hydro Power House Page 1

Guide lines for operation of Hydro Power House

Generals :
The turbines are suitable for operation under the following principal mode of operation :
1) Manual Start and Control. | With the help of selector switch CSS-1
2) Auto Start and Control. | mounted on CD or CSS-7 in UCB
3) Change over from Manual to Auto.
4) Change over from Auto to Manual.
5) Normal Stopping.
6) Emergency Stopping.

It is essential that all auxiliary equipment’s should function satisfactorily and automatically for smooth
operation of the Plant.

Operation of auxiliary system :

1. Compressed air system :

i) H.P. air system :
High pressure air system consists of two H.P. compressor sets 88 MBA and 88 MBB. Under Start-stop control,
pressure switch (63-A-1) starts the compressor 88 MBA when the pressure in air receiver drops to 42 kg/cm²
and stop at 45 kg/cm².
Pressure switch (63-A-2) starts the other compressor (88 MBB) at pressure 40 kg/cm² and stop at 45 kg/cm².
Pressure switch (63-A-3) is set to give alarm at 37 kg/cm².
Pressure switches are adjustable to suit the desired setting. H.P. air is mostly used for P.P.Set.

ii) L.P.Air system :

Low pressure air receiver has been provided for compressed air equipment of Generator brakes and Shaft
sealing. L.P.Air receiver is fed from H.P. air receiver, through isolating valve, Pressure reducer, L.P.Air fitter.
The pressure reducer is adjusted to give constant downstream pressure of around 7 kg/cm².

2. Cooling water system :

The cooling water system are used for the following :-
a) Cooling water to heat exchangers for lubricating oil in turbine bearing.
b) Cooling water for generator coolers and generator guide bearing coolers.
c) Cooling water for turbine shaft sealing.
d) Cooling water for station services eg. Generator transformers etc.

Cooling water for the above requirement is tapped from penstock and passes through an automatic back wash
type strainer. When the pressure differential across the fitter element increases, due to clogging beyond a preset
value, the motor automatically starts the cleaning by rotating. Pressure reducing valve has been fitted in the line
to reduce the water pressure to suit the generator and turbine coolers.

3. Governor and P.P.Set :( G-40 Governor)

The normal function of the governor and the main servo-motors are dependent on a reliable source of
oil under a pressure which is maintained constant within close limit.
The “pressure pumping set” is designed to operate on ‘Continuous operation mode’. Under this
operation mode, one of the oil pumps operates continuously and the stand-by pump is operated intermittently.
Pumping of oil is mainly carried out by the main pump (88 MGA) under the control of ‘Idler valve’ to maintain a
pressure at receiver between 39 kg/cm² and 41.0 kg/cm².
Pressure switch (63G-7) operates to start stand-by pump motor (88 MGB) when pressure falls below
35.0 kg/cm² due to failure of main pump or excessive demand being made from pressure receiver. When the
pressure builds up again to 40 kg/cm², pressure switch (63G-7) stops the pump 88MGB. The roles of main and
stand-by pumps can be interchanged by means of a selector switch or push button fitted in the ‘unit control and
indication Panel’.
The pumping and unloading of the main pump is controlled by a spring loaded unloader valve (called
‘Idler valve’) which at pressure 41 kg/cm² opens to divert oil from receiver to sump tank via oil coolers and at
39 kg/cm² closes thereby allowing oil to pumped into the pressure receiver via non-return valve. A safety valve
is provided in the sump and set to blow off at 44 kg/cm² pressure and release oil back into the sump to avoid
the possibility of dangerous pressure rise building up in the receiver.
The level of oil in the sump is shown by the gauge fitted in the sump and has limit switches G1 & G2 at highest
and lowest point to give alarm respectively. This avoids the possibility of the pump running dry. Pressure switch
(63G-3) is provided to give an alarm when pressure falls below to 34.0 kg/cm² and pressure switch falls to 33.0
kg/cm².

4. Centralised Grease Lubrication System (CGL System) :

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To facilitate grease lubrication of every moving parts of MIV (B.F.Valve) and turbine, a CGL system has been
provided. The system is completely automatic with a synchronous timer adjustment between 6 to 120 hrs for
repeative Greasing cycles.

5. Drainage and Dewatering System :

A drainage sump between Unit II & III and another dewatering sump between Unit I & II has been provided for
removal of water from spiral and penstock together with normal station drainage to the tail pool. These sumps
are common for all the three units Two pumps in each sump have been provided for removal of water. The water
from all outlets will be deposited in the ‘Dry gallery’ at EL 242.00 M. Two submergible pumps have been fitted in
the dry gallery to pump out the water from dry gallery to drainage sump. Periodical running of the pumps are
necessary to drain-out the water from the Power House. Otherwise it may create major disaster to the Power
Station.

Starting sequence of Unit :

For starting a unit from stand still, some guidelines should be followed as prescribed by the manufacturer.
Before starting the machine, the availability of AC & DC supply must be ensured along with the auxiliaries.

GUIDE LINE FROM MANUFACTURE’S (BHEL) :-

A) Pre-start checks :-
Before starting the unit, the following relay in the UCB should be checked and ensured :-

1) Gov. oil Pressure normal - 63 G-1 ax.

2) Master stop Relay reset - 5A1.
3) Controlled action shutdown Relay reset - 86 A.
4) Emergency shutdown Relay reset - 86 B.
5) Electrical lock-out Relay reset - 86 Z.(in C&R panel)
6) Protection D.C. Supply normal - 80
7) Brake Air Press. Normal - 63 AB-1.
8) Guide vanes lock disengaged - 33-42bX.
9) Pressure to shaft gland isolating Seal released - 63 A-32 .
10) Brakes released - 24 BRX.
11) Shear pin normal - 33 SNX.
12) Pre-start check relay reset - 4 PS.

B) After getting the ‘Pre-start checks’ ready (in CD), check the following relay (Unit Start Checks) :-
1) Guide vanes fully closed - 33-25X.
2) Main Breaker open - 52 GX.
3) Field Breaker open - 41 GX.
4) Pre-start check normal - 4 PS.
5) MIV fully closed - 33 – 49 aX.
6) Start check Relay - 4PV
7) AVR in Auto mode

C) Start Sequence .
After resetting all the relays mentioned above, now the unit is ready to start. The indicating lamps (green) in
the control desk for i) ‘Pre-start check OK ’ & ii) ‘Unit ready to start ’ will glow. If indications are not available
the sequence should be checked thoroughly.
Now unit will be started with the help of selector switch ‘ CS –2 ’ mounted on CD. Give the start command. The
sequence will be as follows :
i) Machine Starting in Progress.
ii) By Pass valve open – to equalise the water pressure on both sides of the MIV.
iii) MIV in transit (to open).
iv) MIV open ( By-pass valve closed).
v) H.S. lubrication oil Pressure established.

The hyro-static lubrication system has been designed to provide an oil film between the thrust pad and
rotating parts of the shaft during starting and stopping when there is little likelihood of formation of a hydro-
dynamic oil film.
vi) Open the guide vanes upto 10% manually to get the speed upto 100%.
vii) After attaining the 100% speed, close the field breaker.
viii) Increase the excitation by increasing the reference voltage upto 11KV.
Now unit is ready for synchronisation. Before synchronising the unit, ensure that the line is ready to evacuate
the power.

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D) Synchronisation Sequence :
1. ‘ON’ the ‘Synchronoscope’ with the help of synchronising switch. Before that ensure no other
synchronising switch is on. ( It is advised to make a habit to switch off the synchronoscope as soon as
synchronisation is over).
2. Check the following :-
i) Sending end voltage ( machine side ) must be equal to the ‘receiving end voltage’ – ( Bus voltage ).
ii) Sending end frequency must be equal to receiving end frequency.
iii) Phase sequence for both sides must be same.

To meet the conditions mentioned at sl.no. i) & ii), machine speed may be increased or decreased with
the help of Gate limit switch.
When all the above conditions are fulfilled the pointer of the synchronoscope will stand at 12 O’clock
and both lights will glow bright. At that moment close the circuit breaker. After closing the circuit breaker,
switch off the synchronoscope.
Now, the machine is synchronised. Load may be put in the machine by increasing the ‘Guide vane
opening’ as per grid demand. Machine should not run below 60% of load (15Mw)

E) Stopping :
Following sequence should be followed for stopping the unit when running on load -
a) Reduce the output of the machine till it is almost zero ( not exactly zero ).
b) Open the circuit breaker.
c) Reduce the field current till the terminal voltage is almost zero.
d) Open the field breaker.
e) Give the stop command ( CS –2 in CD)
i) Guide vanes fully closed.
ii) MIV in transit ( to close).
iii) MIV fully closed.
iv) H.S. lub. Pump on.
v) Brakes engaged when the speed reduces less than 30% of full speed.
vi) Brake release when machine comes to standstill.
vii) H.S. lub. Pump off.

F) Unit at Stand Still.

Normal stopping ( Non-electrical lock-out) :
When stop command given from selector switch CS –1 ( in UCB) or CS –2 (in CD), stop relays 5A, 5B and
timer 5T are energised. The stop relay ‘5’ in EHG electronic cubicle will also get energised through contact relay
5A. The limiter in HMC will close through stop relay 5 and guide vanes will close. At no load opening of guide
vanes, main circuit breaker will trip through control action shutdown relay 86A.

G) Emergency Shutdown (Electrical lock-out ) :

In the event of electrical fault, emergency shutdown is initiated through relay 86B. Emergency shutdown can
also be initiated through ‘Push button’ PB –04 (CD) or PB –03 (UCB). The machine is closed through emergency
slide valve by-passing the governor. Trip signal for MIV and gen. CB is also given simultaneously.

Emergency Shutdown device -

Emergency shutdown is caused by any of the following conditions, by operation of the shutdown relay-
a) Over speed device (12 –B)
b) Gov. fail to close guide vanes
Emergency shutdown closes the MIV and guide vanes.
Two form of emergency shutdown action have been provided within the governor control sequence-
1) Emergency lock-out shutdown.
2) Non-electrical lock-out shutdown.
Emergency shutdown would be initiated by electrical fault.
Non-electrical lock-out shutdown would be initiated by mechanical failure, like overheated bearing, low Gov. oil
pressure etc.

No. of Protections are provided in the “Control and Relay Panel ” and “Unit Relay Panel” to take care of
the machine in case of any fault in the machine. The “Protection Chart” given below, describes the protection
provided and results thereof.

Protection Chart

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Sl. Protection Generator CB Field UAT Breaker M/C Remark

No. Tripped Breaker Tripped Tripped s
Tripped
1. Generator Stator E/F Relay ² ² ² ²
(64GS)
2. Field Failure Relay (40) ² ² ² ²
3. Rotor E/F Relay (64GR) ² ² ² ²
4. Overall Differential ² ² ² ²
Protection (87GT)
5. Restricted E/F Relay ² ² ² ²
(64GT)
6. UAT Restricted E/F Relay ² ² ² ²
(64UAT)
7. Emergency Push Button ² ² ² ²
Operated from UCB/CD
8. Generator Differential ² ² ² ²
Protection (87G)
9. Generator Inter turn Fault ² ² ² ²
Protection (87SP)
10. Generator Backup ² ² ²
impedance Protection
(21G)
11. Generator negative phase ² ² ²
sequence relay (46)
12. Generator Transformer HV ² ² ²
over current (51GT)
13. UAT over current Relay ² ² ²
(51UAT)
14. U/F ST – II trip (not in ² ² ²
use)
15. AVR Trouble ² ² ²
16. Emergency Shut down ² ² ² ²
Relay Operated
17. Rotor Temperature very ² ² ² ²
high
18. Stator Temperature very ² ² ² ²
high
19. Bottom Bearing Guide ² ² ² ²
Temperature very high
20. Thrust Bearing ² ² ² ²
Temperature very high
21. Hot air Temperature very ² ² ² ²
high
22. Turbine Guide Bearing ² ² ² ²
Temperature very high
23. Shear Pin Broken ² ² ² ²
24. Excitation Fault Stage – 3 ² ² ² ²
25. Gov. pressure receiver oil ² ² ² ²
level very low
26. Emergency Electrical Shut ² ² ² ²
down Relay Energised
27. Shear Bin broken during ² ² ² ²
M/C Stop
28. Emergency Trip Command ² ² ² ²
(UCB)
29. Unit Overspeed ² ² ² ²
30. Unit Overspeed Mechanical ² ² ² ²
31. CO2 Released ² ² ² ²
32. Gov. Oil pressure very low ² ² ² ²
33. Generator Fire ² ² ² ²
34. Governor Failure ² ² ² ²
monitoring timer Operated

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35. 110% Overspeed – GV Not ² ² ² ²

Closing

The machine, if tripped for any fault, must be attended to rectify the fault. After rectifying the fault and
resetting the relay, machine can be restarted

Important points to be noticed during operation:

1) Do not run the unit below the prescribed minimium load (15MW, within 30% to 60% load) which causes
cavitation.
2) Do not allow to increase the field current above the prescribed value.
3) Do not allow air to enter in the governor.
4) Do not apply voltage in a faulty machine. ( in case of stator E/F and rotor E/F -stage – III).
5) Do not try to bypass any kind of protection.
6) Proper care should be taken during synchronisation of the unit.
7) Do not run the unit without C.W.System.

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