hydro electric project-basic layout for francis, as per is,usbr and other standards

8/3/2019 Hydro Electric Project-basic Layout for Francis, As Per is,USBR and Other Standards

1/15

Input data

Input data to be entered here

Power house type surface type

Installed capacity 450.0000

%overload 0.1500

Power Generation

Max

517500 kW

No of units 3

Discharge 129.13 cumecs

Type of turbine Vertical

Francis 129.13

Type of Generator decided later

MDDL 1948.00 m

MRL 838.70 m

NRL/FRL 1956.00 m

NTWL 1953.30 m

Min TWL 1806.54

Max TWL 1808.36

Pressure Rise 35.00%

rated kVA 166666.667 rated

Generator Output

kVA

191666.67 max

Generation Voltage 13.8000 kv

Rated Frequency 50.0000

Power factor 0.90 lag

Losses 16.5

Page 1


2/15

Power house surface type

Power Generation max 517500.0000 kW

No of units 3.0000

Discharge 129.1300 cumecs

Type of turbine Vertical Francis

MDDL 1948.0000 m1hpU.S =kw 0.7457

MRL 838.7000 m 1hpmetric =hpU.S 1.0140

NRL/FRL 1956.0000 m

Min TWL 1806.5400 m

Max TWL 1808.1400

Gross Head 149.4600

Design Head (hd) 128.5700

Max Net Head 149.4600 m

Min Net Head 118.8600Critical Head 149.4600 loss at no

load

Pressure Rise allowed 35.00% % loss at

design load

10.6900

Generator Output kVA 166666.6667 kVA loss at

overload

21.0000

Generation Voltage 13.8000 kV

Rated Frequency 50.0000 Hz

Power factor 0.9000 lag

this sheet is incom lete, when com lete, I ll u load full version, contact me at uleria.b@ mail.comThe calculations for Turbine are based on 'Modern trends in selectin and desi nin Francis Turbine'b

Conversions used

head loss details


3/15

Turbine Output Power(Pd)

Pd=Pd= 240579.3214 hp metric

Trial Specific speed (ns') 2334/(hd)^.5 205.8406 rpm

Trial S nchronous s eed (n')Therefore, n' 181.7 rpm

Now, Pole (P) 33.0236 nos.So, the nearest oles 36.0000 36.0000do iterations here.

166.67 rpm

Hmax 149.4600

Hmin 118.8600

16.25% to 7.55% (-)

36.0000

166.67

The no of Poles= 36.0000

Pole pairs= 18.0000

Desi n-S ecific S eed Ns or (N*P ^.5)/(h ^1.25) 189

Year S ecific s eed1970-75 1671965-69 1561960-64 142

As per de Siervo & de Leva, there is tendency for going towards higher specific speeds in recent times and

Therefore, Synchronous speed for IN RPM

Increase in specific speed, lowers the size of machine in case of large machine and power house size however in smaller

rpm (specific speed)A study paper was presented by de Siervo & de Leva Modern trends in designing Francis TurbinesCorrelation of sp speed ns=

3470*Hd^-0.625

3250*Hd^-0.625

2959*Hd^-0.625

n' * h5/4

/ P1/2

formula fails here when poles are

even. Use the nearest poles.

Therefore, S nchronous s eed (n)

Since, head variation is

Therefore referred ole m/c is

DESIGN CALCULATIONS

(Output Power*hpmetric)/(hpU.S * Efficiency of Generator)


4/15

RUNNER:-

3 0.0211(ns2/3

) i.e. 0.6945

Dischar e DiameterD 84.47* * (H)^.5/n 3.99

D3 As per Warnick D3=(26.2+0.211*Ns)(H^.5)/n 4.49

D3 As per Siervo Ku=0.31+2.5*10-3*Ns 0.7821

D3=(84.5*Ku*(H)^.5)/n 4.50

As per Warnick

Dm (66.76+0.136Ns)*(H)^.5/n 6.29

D1 D3*(0.4+94.5/Ns)

D1 4.0458 m

D2 D3/(0.96+0.000386*Ns)

D2 4.3500 m

H1 D3*(0.094+0.000025*Ns)

0.4436 m

H2 D3/(3.16-.0013*Ns)

1.5416 m

Shaft :- Dia as per USBR

Shaft diameter 2.54*(70*Pd/n)1/3 i.e. 118 cm

Flange diameter 1.75*shaft dia. i.e. 207 cm

Flange thickness 0.22*shaft dia i.e. 26 cm

Weight of Runner :- Wkg 607*(Dmax)2.75 i.e. 95342 kg

Turbine Weight:- Wkg 15175*(Dmax)2.33 i.e. 1101085 kg

Turbine Spiral Case:-

a)

Ve 0.22(2ghd)1/2 i.e. 11.0495 m/sec.

b)

As per USBR

The water velocity in the casing when measured tangentially should be 22% of spouting

Entrance diameter Penstock dia.(2.92m)


5/15

c)

A D3*(1.2-19.5/Ns) 4.9276 m

B D3*(1.1+54.8/Ns) 6.2463 m

C D3*(1.32+49.25/Ns) 7.1027 m

D D3*(1.50+48.8/Ns) 7.9007 m

E D3*(0.98+63.60/Ns) 5.9165 m

F D3*(1+131.4/Ns) 7.6197 m

G D3*(0.89+96.5/Ns) 6.2950 m

HD3*(0.79+81.75/Ns)

5.4947 mI D3*(0.1+.00065*Ns) 1.0007 m

L D3*(0.88+.00049*Ns) 4.3696 m

M D3*(0.60+.000015*Ns) 2.7085 m

Semi spiral case:-

1) Va = q/a

2)

= -

2

A = at 0 or 1.115 in basic la out

K = A - at 0 /2

= angle of turn expressed in radian at 135 with in the basic layout. =0.5 & =2.356 giving K = 0.1108

q = diminish in proportion to remaining stay ring

a = cross sectional area

0.7coefficient of contraction from intake o enin to casin entrance

0.3 * height of the opening

0 of semi-spiral

( = distance from center of unit to neat line of large

Dimensions of spiral case (IN METRE)


6/15

Recommended Draft Head:- Z = Hs + b

Hs = Hb - hcr

Hb = Ha - Hv

= ns

1.64

/50327i.e. 0.1074

Therefore, = 0.1074

Also, Ha :- El.765

EL.500m = 9.7510 EL.1000m= 9.1800 9.4484

Hv :- at 15C= 0.1740 at 20C= 0.2390Hb = Ha - Hv i.e. 9.2094

Hb = 9.2094

Now, HS = Hb - *hcr i.e. -6.8398

HS = -6.8398

Z = Hs + b b = 0.9435

Therefore, Z = -5.8962

-6.000.1800

>

b = vertical distance from centreline of spiral or case to D2 or min. runner diameterHs = Static draft head in meter

The value ofb is acc. to fig.17, USBR or page111 of Warnick and is 21% of D3

Total Draft Head means that C/L of Distributor is above/below Min. TWL by (meter)from fig.17(USBR), the Plant sigma

hcr = max. head at which turbine may be operated = cavitation factor


7/15

Draft Tube parameters

N D3*(1.54+203.3/Ns) 11.7600 4950 m cone ht

O D3*(0.83+140.7/Ns) 7.0772 2900 m 4.6828

P D3*(1.37-0.00056*Ns) 5.6803 2600 m 6.2244

Q D3*(0.58+22.6/Ns) 3.1437 1400 m

R D3*(1.6-0.0013/Ns) 7.1888 3400 m

S D3*Ns/(-9.28+0.25*Ns) 22.3696 9900 m

T D3*(1.50+0.00019*Ns) 6.9007 3300 mU D3*(.51-0.0007*Ns) 1.6976 700 m

V D3*(1.10+53.7/Ns) 6.2201 2800 m 0.8651

Z D3*(2.63+33.8/Ns) 12.6209 5600 m

Governor Capacity:-

1)

FYM = 34*(hwh*Dg*I)1.14

where

5.0322water hammer= 0.3500 52.3110 m

Here, hwh = 201.7710 m 20.1771

FYM= 91073.2854 kgm

2) Hydraulic Thrust:-

therefore, FH = 415427.7603 kg

Turbine Performance:-

where n is rotational speed

WR2

is roduct of wei ht of rotatin arts

The value of Dg can be approximated from USBR EM 20, fig15 wicket gate circle diameter,D =

Accordin to formula iven in fi .23 h draulic thrust is F =10.02*n1/2

*D2*H

Flywheel Effect is conveniently referrred as startup time for unit:

= W2 2

*

P is turbine full gate capacity

Dimension in terms of turbine runner diameter,D3 and specific speed,Ns (as per Warnick)

Wicket gates servomotors capacity:-

I = wicket gate height,hwh = maximum head,including water hammer


8/15

Turbine WR2 24213*( Pd/n^1.5)^ 1.25 2151.6574

8803493.8671

2 15000* (kVA/n^1.5)^1.25 If onl Generator

3446956.4034 3446956.4034

Combined Inertia is 12250450.2704 3791652.0437Machine startup time 21.1114 6.5342

Tm= WR2n2/(67000*P) 21.0000

Water Column Startup time is Tw= Sum of(LV)/(gH) specific of project manual input

Sum of LV

Tw= 0.7600

Tm=>2Tw2

2Tw2 1.0000 satisfied not satisfied

The stability criteria is satisfied

Speed rise:-

Tf= 8.0000 manual input

Tk=0.25 + Tf 8.2500

Tk/Tm= 0.3929

Sr= 26.0000

Tw= 0.7600

K= Tw/Tf

K= 0.0950

S'r= Sr*(1+k)

28.4700

28.0000

However, the surge shaft location may be shifted to away by about 140m or the machine size may be reduced. The machine

The servomotor full closing and opening time has been assumed under:

Speed rise Sr in % of rotational speed can be derived from Fig 24,USBR EM 20

The s eed rise in this turbine

these calculations here are as per

10% for turbine

The machine inertia Tm has stabilisin effect whereas the water column (here in terms of time) Tw has destabilisin

Alternatively, Hadley (Guthrie & Brown) has also mentioned a criteria Tm=3Tw and can be used.


9/15

n/n is speed rise. speed rise assumed to be= 30.00% pressure

rise

K= 0.8660

Tf=

K*(1+h)3/2= 1.2248

(n/n+1)2-1= 0.6900

11.8303

Run away Speed

Nr/N= 0.63*Ns^0.20

1.7970

Or 90% above normal speed. Nr= 712.5000

Nmax Nr*(Hmax/Hd)^0.5

768.2057

768.0000 r m

= *3/2

-

K is variation of overnor coefficient with s ecific s eed and is iven b Table 10.2 from Warnick or Hadle .

h is variation in ressure rise and ressure dro with servomotor o enin and closin time Hadle 1970.

* +

* +

2

-

Hence the selection of Governor closin time of 8 sec is correct, in view of the ressure rise and s eed rise

Maximum runawa s eed is

Alternativel the overnor closin time is also iven b ex ression Hadle 1970 :


10/15

GENERATOR

Parameter Formula calculated by IS (in

metres)

Supplied

Values

Constan

ts table

Air gap diameter (Dg) Dg=(60/pi )*( Vr/n) 9.1000 5.1000 Vr 79.0000

Outer Core Diameter (Do) Do=Dg*(1 + pi/2p) 9.9000 5.9000 n(RPM) #######

Stator Frame Diameter (Df) Df=Do+1.2 11.1000 7.1000 P(in

pairs)

18.0000

Inner Diameter of Generator

Barrel (Db)

Db=Df+1.8 12.9000 8.9000 kW #######

Core length of stator (Lc) Lc=W/(Ko*Dg2*n) 1.9320 0.3660 Ko 6.2500

Ratio of Core Length to Air

Gap Diameter

Lc/Dg 0.2120 0.0718

Length of stator frame (Lf) Lf=Lc+1.55 3.4300 1.9000 K for hj

Height of load bearing bracket

(hj)

hj=KDg 1.9608 1.5000 K for PH

Number of arms of bracket 4 to 8 arms 4.0000 4.0000

Axial hydraulic thrust (PH) PH=K*D12*Hmax 415427.7603 89340.0000 USBR

Weight of Turbine 1101084.5253 54.6000 USBR

Total load on bearing 1516512.2855 ########## kg

or 1517.0000 144.0000 tonnes

per arm 379.2500 36.0000

Length of Power House

Unit s acin = outer barrelOuter barrel dia= 13.4000 say 8600

unit spacing= 16.4000 say 12m

Length of erection bay( 1to 1.5

times of unit spacing)

13.1000

Total length of PH

63.100064.3000

Width of Power HouseApproximate MIV size 3200.0000

Nominal diameter MIV 2400.0000

GENERATOR mm 6.7000

Spiral Size (E) 5.9165 concreting 1.5000

MIV 3.2000 Manhole/gallery/prv 2.0000

Column width 1.0000

Approximately m. 10.1165

K depends on number of cranes and handling for lastIf the control block is to be taken upstream side of PH the width

The width depends upon the MIV size, barrel width and spiral width including statutory

Upstream Width

The value of k from IS for this thrust er arm shall be decided.

Outer barrel diameter +1.5 to 2 inner barrel dia+

No of units* Unit spacing+ Service Bay+K+ Control Block


11/15

Downstream width

GENERATOR mm 6.7000

Spiral Size(D) 7.9007

Clearance Downstream 2.0000 Downstream

clearance

2-2.5m


Total Width of PH 20.0172 metres

Hei ht of Power House=

Hei ht of machine= height of draft tube 5000.0000

Clreance from bottom 1000.0000

Total height from C/L to bottom= 6000.0000

Height upto M/C floor Lf+hj+K K=5.5 to 7

Lf= 3.4300

Hj= 1.9608

K= 5.5000

10.8908 say 9 metres

Clearance from M/c to Crane

Beam

10m EL 777.00m

Height of crane 4m EL 781.00m

Roof 2.5m EL 783.50m

As per Details GordonGenerator WR^2= 15000* (kVA/n^1.5)^1.25 3446956.4034

Turbine WR^2 10% times Gen WR^2 344695.6403

Therefore, total WR^2 = 3791652.0437 kg m^2

GD^2=4WR^2 15166608.1748 kg m^2

Inertia Constant,H= 1.37*10^-6*GD^2*N^2/KVAInertia Constant,H= 32.4674

EOT sizing

EOT capacity in tons= 50*(MVA/sqrt(n))^.74

MVA= 166.6666667

n=speed in rpm= 166.6667

12.9099

EOT capacity in tons= 331.9358

332.0000

Basic Data

Rated MW MW 172.50

Rated speed N 166.67

Rated Head Hn 128.57

Rated Discharge Q 129.13

Discharge dia of runner D3 4.49

Generator KVA with o/l KVA 191666.67 hp

Turbine capacity in KW Pt 172500.00 172.50 228567.64

The centreline of Spiral/distributor is 2m below Min TWL(EL 760.00m) i.e. EL 758.00m.

The bottom of Draft tube concrete is 8m below C/L and clearances i.e. EL 750.00m.

The machine floor elevation is EL 766.90m.

Com utation of Inertia Constant

The next EOT size nearest meeting this Capacity is 63T.

Speed rise and Pressure rise (this section has invalid cross references, change to get correct

Height of machine + height M/c floor to Roof

Hei ht of bottom of draft tube from C/L of distributor and C/L to Machine floor


12/15

1387.96

Windage loss (HP) =2/3x total loss 925.31

Friction Loss (HP) =1/3 x total loss 462.65Flywheel Effect WR

.

Turbine WR 410495.21

Total WR2 (Kgm2) 4515447.28

GD 18061789.12

Inertia Constant, KW sec / H 3.59

Unit Acceleration Time Tm 8.05

Flywheel Effect WR 4104952.07

346887.19

Total intertia (Kgm2) I 4451839.26 #######

GD2 17807357.05

Inertia constant H 3.54

Unit Acceleration Time Tm 7.86Flywheel Effect WR

4563612.05

Turbine WR 362530.39

Total WR2 (Kgm2) 4926142.45

GD2 19704569.79Inertia Constant H 3.91Unit Acceleration Time Tm 8.78

Selected Inertia Constant H 4.00

Unit Acceleration Time By

back Calculation Tm8.97

Therefore H 4.00 WR2 ####### Kgm2

Tm 8.97 GD2 ####### Kgm2

Water Starting time, Tw

Effective closing time Te

Pressure rise, h, range 30-35 IS 12837

Speed rise, n, range 35-55 IS 12837

WCS-1

HRT-1 L1 0.00

Diameter D1 0.00

Velocity in L1 V1 0.00

L1V1 0.00

HRT-2 L1 0.00

Diameter D1 0.00


L1V1 0.00

Pressure shaft L2 0.00

Diameter D2 5.50


L2V2 0.00

Penstock L3 200.00

Diameter D3 5.50


L3V3 0.00

Spiral casing L4 #VALUE!


L4V4 #VALUE!

1047.2*(HP/N^1.5)^1.25

4 X Total WR1.37 x 10

-6x GD

2x N

2/ KVA

(WR X N ) / (9.038 X 10 x Pt)

LV / gH

As per Choudary15000 )

. .

1446 ). .

I X N /(91.2 X 10^

X P (MW)As per TNHB

16676 (KVA) / N

5 to 10 % of Generator WR

4 X Total WR

1.37 x 10-

x GD x N / KVA

(WR X N ) / (9.038 X 10 x Pt)(Tm > 5 sec. is recommended for ensuring governor performance of high quality.)

Windage loss & Friction Loss (HP) (0.6 % x (Rated MW )x10 ) /0.74

As per USBR15000 )


13/15

Draft tube, L5V5 L5V5 #VALUE!

TRT-1 L6 0.00

Diameter D6 5.50


L6V6 0.00

TRT-2 L6 0.00

Diameter D6 7.75


L6V6 0.00TRT L7 0.00

Diameter D7 9.50 Total L #######

Velocity in L6 V7 0.00 L/H #######

L7V7 0.00

LV = L1V1 + L2V2 + L3V3 +

L4V4 + L5V5+ L6V6+ L7V7#VALUE! #VALUE!

Tw'

TM / TW TM / TW2

Water Starting Time Tw #VALUE! #VALUE! ####### #######

GORDON'S STABILITY

TM / TG 1.79

TW' / TC #VALUE!

For good regulation in isolated

system maximum TW' / TC 1.06For good regulation in

connected system maximum

TW' / TC 1.35

Regulation

Also,

To 0.25

Tw #VALUE!

Tm 0.00

a = Tw / (4 X Tm) #VALUE!

c = To / (2 X Tm) #DIV/0!

r =(1/a -0.5 +(1/a+To)^0.5)^-

0.5 #VALUE!

n = a / r + c #VALUE!

z = r + sqrt.(r2

+ 1) #VALUE!

h = z2

- 1 #VALUE!

Te = Tw / (2 X r) #VALUE!

Te taken TG 5.00 6.00 7.00 8.00

a = Tw' / (4 X Tm) #VALUE! #VALUE! ####### #######

r = Tw' / (2 X Te) #VALUE! #VALUE! ####### #######

z = r + sqrt.(r2

+ 1) #VALUE! #VALUE! ####### #######

n = a / r + c #VALUE! #VALUE! ####### #######

h = z2

- 1 #VALUE! #VALUE! ####### #######

Values taken TG 5.00 6.00 7.00

n #VALUE! #VALUE! #######

h #VALUE! #VALUE! #######

(For good regulation, USBR recommends Tm 2 x Tw2)

#VALUE!

#VALUE!

Speed rise & Pressure rise Calculation as per Water Power

(For good regulation, B.Hadley recommends Tm > 3 x Tw)


14/15

GENERATOR

Parameter Formula calculated by IS (in

metres)

Supplied

Values

Constan

ts table

Air gap diameter (Dg) Dg=(60/pi )*( Vr/n) 9.1000 5.1000 Vr 79.0000

Outer Core Diameter (Do) Do=Dg*(1 + pi/2p) 9.3000 5.9000 n(RPM) 0.0000

Stator Frame Diameter (Df) Df=Do+1.2 10.5000 7.1000 P(in

pairs)

0.0000

Inner Diameter of GeneratorBarrel (Db)

Db=Df+1.8 12.3000 8.9000 kW #######

Core length of stator (Lc) Lc=W/(Ko*Dg2*n) 1.9320 0.3660 Ko 6.2500

Ratio of Core Length to Air

Gap Diameter

Lc/Dg 0.2120 0.0718

Length of stator frame (Lf) Lf=Lc+1.55 3.4300 1.9000 K for hj

Height of load bearing bracket

(hj)

hj=KDg 1.9608 1.5000 K for PH

Number of arms of bracket 4 to 8 arms 4.0000 4.0000

Axial hydraulic thrust (PH) PH=K*D12*Hmax 0.0000 89340.0000 USBR

Weight of Turbine 0.0000 54.6000 USBR

Total load on bearing 0.0000 ########## kg

or 0.0000 144.0000 tonnes

per arm 0.0000 36.0000

Length of Power House

Unit s acin = outer barrelOuter barrel dia= 12.8000 say 8600

unit spacing= 15.8000 say 12m

Length of erection bay( 1to 1.5

times of unit spacing)

12.6000

Total length of PH

26.6000

14.6000Width of Power HouseApproximate MIV size 3200.0000

Nominal diameter MIV 2400.0000

GENERATOR mm 6.4000

Spiral Size (E) 0.0000 concreting 1.5000

MIV 3.2000 Manhole/gallery/prv 2.0000

Column width 1.0000


Downstream width

GENERATOR mm 6.4000

Spiral Size(D) 0.0000

Clearance Downstream 2.0000 Downstream

clearance

2-2.5m


Total Width of PH 19.0000 metres

Hei ht of Power House=

Hei ht of machine=height of draft tube 5000.0000

Clreance from bottom 1000.0000

The width depends upon the MIV size, barrel width and spiral width including statutory

Upstream Width

Height of machine + height M/c floor to Roof

Hei ht of bottom of draft tube from C/L of distributor and C/L to Machine floor

Outer barrel diameter +1.5 to 2 inner barrel dia+

No of units* Unit spacing+ Service Bay+K+ Control BlockK depends on number of cranes and handling for last

If the control block is to be taken upstream side of PH the width

The value of k from IS for this thrust per arm shall be decided.


15/15

Total height from C/L to bottom= 6000.0000

Height upto M/C floor Lf+hj+K K=5.5 to 7

Lf= 3.4300

Hj= 1.9608

K= 5.5000

10.8908 say 9 metres

Clearance from M/c to Crane

Beam

10m EL 777.00m

Height of crane 4m EL 781.00m

Roof 2.5m EL 783.50m

The machine floor elevation is EL 766.90m.

The centreline of Spiral/distributor is 2m below Min TWL(EL 760.00m) i.e. EL 758.00m.

The bottom of Draft tube concrete is 8m below C/L and clearances i.e. EL 750.00m.

hydro electric project-basic layout for francis, as per is,usbr and other standards

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