MODERN HYDROELECTRIC ENGINEERING PRACTICE IN INDIA

ELECTRO-MECHANICAL WORKS
• MEGA • LARGE • SMALL • MICRO

OVERVIEW
1. Introduction
Hydro energy is a clean renewable energy resource. Rapidly rising cost of electricity generation using fast
depleting fossil fuel energy sources and acute environmental degradation caused by these resources has
resulted in a demand for development of abundantly available, hydro energy resource which can be
converted into electricity very efficiently. It is a non consumptive use of water.

Large amount of energy available in our flowing rivers, streams, canal falls etc. remains untapped. There
are large seasonal variations in availability of this resource. Initially small scale isolated development of
hydro electric power in India was confined to providing a reliable and continuously available electric
energy for the load and was accordingly based on minimum dependable dry period stream flows so that
curtailment of load during dry period is minimized. Very large wet period inflows were not utilized.
Change to this defective design principle is called for because of the following reasons in addition to rising
cost of power generation.

i) A large integrated hydro thermal power system is developing in which thermal nuclear generating
capacity is very large portion of total capacity.
ii) Induction of large thermal/nuclear generating capacity in the interconnected grid provide dependable
energy at flexible rate which is not dependent on vagaries of stream flow and thus provide for
deficiency of energy during periods of low stream flow.

It is now being recognized that hydro energy is an alternate renewable source of energy and maximum
possible hydro energy be converted into electricity. Installations at all existing stations be uprated and new
hydroelectric installations designed accordingly for maximum economical energy. The hydroelectric is the
cheapest form of clean energy. Accordingly great stress is being laid in India and other countries on
development of enormous undeveloped hydro power potential and uprate/modernize existing installation
for optimum cost effective sustainable development of this renewable resource. Modernizing of existing
hydroelectric practices to meet National requirement (Hydropower Development National Policy) in
accordance with National and International Standards and Technology advance is required.

2. Hydro Power Development and Potential

2.1 Hydropower is a renewable economic, non polluting and environmentally benign source of energy. Hydro
power stations have inherent ability for instantaneous starting, stopping, load variations etc. and help in
improving reliability of power system. Hydro stations are the best choice for meeting the peak demand. The
generation cost is not only inflation free but reduces with time. Hydroelectric projects have long useful life
extending over 50 years and help in conserving scarce fossil fuels. They also help in opening of avenues for
development of remote and backward areas.

Hydro power potential as per Govt. of India Policy Statements – 1985.

Our country is endowed with enormous economically exploitable and viable hydro
potential assessed to be about 84,000 MW at 60% load factor (1,48,700 MW
installed capacity). In addition, 6781.81 MW in terms of installed capacity from
small, mini and micro hydro schemes have been assessed. Also, 56 sites for pumped
storage schemes with an aggregate installed capacity of 94,000 MW have been
identified. However, only 15% of the hydroelectric potential has been harnessed so
far and 7% is under various stages of development. Thus, 78% of the potential
remains without any plan for exploitation.
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2.2 National Electricity Policy (2005 & 2008)

National Electricity Policy reiterates as follows:

i) Hydroelectricity is a clean and renewable source of energy. Maximum emphasis would be laid on the
full development of the feasible hydro potential in the country.
ii) Harnessing hydro potential speedily will also facilitate economic development of states, particularly
North-Eastern States, Sikkim, Uttaranchal, Himachal Pradesh and J & K, since a large proportion of
our hydro power potential is located in theses states.
iii) The states with hydro potential need to focus on the full development of these potentials at the
earliest.
iv) Develop requisite transmission lines

Technology Development: National electricity policy (2005) recommends as follows regarding

technology development for power generation including hydro development (Extracts).

Effective utilization of all available resources for generation, transmission and

distribution of electricity using efficient and cost effective technologies is of
paramount importance. Operations and management of vast and complex power
systems require coordination among the multiple agencies involved. Effective
control of power system at state, regional and national level can be achieved only
through use of Information Technology. Application of IT has great potential in
reducing technical & commercial losses in distribution and providing consumer
friendly services. Integrated resource planning and demand side management would
also require adopting state of the art technologies.

Special efforts would be made for research, development demonstration and

commercialization of non-conventional energy systems. Such systems would need to
meet international standards, specifications and performance parameters.

Similarly, cost effective technologies would require to be developed for high voltage
power flows over long distances with minimum possible losses. Specific information
technology tools need to be developed for meeting the requirements of the electricity
industry including highly sophisticated control systems for complex generation and
transmission operations, efficient distribution business and user friendly consumer
interface.

Induction of modern technology, International standards and continuous research and development inputs
are required to modernize engineering practices for hydropower development.

Rural Electrification by Small & Micro Hydro Projects: The development objective of the power sector
in the country is supply of electricity to all areas including rural areas as per Indian Electricity Act.

Reliable rural electrification systems with small and micro hydro projects especially in Northern states
which aim at creating the following are required.

(a) Rural Electrification backbone (REDB) with at least one 33/11 kV (or 66/11 kV) substation in every
block and more if required as per load, networked and connected appropriately to the state
transmission system.
(b) Emanating from REDB would be supply feeders and one distribution transformer at least in every
village settlement.
(c) Household Electrification from distribution transformer to connect every household on demand.
(d) Wherever above is not feasible (it is neither cost effective nor the optimal solution to provide grid
connectivity) decentralized distributed generation facilities together with local distribution network
would be provided so that every household gets access to electricity. This would be done either
through conventional or non-conventional methods of electricity generation whichever is more
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 suitable and economical. Non-conventional sources of energy could be utilized even where grid
connectivity exists provided it is found to be cost effective.

Renovation, Modernisation & Uprating: Renovation, Modernisation & Uprating of old hydro power
plants is to be accorded priority as it is a faster and cheaper way of capacity addition than installing new
capacity. Guidelines are required.

Inter State Mega Projects: A substantial hydro power potential has remained locked up and many mega
hydro projects could not be taken up for implementation, even though these projects are well recognised as
attractive and viable. The selection and design of project is required to be based on integrated basin wise
studies. Basic parameters involved and mechanism through which each project should be constructed and
operated by the basin states need formulation. As far as possible, there would be preference to take up
simple run-of-the-river schemes that do not involve any major storage or consumptive uses. These projects
have to be designed as the backbone for the stability of the National Grid system and parameters need to be
designed after careful studies.

3. Development of Water Resources for Irrigation, Drinking Water and Flood Control

Urgent development of water sources is required to meet following urgent needs for sustainable
development.

a) Increased irrigation for agriculture to meet food demands.

b) Provide drinking water to towns/villages.
c) Recharge depleting ground water to provide water for irrigation and drinking.
d) Minimize huge annual flood loss to life properly and crops.
e) Electricity to meet energy needs.
f) Industry

Rain water is our only source of potable water. Only a limited quantity of rain water can be conserved in
the catchment, conservation and storage of this rain water in a series of dams/barrages at feasible locations
along the entire length of our streams and rivers is a major option to meet the demand of increasing
population for food (increased irrigation), drinking water etc. and control flood loss. In the plains barrages
may be used to spread floods waters within the existing flood zones along the streams and rivers to
minimize flood damage. Stored water may be released for consumptive use in neighborhood for drinking
purposes and irrigation. Spread of water may help in recharge of ground water.

Hydropower is non consumptive use of water and can produce energy from water when released for
irrigation, drinking and other consumptive uses. This power can be fed into grids as clean renewable source
of energy displacing fossil fuel energy and will be economical. Bhakra, Tehri Dam etc. store rain water not
only to meet increased irrigation, drinking water needs and control floods but also provides stable low cost
clean power energy to the grid.

Ararghat (4 x 3 MW) and Bathnahan Small Hydro Project (4 x 2 MW) of Bihar State Hydro Electric Power
Corporation Ltd. are examples of flood control barrages.

UNDP/World Bank Project for cost effective irrigation Mini Hydro Schemes in India under Energy Sector
Management Programme (ESMAP) is notable effort in this direction.

Hydropower development may have adverse effects by way of submergence of land leading to destruction
of forest and displacement of people. It may also have adverse environmental consequences. These
concerns should be addressed and solved for sustainable development.

Detailed studies at basin level are required for such multipurpose project for irrigation, drinking water
supply, ground water recharge, flood control and hydro energy development.

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4. Modern Engineering Practice in India

4.1 Hydro-Electric as Energy Source - Installed Capacity

Hydro is value-able renewable energy resources and optimum utilizations of energy resource is required.
The energy is to be fed into the grid and with the provision of banking and other measures now available
installed capacities are required to be based on dependable flows available throughout the year and energy
produced can be utilized displacing fossil fuel energy. The basis for development of hydro power project is
to be modified so that hydro power projects are developed as Alternate source of energy. Criteria for
development of resource has to be optimum utilization of the energy resource as dependable electrical
energy in the grid in integration with other energy sources.

4.2 Small and Mini Hydro Projects

Feasible potential of small hydro is also needed to be exploited fully to create additional power generation
capacity. Small and mini hydro potential can provide a solution for the energy problems in remote and hilly
areas and also along the canal systems having sufficient drops. The small hydro potential could be
developed economically by simple design of turbines, generators and the civil works. Criteria for installed
capacity simplified guidelines for design of electro-mechanical equipment and system is required for rapid
development.

4.3 Micro Hydro Projects

Energy problems in remote and hilly areas where extension of grid system is uneconomical can be met by
micro hydros. Guidelines for developing these micro hydro to meet energy needs is required which can be
operated by type of man power available and is economically viable. A cluster approach of development of
micro hydro in an area for economic viability is considered necessary.

4.4 Modern Engineering practices for hydro power development incorporate significant changes in existing
guidelines and practices as high lighted below.

i) Techno-economic studies are required to be carried out to determine capacity, unit size, and type for
optimum utilization of hydro energy resource at new power stations.
ii) Recent technology advances in all fields requires existing engineering practice to be
modified/updated
iii) Computerized control system and microprocessor based protection relay technology has almost
completely changed control and protection system of hydro plants.
iv) Detailed studies are required for optimizing selection of equipment parameters and field adjustment
of variable parameters etc. as per present guidelines and standards.
v) Formation of large power grids require careful selection of economic parameters of generating
equipment for stable grid operation, Islanding etc.
vi) Manpower costs are rising, human errors at all levels can be very costly. Non attended operation,
intelligent control and protection system design is becoming increasingly important.
vii) Development of small hydro from micro hydro (up to 100 kW) to 25,000 kW require very special
consideration to make them economically viable suitable for unattended operation due to non
availability of suitable manpower for operation and grid interconnected to improve load factors.
Modern practice in accordance with UNDP Hilly SHP Project and UNDP/World Bank Project for
cost effective irrigation Mini Hydro Schemes in India under Energy Sector management Programme
(ESMAP) is a notable effort in this direction.
viii) Development of dependable micro hydro and small hydros for rural electrification of far flung areas
as per rural electrification norms.
ix) Development of cost effective low and ultra low head canal fall and head works small hydro for
utilizing the energy available near load centres.
x) Renovation, modernization and uprating (RMU) of existing projects is required to utilize maximum
available water power potential, improve efficiencies and reduce forced outages.
xi) Small hydro development in conjunction with other renewable energy sources for maximizing SHP
benefits in hybrid system is a matter of development and research.

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5. Basis for Modern Engineering Practices and Guidelines for Design of Hydro Stations and Schemes

Engineering practice and studies carried out for selected typical existing power plants for selection,
performance and testing of equipment parameters and design of power house based on standards etc.
prevailing at the time of planning and design of large and small hydro projects have been discussed in
details and form the basis of modern guidelines. Modern practice based on the current standards and
guides are brought out in the book. Central Board of Irrigation and Power is the nodel agency in India for
this purpose.

5.1 Mega Projects (high capacity interstate projects)

Mega projects are discussed with special reference to Bhakra and Beas interstate projects. These represent
deigns of Mega Projects in the country. Detailed design of Bhakra Left Bank Powerhouse was done in
India and Bhakra Right Bank was designed with the help of Russian design organisation Lengidep in
Russian and India. The power plants have been renovated, modernized and uprated.

Bhakra Power Projects – Left Bank (5 x 90 MW) and Right Bank (5 x 120 MW) are the first mega projects
of the country. Beas Project Power Plants - Dehar (6 x 165MW) and Pong (6 x 60 MW) were the first
power plants for which indigenous equipment was supplied by M/s Bharat Heavy Electricals Bhopal.

Detailed studies were carried out for initial design of these power plants for determining capacity, unit size,
generator parameters and excitation system response. These form the basis of modern practice for Mega
projects.

Bhakra power plants are shown in figure 1 and Dehar Power plant in figure 2.

Recent trends in hydro-electric engineering design of electro-mechanical works is discussed with reference
to 2400 MW Tehri Hydro Power Complex which was specially visited for the purpose. Figure 3 shows
Tehri and Koteshwar power plants recently commissioned.

5.2 Small Hydro Projects

Modern Design of small hydro projects are discussed with special reference to Sobla power house (2 x
3000 kW); Kanchauti (2 x 1000 kW); Chirkila (1 x 1000 + 1 x 500 kW) and Kulagarh (2 x 600 kW)
typically shown in figure 4. These are the first small hydro power projects of Uttar Pradesh Small Hydro
Power Corporation which were designed/guided by the author.

Fig 1: Bhakra Power Plants (Country’s first Mega Project)

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 Fig. 2: Dehar Power Plant

Tehri Power Plant Koteshwar Power Plant

Fig. 3: Tehri & Koteshwar Power Plant (Recently commissioned/under commissioning)
Dehar and Pong Power projects Country’s first Project for which Indigenous Equipment was supplied by M/s BHEL Bhopal
(Hydroelectric Power Station in Operation in India CBI & P Publication No. 288- 2003)

Fig. 4: Typical Small Hydro Projects at Sobla, Kanchauti, Chirkila and Kulagarh - First Small Hydro
Projects by Uttar Pradesh Small Hydro power Corporation

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 Fig 5: Typical Canal Fall Small Hydro Station –Kakroi (World Lowest Head Project)
Undertaken under Indo – US Collaborative Programmes

5.3 Low and Ultra Low Head Small Hydro Projects

Low and ultra low head (below 3 meters) to extract power from existing and proposed irrigation canal
system are specifically discussed. It may be mentioned that 1.6 m head Kakroi Fall project (Figure 5) is one
of the lowest head economically viable project in the world and is in successfully operating. The project
was undertaken under INDO - US Collaborative programmes.

In all these cases changes which could be incorporated due to modern standard and practices are brought
out.

5.4 Micro Hydro Projects

Micro hydro projects are based on a large number of these projects designed in AHEC and Electronic Load
Controller specifically designed for these projects by Pradeep Digitek Pvt. Ltd.

6. Organization of the Book

Major components of a hydroelectric plant for design practices are as follows:

a) Planning for capacity, type and unit size

b) Main generating equipment
c) Control and protection systems
d) Auxiliaries Systems
e) Switchyard equipment and layout

The book is divided into TWO volumes as follows:

VOLUME I: MAIN GENERATING EQUIPMENT AND PLANNING

Overview

Chapter – 1 Type of Hydro Electric Development

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Chapter – 2 Techno-Economic Studies for Capacity and Unit Size of Hydro Electric Schemes
(Reviewed by Dr. S. K. Singal)

Chapter – 3 Hydraulic turbine classification and Selection

Chapter – 4 Turbine, Regulatory Characteristics

Chapter – 5 Turbine performance characteristics (Reviewed by Dr. R. P. Saini)

Chapter – 6 Hydro-turbine governing system

Chapter – 7 Turbine & governor specification

Chapter – 8 Turbine & governor testing (Reviewed by Dr. R. P. Saini)

Chapter – 9 Hydro generator, characteristics and performance

Chapter – 10 Hydro generator excitation systems

Chapter – 11 Generator technical & excitation system specification

Chapter – 12 Hydro generator and excitation system testing

Chapter – 13 Low head small hydro development

Chapter – 14 Recent Trends in Hydro-Electric Engineering Practice

VOLUME II: CONTROL, PROTECTION, AUXILIARY SYSTEMS AND STEP UP

SUBSTATION

Overview

Section – I: Control and Protection Systems

Chapter – 1: General Considerations, Technology Development

Chapter – 2: Control System

• Conventional control
• Modern control of large hydro station
• Modern Control of small hydro stations
• Modern Control of micro hydro

Chapter – 3: Protection System

• Design consideration
• Instrument transformer
• Generator protection
• Generator transformer protection
• Bus bar protection
• Line protection
• EHV Relaying
• Typical specifications for protection system (Small hydro)
• Typical specifications for protection system (Small hydro)

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 Section – II: Auxiliary Systems

Chapter - 4: Electrical Auxiliary System

• General requirements
• Auxiliary power system
• DC system
• Power and control cables and cabling
• Lighting system
• Grounding system
• Communication system

Chapter –5: Mechanical Auxiliary System

• General requirements
• EOT cranes of power house
• Cooling water system
• Drainage and dewatering system
• Compressed air system
• Water level measuring & transmitting devices
• Fire protection system
• Oil purification system
• Ventilation and air conditioning system

Section – III: Step up Substation

Chapter – 6: Generator Transformer

Chapter – 7: H. V. Circuit Breaker

Chapter – 8: Switchyard Equipment

Chapter – 9: Switchyard Layout

Chapter – 10: Design of EHV and UHV Sub-Station

7. Hydro-electric Equipment Manufacturers

List of major Indian Manufacturers (as per Indian Manufacturers) along with their collaborators is given in
table 1.
Table 1
S. No. Manufacturers Collaboration Type
1. BHEL, Hardwar & Bhopal Fuji, Japan Technical
2. Alstom, Baroda Alstom, France JV
3. Boving Fouress, Bangalore Kavernaener Boving now GE JV
UK/ Norway
4. HPP, Delhi HPP France JV
5. Jyoti, Vadodra Gilks, UK (now expired) Turbo Technical
Institute of Slovenia
6. Kirloskar, Pune Ebara Corp, Japan Technical
7. ANDRITZ Hydro Bhopal VA tech, Austria JV
8. Voith Siemens Hydro Pvt. Ltd. Voith Siemens, Germany Technical
9. Steel Industries, Thissur Kossler, Austria Technical
10. Flovel Faridabad Technical
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 References

1. Thapar, O..D. (1979) – “Hydro-Electric and Future Power Energy Systems” Proceedings 3rd world congress
on water resources Maxico; 1979.

2. Alternate Hydro Energy Centre, IIT Roorkee – 2003 – Small Hydro Initiatives and private sector
participation – 3rd edition.

3. www.power.min.nic.in Govt. of India Hydropower Policy 1998, 2005, 2008 and other publications

4. www.bbmb.gov.in – Rénovation, modernisation and upgradtion of hydro plants in Bhakra Beas River
Valley Development – Chairman BBMB.

5. Hydroelectric Power Station in Operation in India CBI & P Publication No. 288- 2003.