Report on Capital Maintenance of

Unit No. 1 of 2x11.25MW Ganvi

Power House Stage 1 under Ganvi
Power House Division, HPSEBL,
Jeori.

BRIEF OUTLINE OF GANVI POWER HOUSE STAGE 1

(2x11.25MW)
 Ganvi Power House Stage 1 is situated on right Bank of River Satluj, just opposite
Jeori Town of Shimla district of Himachal Pradesh. The power house has two units of 11.25MW
capacity each. The power house is a run of the river type built on Ganvi stream, a tributary of river
Satluj. A maximum discharge of 8.50 cumecs has been diverted from Ganvi stream, through a drop
type trench weir. After separation of shingle via the shingle flushing gate, water is carried to de-
silting tank and then to Forebay through an open power channel. A single penstock has been
provided to carry water to house which bifurcates into two branches just near the power hose and
run to vertical shaft Pelton wheel generating units. The catchments area of Ganvi upstream of trench
weir is 111.30 km2. Out of which 8 km2 remains covered with snow for most part of year. The
design energy of this power house is 93.34 MU during 90 % dependable year with a PLF of 47.36
%

22.50 MW (2x11.25 MW) power house has been commissioned during the month of
December, 2000. The power house has been in operation for the last 21 years. The OEM of power
house is BHEL which has designed, manufactured and erected the generator, Excitation System,
Governor, MIV etc.

SALIENT FEATURES OF THE POWER HOUSE

1 LOCATION
State Himachal Pradesh
District Shimla
River/Khad Ganvi stream(Tributary of river Satluj)
Power House On left bank of Ganvi stream
2 HYDROLOGY
a) at Diversion site:111.30 sq.km
b) at Discharge site: 90% available
c)Discharge at diversion site:116.50 sq.km
Catchment area
d)Design discharge i/c requirement:10.42 cumecs for
flushing out shingle & sediments
Design Flood:413 cumecs
3 INTAKE WORKS
Trench Weir type Drop type trench weir
Trash Rack To prevent entry of boulders and trash
4 WATER CONDUCTOR SYSTEM
A) R.C.C Box Length 7.623 m
width 2.0 m
slope 1.4
 B)Intake tunnel 142.893 m long
Length and Size 2.35m D-shaped
Design Discharge 8.50 cumecs i/c flushing discharge

C) Power Channel
Length and size 97.13 m long
2.35x2.35(part of channel covered with cement concrete
sleeper)
Design discharge 8.50 cumecs i/c flushing discharge

D) Desilting Tank
Vortex tube type having two chambers 87.00 long,6.00 m
Type and size
wide
Length of transitions 15.00 m each
Design discharge 8.50 cumecs i/c flushing discharge

E) Power channel d/s of

Length=1104.50m, Size=2.1mx2.1m Design
desilting tank i/c spill
Discharge=7.25 cumecs
weir

F) Forebay Tunnel Length=373.327m, Design Discharge=7.25 cumecs

G)Forebay Length=16.45 m
5 PENSTOCK
Number One(Bifurcated near Power House)
Type Steel Penstock
Dia Main 1400 mm
Dia Branches 1000 mm
Length 698.746 m(i/c two branches)
Plate Thickness 8mm to 30 mm
Design discharge 7.25 cumecs
6 POWER HOUSE
Type Underground Power House
 Size 77.50mx11.0m
Installed Capacity 22.5 MW
Gross Head 385 m
Net Head 375 m
Type of turbines Vertical axis, Pelton
7 POWER POTENTIAL
90% dependable year=93.34MU
Energy Generation
50% dependable year=124.12MU
8 TAIL RACE TUNNEL
3.30x4.35m D-shaped varying in heigths
Size & Shape
Length=108.317m

BRIEF DETAILS
During the Annual Maintenance of Unit No. 1, groove formation was observed on the surface of the
Turbine Guide Bearing (TGB) Journal of the Turbine Shaft of the machine. Accordingly, this office
hired the services of the expert for assistance in the problem of TGB Journal and alignment and
balancing works of Unit No. 1. Best efforts were made at the power house site to attend the problem
of TGB Journal in the best possible way and the annual maintenance of the Unit No. 1 was
completed by 15.04.2023. The works done during the annual maintenance are more or less
sufficient to run the machine for this peak season. However, in order to run the machine smoothly
for the time to come, it is important that the grooves in TGB Journal be machined at appropriate
factory/works.

Previously, 01 No. Spare turbine shaft was procured from the OEM i.e. M/s BHEL Haridwar and
the same was installed in Unit No. 2 in the year 2017. The Turbine Shaft thus dismantled from Unit
No. 2 is kept at service bay of the power house. This shaft has not been repaired and is required to
repaired at the earliest.

In order to rectify the problem in TGB Journal of the Turbine Shaft of the Unit No. 1, the turbine
shaft of Unit No. 1 needs to be dismantled and replaced with the turbine shaft dismantled from Unit
No. 2. However, this dismantled from the Unit No. 2 is also required to be repaired first.
The dismantling of the turbine shaft is lengthy and complex procedure and involves dismantling of
the Upper Guide Bearing (UGB) Journal Housing, Complete Rotor Assembly and generator shaft.
The dismantling of the rotor, UGB Housing provides an opportunity to perform the capital
maintenance of Unit No. 1. Capital Maintenance of Unit No. 1 was done in the year ………

DETAILS OF WORKS PROPOSED DURING THE CAPITAL

MAINTENANCE OF UNIT NO. 1
Following is the list of the works proposed to be carried out during the Capital Maintenance of Unit
No. 1.
• Repair of the damaged turbine shaft replaced in Unit no. 2 in 2017.
• Dismantling of the UGB Housing, Rotor, Thrust Block and Turbine Shaft of Unit no. 1.
• Repair of the damaged turbine shaft dismantled from Unit No. 1.
• Cleaning and Red Gel application on the stator and stator and Complete painting of the machine.
• Machining of the Thrust Block, Thrust Runner and Textolite Insulation to improve the surface
contact.
• Hiring of the expert for supervision of the repair works of the Turbine Shaft and Thrust Runner.
• Re-babbitting/Re-metaling of the Thrust Pads, Turbine Guide Bearing Pads with more than 85%
Tin Based Alloy white metal.
• Fabrication of Textolite Ring for UGB, LGB and TGB Housing
• Repair/Overhauling of the MIV, By-Pass Valve, De-Compression Valve, Seal Valve and
replacement of all seals of the MIV.
• Modification of TGB Cooling pipeline to allow easy dismantling and online replacement of TGB
coolers.
• Procurement of complete set of TGB Coolers
• Cleaning of carbon deposits from UGB coolers and De-Scaling of all coolers (UGB, LGB, TGB
and Stator Coolers) by chemical treatment.
• Overhauling of the braking and jacking system.
• Procurement of Turbine Generator Coupling Nut - Bolt set.
• Replacement of Nozzle liners and Nozzle Liner Holding assembly and Replacement of Cams and
Cam-Conjugation of Unit No. 1.
• Replacement of Penstock of Distributor Drain Valve.
• Repair of the CGL system by providing pipes in the turbine pit.
• Sand Blasting, cleaning and painting/epoxy-coating of the turbine pit.
• Repair of the damaged bottom cone/labyrinth and Nut-Guard.
• Repair of the labyrinth holding ring in the turbine pit.
• Replacement of the Guide Bearing Housing Oil level Indicator and Transmitter.
• Repair of the turbine shaft dismantled from Unit No. 1.
• Hiring of expert for Installation of Turbine Shaft, Rotor, UGB Housing and thereafter for
reassembly, alignment and balancing of the Unit.
• Hiring of expert for paralleling and tuning of the DVR and Governor cards of Unit No. 1
• Procurement of Consumables and T&P for the dismantling and reassembly job of Unit No. 1.