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1. SUMMER INTERNSHIP HIRAKUD HYDRO ELECTRIC PROJECT(HHEP) Presented by: Name : Pratyush Tarania Roll no : 2302060032 Internship organization : Odisha Hydro Power Corporation Limited (OHPC), Burla

2. Table Of Contents: Hydro Electric Project Turbines Governing System Generators Excitation System Penstocks Conclusion

3. Hydro Electric Project: Hydroelectric Project: A hydroelectric project generates electricity by harnessing the energy of flowing or falling water. The water is stored in a reservoir or diverted from a river, passed through turbines, and converted into electrical energy. It is a renewable, clean, and reliable source of power. Hirakud Hydroelectric Project: The Hirakud Hydroelectric Project is located on the Mahanadi River in Sambalpur district, Odisha. It is one of the longest earthen dams in the world and was built primarily for flood control, irrigation, and power generation.

4. Construction Chart (OHPC Burla): Date Event January 1957 Civil construction of Hirakud Hydro Electric Project (HHEP) started April 1957 Electrical construction work began 19 April 1962 Unit-5 (37.5 MW) commissioned at Burla Power House 05 August 1963 Unit-6 (37.5 MW) commissioned 13 September 1990 Unit-7 (37.5 MW) commissioned Various (1960s) Units 1–4 (2×24 MW + 2×37.5 MW) constructed and commissioned in stages 14 September 1963 Project inaugurated by Dr. A.N. Khosla 2021–2022 Renovation & Modernization of Units 5 & 6 completed by Voith Hydro Commissioning Details – OHPC Burla (HHEP): Sl. No. Unit Details Commissioning Date Renovation / Modernization 1 37.5 MW Hydro Generating Set (Unit-1) – Make: Boving, UK 1957–1960s (Phase-wise) Original Unit, Retired 2 37.5 MW Hydro Generating Set (Unit-2) – Make: Boving, UK 1957–1960s (Phase-wise) Original Unit, Retired 3 24 MW Hydro Generating Set (Unit-3) – Make: Soviet Union 1960s Functional 4 24 MW Hydro Generating Set (Unit-4) – Make: Soviet Union 1960s Functional 5 37.5 MW Hydro Generating Set (Unit-5) – Make: Voith, Germany 19.04.1962 Renovated by Voith Hydro – Nov 2022 6 37.5 MW Hydro Generating Set (Unit-6) – Make: Voith, Germany 05.08.1963 Renovated by Voith Hydro – Jan 2022 7 37.5 MW Hydro Generating Set (Unit-7) – Make: BHEL 13.09.1990 Operational (Original Configuration)

5. Turbines: Turbines convert the kinetic energy of falling water into mechanical energy. This type of turbine is known as a hydro turbine. Types of Hydro Turbines used in HHEP: Kaplan (# 1,2,5,6,7) Francis (# 3 & 4) Francis Turbine: Uses radial + axial flow , converting water’s pressure and velocity into mechanical energy. Spiral casing, guide vanes, and runner blades control and extract energy. Drives a generator with high efficiency (up to 95%) and adapts to varying loads. Francis turbine: most common hydro reaction turbine, suited for medium head (30–600 m) .

6. Working Principle: Water enters the spiral (scroll) casing . Guide vanes direct flow onto runner blades. Water flows radially inward , then turns axially . Pressure + velocity energy converted to mechanical rotation. Runner shaft drives the generator to produce electricity. Key Features – Francis Turbine Type: Reaction turbine (mixed radial & axial flow). Head Range: 30 – 600 m (medium head). Flow Direction: Water enters radially, exits axially. Efficiency: Very high (up to 95%). Speed: Medium speed range. Blades: Fixed runner blades, adjustable guide vanes. Applications: Most commonly used in large hydro power plants worldwide. Advantages High efficiency (up to 95% ). Suitable for variable load conditions . Handles a wide range of water heads.

7. Working of Kaplan Turbine: Water from penstock enters scroll casing. Guide vanes direct & control water flow. Water turns 90° → flows axially through runner blades. Blades rotate due to reaction force (adjustable for efficiency). Water exits via draft tube, energy converted. Shaft rotation drives generator → electricity production. Kaplan Turbine The Kaplan turbine is a propeller-type water turbine with adjustable blades, developed in 1913 by Austrian professor Viktor Kaplan. It combines adjustable propeller blades with wicket gates to achieve high efficiency across varying flow rates and water levels.

8. Key Features (OHPC, Burla Specific): Evolution:  An improvement over Francis turbines for  low-head, high-flow  applications. Head Range:   30–40 meters  (Hirakud Dam specific). Output:   37.5 MW (Units 1–2) and 24 MW (Units 3–7) . Runner Diameter:   ~4–6 meters  (varies by unit). Rotation Speed:   150–200 rpm  (constant for grid synchronization). Applications:  Widely used in  run-of-river and multi-purpose projects  like Hirakud. Advantages at OHPC, Burla: Efficiency:  Maintains >90% efficiency even at partial loads due to adjustable blades. Flexibility:  Ideal for Hirakud’s variable water flow (flood control + power generation). Low Head Optimization:  Designed for Hirakud’s  moderate head (30–40 m) .

9. Governing System: Governing system or governor is the main controller of the hydraulic turbine. The governor varies the water flow through the turbine to control its speed or power output. Theory of Operation: Hydraulic turbines are coupled with generators . Generators must run at constant speed for stable power output. Load changes affect turbine speed: No load → speed increases. Overload → speed decreases. To maintain constant speed, water flow to runner is controlled . This regulation of speed = Governing . Governing is done automatically by a governor . Main Functions of the Governing System control of the turbine start-up and shutdown sequences. synchronization of the turbine with the grid. control of the active power supplied by the generator to an interconnected network.

10. Generators: The generator transforms the mechanical energy into electricity. In hydropower plants, this combination of generator and turbine is called a generating unit.   Theory of working : Water flows through penstock → scroll case → turbine blades . Water exits via draft tube , converting energy. Turbine shaft transmits mechanical energy to generator. Generator parts: Rotor (moving part) – carries electromagnets. Stator (fixed part) – has copper windings. Rotor rotates inside stator → electrons in windings move. This motion induces electric current (electricity generation) . No. of Units 7 (Seven) Type #1,2 – Semi Umbrella #3,4 – Suspended #5,6,7 – Umbrella Make #1,2 – GEPIL #3,4 – Voith Siemens #5,6 – Voith Hydro #7 – Hitachi Voltage 11 KV Current #1,2 – 3149 A #3,4 – 1877 A #5,6 – 2546 A #7 – 2187 A Power Factor 0.9   Generator Details – HHEP

11. Excitation System: The rotor or the field coils in a generator produce the magnetic flux that is essential to the production of the electric power. The rotor is a rotating electromagnet that requires a DC (Direct Current) electric power source to excite the magnetic field. This power comes from an exciter . Working Representation:

12. Excitation Systems: DC Exciter Small DC generator coupled to rotor shaft. Supplies DC to rotor via slip rings. Field current adjusted to control voltage output. Static Exciter Uses generator’s own output (AC → DC via thyristors). Feeds rotor through slip rings. Needs battery bank for startup. Low maintenance, good voltage regulation. Brushless Exciter Exciter armature on same shaft as rotor. DC fed via rotating rectifiers (no slip rings). No sparking, low maintenance, high reliability.

13. Penstock Penstocks are pipes or long channels that carry  water  down from the hydroelectric  reservoir  to the  turbines  inside the actual  power station .    Control of Penstock Penstocks are steel pipes that carry high-pressure water to turbines. They are a vital link between the reservoir and the power house. Grates/filters are placed at the inlet to trap debris (branches, waste). Water flow is controlled using a sluice gate : Fully open → maximum water flows to turbine. Partially closed → restricts water flow as required. Flow regulation helps ensure safe, efficient turbine operation . Importance of Penstock Controls water flow to turbines, ensuring stable operation. Regulates seasonal flow : Dry season → kept wide open to allow sufficient water. Wet season → partially closed to prevent flooding. Containment ponds at inlet store excess water and reduce pressure.

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