SUCCESS STORY ON R, M & U WORKS OF UMIAM STAGE II HEPP,

Meghalaya Power Generation Corporation Limited, UMSUMER

Umiam Stage II Hydroelectric Power Plant is located at Umsumer in Meghalaya State of India, which is 36-km from Shillong, the capital of the State. The project site is at an elevation of 729-meters above mean sea level at around latitude 25.6 N, longitude 91.5E and is surrounded by hills. The maximum ambient temperature experienced has been 32.5C and the minimum temperature has been 5C outdoors and 9C indoors, respectively. MeECL has been controlling following five hydro electric power plants in the Umiam-Umtru river basin. (a) Umiam Stage I Hydroelectric Power Plant, (4 x 9 MW) Commissioned in 1965 (b) Umiam Stage II Hydroelectric Power Plant, (2 x 9 MW) Commissioned in 1970 (c) Umiam Stage III Hydroelectric Power Plant, (2 x 30 MW) Commissioned in 1980 (d) Umiam Stage IV Hydroelectric Power Plant, (2 x 30 MW) Commissioned in 1992 (e) Umtru Hydroelectric Power Plant (4 x 2.8 MW), Commissioned in 1957 & 1970 The total installed capacity of the system in the basin is 185.2 MW.

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Fig. 1 The Umiam Stage II Hydroelectric Power Plant was commissioned in 1970. Both the hydro turbines and generators of the power plant were manufactured by Toshiba Corporation, Japan. After operation of approximately 40 years, some problems have occurred on the generating units. Because of the importance of Umiam Stage II Hydroelectric Power Plant for coordinated economic operation of the above mentioned Power Stations of MeECL located at the downstream cannot be ignored in the context of draw down water from Umiam reservoir for running the downstream power stations. If this power station ceases to operate, all other stations will starve because of a cascade generation system. As such, Renovation of Umiam Stage II Hydroelectric Power Plant was necessitated. In the month of May 2003, Meghalaya State Electricity Board (MeSEB), now Meghalaya Energy Corporation Limited (MeECL) approached Japan Bank for International Cooperation (JBIC) for financial assistance for the complete R&M works of the Umiam Stage-II Power Plant. In response, the JBIC arranged the technical team TERI (The Energy & Resource Institute) to conduct a survey about the machine condition for R&M. Soon after, JBIC entrusted a consultant firm, TEPSCO (Tokyo Electric Power Services Company, Japan) which carried out a feasibility study under the team (SAPROF) Special Assistance for Project Formation) after which a report was submitted on September 2003. The report recommended for the renovation and modernization work on the generating Units for Umiam Stage-II Power Plant including 132 kV Switchyard Equipments and Generator Transformers. In 2005, Joint Venture of Tokyo Electric Power Services Company (TEPSCO) Limited and the Tokyo Electric Power Company (TEPCO) signed contract for the consultancy services for the RM&U works of Umiam Stage-II HEPP with MeECL. In 2009, after the bidding, MeECL contracted RM&U works for the project with the following company on December 4, 2009: Toshiba Corporation, Japan (Toshiba) (for design & supply of hydro turbine, generator & control/protection system). Toshiba Plant System Corporation, India (TPSC) (for design & supply of BOP and installation & commissioning works). Toshiba Technical Services International Corporation, Japan (TTSI) (for dispatching installation & pre-commissioning technical supervisors).

The work for Renovation and Modernisation started in May 2011 with the disassembling, replacement and repair works for the existing equipment/parts and continued until October 2011. Later, pre-commissioning test and commissioning tests were performed by the contractors. The project was finally commissioned on January 6, 2012 (25 monthly form the commencement date of the contract). The following were the major works carried out.

1.1.Hydraulic Turbine 1.1.1. General

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Prior to R,M and U work the turbine in Umiam Stage II HEPP had a capability of unit output of 10.5MW. However, the turbine could not output 10.5MW due to the limitation of the generator capacity of 10.6MVA with a power factor of 0.85. The project had the total capacity of 2 x 9MW only since the original commissioning. In this R, M & U Works, in order to enable the turbine to output 10.5MW, the generator is designed to have as capacity of 12MVA with a power factor of 0.9. The major parts of turbine except the existing turbine shaft, guide vanes and embedded parts (draft tube liner, stay ring, bottom ring) are replaced with the new ones based on the latest design. The main inlet valves, governor system and the related mechanical equipment also are replaced with the new ones. 1.1.2. Hydraulic Turbine 1.1.2.1. Type and Rating (1) Number installed (2) Type of Turbine (3) Elevation a) Reservoir water level - Maximum - Minimum b) Tail water level - Maximum - Minimum c) Centerline of turbine distributer (4) Net Head - Maximum - Design - Minimum (5) Turbine Output - at Maximum net head - at Design net head - at Minimum net head (6) Rated Turbine Discharge (7) Rated Speed 1.1.3. Pressure Relief Valve (PRV) All reused parts of Pressure Relief Valve such as the valve body, cylinder, cylinder cover, valve, piston were repaired and/or machined in shop and the embedded part (lower body) were repaired at site. All other parts for PRV were replaced with the new ones and self-lubricated bearings were applied to all bearing portions for PRV. 1.1.4. Governor System including Oil Pressure & Compressed Air Supply Systems (1) Type and Rating
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: Two (2) : Vertical Shaft Francis Type

: EL. 804.02 m (2,638 ft.) : EL. 801.58 m (2,630 ft.)

: EL. 725.08 m (2,379 ft.) : EL. 722.34 m (2,370 ft.) : EL. 722.16 m

: 78.50 m : 77.67 m : 75.00 m

: 10,500 kW : 10,500 kW : 9,980 kW : 15.47 m3/s (per unit) : 428.5 min-1

a) Number of Governor b) Type of Governor

: Two (2) : Digital PID electro-hydraulic type

(2) System Description The existing governor actuators were replaced with the latest designed ones, and oil pumping sets and oil pressure tanks, air compressors, air tank, oil & air piping, electrical cables and their accessories were replaced with the new ones except the existing oil sump tanks. The existing governor regulators were removed. In the Contractors governor design, the governor regulator functions were accommodated in the unit control cubicle. The oil pressure supply system for each unit is commonly used for operation of the guide vane, PRV and MIV. The oil pumps and air compressors for the system are automatically controlled by the new Motor Control Center (MCC), which was installed on the Generator Floor. Compressed Air Supply System: The Compressed air supply system is commonly used for generator brake operation, governor system of both units.

1.1.5.

MIV and By-pass Valve

(1) Type and Rating a) Number of MIV b) Type of MIV c) Nominal diameter d) Maximum flow e) Operation of MIV (2) Description of MIV The existing MIVs were removed and the new MIVs were designed, manufactured by FOURESS ENGINEERING (INDIA) LIMITED. Each new MIV is operated by two (2) oil operated servomotors mounted on the top of MIV. The oil pressure of MIV servomotors is supplied from the oil pressure supply system commonly used for the governor & MIV. 1.1.6. Cooling Water Supply System & Drainage/Dewatering System (1) System Description The existing equipment, parts, devices and piping (excluding embedded piping) for the cooling water supply system and drainage/dewatering system were removed and all new system were installed. Cooling water for the generating units is taken from the penstock and cooling water is filtered through the strainer mounted on the line between the penstock and water head tank and, after that, cooling water is filtered again through the strainer mounted on the line between the head tank. The automatic water strainers and their sand discharge valves are controlled by the new Motor Control Center (MCC) with detecting a differential pressure between the outlet and inlet of strainer and/or timer. The drainage pumps for the
SUCCESS STORY ON R, M & U WORKS OF UMIAM STAGE II HEPP Page 4 of 37

: Two (2) : Thru-flow type : 1,700 mm : 15.47 m3/s :Oil pressure (2 servomotors for each MIV)

drainage/dewatering system are controlled by the new Motor Control Center (MCC) with detecting the water level in the drainage pit. (2) Construction of Cooling Water Supply System a) b) Water head tank (existing one) Automatic motor-operated water strainer - between the penstock and water head tank - between the water head tank and generating unit c) d) 3) Shaft seal strainer Automatic motor-operated valve : Two (2) : Two (2) : Two (2) : Two (2) : One (1)

Construction of Drainage/dewatering System a) b) Drainage pump (submergible type) Water level switch (float type) : Two (2) : One (1)

1.1.7.

Motor Control Center (MCC) The new Motor Control Center (MCC) is installed on the Generator floor. The MCC controls the following auxiliary equipment of the generating units. (1) Oil Pumps for Governor System

Two (2) oil pumps (one for normal use and other for stand-by) for each unit are installed on the turbine floor. The oil pumps are controlled by detecting oil pressures and oil levels in the oil pressure tank. (2) Generator Space Heaters

Three (3) Generator Space Heaters were installed in the generator air housing and they are controlled by detecting temperature inside the generator air housing. (3) Air Compressors for Compressed Air Supply System

Two (2) oil pumps (one for normal use and other for stand-by) for each unit are installed on the turbine floor. The oil pumps are controlled by detecting oil pressures in the oil pressure tank. (4) Drainage Pumps for Drainage/Dewatering System

Two (2) submergible drainage pumps are installed in the drainage pit. The drainage pumps are controlled by detecting water levels in the drainage pit. (5) Automatic Motor-operated Water Strainers and Sand Discharge Valve

Two (2) automatic strainers (one for normal use and other for stand-by) is installed on the line between the penstock and water head tank and other two (2) automatic strainers (one for normal use and other for stand-by) are installed on the line between the water head tank and generating units. The automatic strainers are controlled by detecting a differential pressure between the inlet & outlet of strainer and/or timer. Each strainer is equipped with an automatic sand discharge valve and water after filtering in the strainer is discharged to the tailrace through the sand discharge valve. (6) Automatic Motor-operated Valves

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Two (2) automatic valves (inlet from the penstock to water head tank and outlet from the water head tank to the generating units) are installed on the line of cooling water supply system. The automatic valves are opened before starting the generating unit and closed after stopping the generating unit. 1.2.Generator 1.2.1. General The existing generator in Umiam Stage II HEPP with capacity of 10.6MVA at a power factor of 0.85 (lagging) was upgraded to a capacity of 12MVA at power factor of 0.9 (lagging) so that turbine could deliver maximum output of 10.5MW in this R, M & U Works. The major parts of generator except the existing generator main shaft, rotor rim, stator frame, bearing brackets, and base block for stator, are replaced with the new ones based on the latest design. The air cooler, oil cooler, excitation system and the related mechanical and electrical equipment also are replaced with the new ones.

1.2.2.

Generator 1.2.2.1. Type and Rating (1) Number installed (2) Type of generator : Two (2) : Vertical shaft, Francis Turbine driven, and alternating current synchronous generator (3) Rated output (4) Rated power factor (5) Rated frequency (6) No. of phases (7) Rated voltage (8) Rated speed (9) Direction of rotation (10) Runaway speed (12) Stator winding connection (15) Maximum cooling water temperature (16) The value of I2 t capacity of the generator (17) Required flywheel effect (18) Excitation system Excitation ceiling voltage : 110 % : 0.06 sec-1
2

: 12.0 MVA : 0.9 lagging : 50 Hz : Three (3) : 11.0 kV : 428.5 min-1 : Clockwise viewed from top : 780 min-1 : Star (Y) : 25 : not less than 20 : not less than 123 t-m2

Ratio of ceiling voltage to rated excitation voltage : 211.8 % Excitation system nominal response

(19) Type and Cooling method - Type of generator -Cooling method 1.3. Excitation System
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: Suspended Type : By air

1.3.1.

Type and Rating : IEC

(1) Applied standard (2) Ratings of excitation system a) Type of excitation system b) Rated capacity c) Rated voltage d) Rated speed of AC exciter and rotating rectifier e) Rated frequency - Input and output of excitation transformer - Output of AC exciter (3) Parameters and performances of excitation system a) Ceiling voltage b) Ratio of ceiling voltage to rated excitation voltage

: Brushless excitation system : 69.5 kW : 151 V : 428.5 min-1

: 42.9 Hz : 42.9 Hz

: 225 V : 200 % : 6 A 15 sec.

c) Flashing current and duration period for excitation system d) Voltage setting range - for AVR setter (90R) - for Manual voltage setter (70E) e) Excitation system nominal response f) Excitation system voltage response time g) Excitation control accuracy h) Maximum generator voltage rise at full load rejection i) Power frequency withstand voltage for 1 minute - Circuits electrically connected with generator rotor winding - Circuits not connected with generator rotor winding - Control and detection circuits (4) AC exciter a) Type b) Number of poles c) Rating of AC exciter - Rated capacity - Rated voltage - Rated speed - Rated frequency - Insulation class (armature and field winding) - Temperature rise (armature and field winding) - Power frequency withstand voltage for 1 minute Fig. 2 Outline of AC Excitation System. measurement during site commissioning test.
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: 80 % - 110% rated voltage : 30 % - 110% rated voltage : less than 0.06 sec-1 : less than 1.0 sec :2% : 30 % rated voltage

: 1500 V : 1500 V : 1500 V

: Three phase, rotating armature type : 12

: 74 kVA : 114 V : 428.5 min-1 : 42.9Hz : Class F : 80 K : 2 kV

Existing DC exciter was completely replaced by brushless AC excitation system as shown in In the drawing collector ring is for resistance

Fig. 2 Outline of AC Excitation System

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1.4. Main Transformer 1.4.1. General The existing main transformers in Umiam Stage II HEPP were replaced by new main transformer with rating of 3-phase step-up oil immersed with external heat exchangers suitable for outdoor services in the climate conditions at site as given in Special Conditions of Contract, and ONAF rating , and ONAN rating when the transformer is operated with the power less than 80 % of the rated capacity. 1.4.2. Main transformer 1.4.2.1. Type and Rating (1) Number installed (2) Type of transformer : Two (2) : Three (3) phase, outdoor, two (2) winding, natural-air-cooled, step-up,

oil-immersed-type, generator transformer (3) Ratings a) Operating duty b) Rated capacity - High-voltage winding : 9600/12000 kVA (ONAN/ONAF) - Low voltage winding : 9600/12000 kVA (ONAN/ONAF) c) Rated frequency d) Rated voltage - High-voltage winding - Low voltage winding f) Tapped winding capacity i) Maximum temperature rise - Windings (Resistance method) - Top oil (Thermometer) j) Connection of windings - High voltage side - Low voltage side - Phase displacement (4) Temperature rises at rated operating conditions Windings (average) Oil (top) : 55 K : 50 K : 70 : 70 : 70 : Grounded Y : Delta : YNd11 : 55 K : 50 K : 132 kV : 11 kV : 12,000 kVA : 50 Hz : Continuous

(5) Temperature at rated operating conditions Thrust bearing Upper guide bearing Lower guide bearing

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1.4.2.2. Technical Data of Main Transformer (1) Applied standard (2) Type and cooling method - Type of main transformer - Cooling method of main transformer (3) Ratings a) Operating duty b) Number of phases c) Rated capacity - High voltage winding - Low voltage winding d) Rated frequency e) Rated voltage - High voltage winding - Low voltage winding f) Connection and phase displacement : 132 kV : 11 kV : YNd11 : 12,000 kVA : 12,000 kVA : 50 Hz : Continuous :3 : 3-phase oil immersed outdoor type : ONAN/ONAF : IS 2026

1.5.

11 KV Metal-enclosed Switchgear and Service Transformers 1.5.1. General 11kV Metal Enclosed Switchgears are composed of 11kV Generator incoming cubicle, 11kV Link cubicle, 11kV VCB cubicle, 11kV Station service transformer cubicle and NGR cubicle. The existing 11kV Metal Enclosed Switchgears and Service Transformers were replaced with new ones. New 11kV Metal Enclosed Switchgears and Service Transformers were manufactured by C&S EFACEC MV INDIA PVT.LTD in India. The 11kV Metal Enclosed Switchgears were transported inland with all accessories including supporting structures, spares, and all other equipment making the 11kV system.

1.6. Station Power Supply Facilities 1.6.1. General Station Power Supply Facilities are composed of Battery, Battery Charger, AC & DC power supply boards. The existing Station Power Supply Facilities were replaced with new ones. Battery, Battery Charger, DC power supply board were manufactured by Statcon Power Controls Ltd. in India. AC power supply boards were manufactured by Larsen & Toubro Limited. The Station Power Supply Facilities were transported inland with all accessories including supporting structures, spares, and all other equipment making the Station Power Supply Facilities.

1.7. Control and Protection Boards 1.7.1. General

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The existing generator-transformer boards were replaced with new designed Control and Protection boards. Control and Protection Boards are composed of two Unit Control Board, one 132kV Switchyard Control Board and Recording Board. The Control and Protection Boards are integrated type. Unit Control Board has sequence controller, automatic synchronizer and HMI (Human Machine Interface). Each unit can connect in parallel with power system automatically by using automatic synchronizer. The Control and Protection Boards were manufactured by Toshiba in Japan. The Control and Protection Boards were transported from Japan with all accessories including supporting structures, spares, and all other equipment making the Control and Protection Boards. 1.7.2. Unit Control Boards (1) Components in board a) HMI b) Meters c) Status indicators d) Fault indicators e) Control switches f) Mimic bus

g) Test terminals h) Protection relays for Turbine and Generator A compact list of the items replaced or repaired during the Renovation is given in Annexure I. and photos showing before and after R&M is given in Annexure II.

Pre-commissioning Tests. Prior to commissioning of the Units in January 2012, all tests as per contract were performed. Besides other tests, Generator Efficiency Test were performed on Unit #2 and Turbine Index Tests for comparison/confirmation with CFD analysis were performed on both Unit #1 and Unit #2.

Final Acceptance Tests All the tests for final acceptance as per contract were performed in for 10th December up to 5th December 2012. The tests include the following: 1. PRV operation check of Unit #1. 2. Load Rejection Test of both Unit #1 and Unit #2. 3. Output Test of both Unit #1 and Unit #2. 4. Heat Run of both Unit #1 and Unit #2.

The following excerpt from the IEEMA Journal Volume 3-No.9. May 2012, page 112 During the Annual review meeting held in CEA during March-April 2012 with various utilities, 4 schemes
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which were earlier scheduled to be completed during XI plan have been shifted to XII plan. However, R&M of one scheme namely Umiam Stage II (2X9 MW) of MeECL which was scheduled for XII plan, was completed in 2011- 12, Thus, during XII Plan a total of 43 hydro R&M schemes (5 in Central Sector and 38 in State Sector) having an installed capacity of about 6663 MW at an estimated cost of about Rs. 4433 Crs. which will accrue benefit of about 3773 MW through uprating, life extension and restoration are planned for implementation. One scheme of MeECL namely Umiam St. III (Kyrdemkulai) shall be taken up in XII plan and will accrue benefit of 66 MW (6 MW uprating & 60 MW-LE) during plan

A comparison of Energy generated of Umiam Stage II with reference to Umiam Stage I, before and after RM&U of the station is given below:

Generation of Stage I and Stage II in KWH for the last five years before RM&U of Stage II Year Stage I (a) 61642800 150633800 107800680 110320850 103803640 Stage II (b) 27660080 67267000 48667500 51176900 47519700 % Generation of Stage II w.r.t. Stage I (b/a)x100 44.87% 44.66% 45.15% 46.39% 45.78% 45.37% Average

2006-2007 2007-2008 2008-2009 2009-2010 2010-2011

Month Feb 2012 to Jan 2013

Generation of Stage I and Stage II in KWH After RM&U of Stage II Stage I Stage II Average % Generation of Stage II w.r.t. Stage I (a) (b) (b/a)x100 99022800 48251300 49.57%

As a result of the R,M&U works on the Umiam Stage-II HEPP, it is observed that the percentage generation of Umiam Stage-II with respect to Umiam Stage-I Power Station, shows an upliftment by about 4.20 % as compared to the generation before the R,M&U work.

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ANNEXURE- I The outline of R, M & U Works done for Umiam Stage II HEPP is described in table below.

Table 2.1-1 Works done for Equipment and Parts

R: Replacement item with new one O: Overhauling and repairing item X: Removal

Items
1. Mechanical Equipment (1) Turbine and Its Auxiliary

Unit 1

Unit 2

Descriptions

The runners were replaced with the newly designed a) Runner R R ones made of 13Cr-high Ni stainless steel material based on CFD analysis. b) Spiral case & stay ring O O The hydraulic surfaces of spiral case and stay ring were cleaned, repaired and painted. The hydraulic surfaces of guide vanes were cleaned c) Guide vanes O O and painted for both units. The spindles of guide vane were machined in shop for applying self-lubricated bearing. The head covers were replaced with the newly designed ones having self-lubricated bearing and d) Head cover R R separated construction from the bearing housing in consideration of ease of maintenance for the shaft seal and applying the new type (segment type) guide bearing. The guide vane bearing portions of bottom ring for e) Bottom ring O O both units were bored/machined at site for applying self-lubricated bearing. f) Facing plates and wearing rings R R The facing plates and wearing rings on the head cover and bottom ring were replaced with the new ones. The guide vane servomotors were replaced with the Guide vane servomotors and gate operating mechanism new ones excluding the cylinders and cylinder covers. R R The gate operating mechanisms including guide ring were replaced with the newly designed ones having self-lubricated bushings. The guide bearing and the bearing housing were h) Guide bearing, cooler and R R replaced with the newly designed ones (Guide bearing: segment type/Housing: separated construction from head cover). The shaft seals were replaced with new designed one i) Shaft seal and sealing box R R (Carbon seal type) and also the sealing boxes were replaced with the newly designed ones.

g)

bearing housing

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j)

Upper draft tube and draft tube liner

The air injection pipes were replaced with the new ones O O and the inner surfaces of upper draft tube liner were repaired and painted. MIVs with its servomotors were replaced with the R R newly designed thru-flow type MIV with servomotor. Each MIV has two (2) servomotors. R R The by-pass valves were replaced with the newly designed ones. The PRVs were overhauled. The existing parts for applying self-lubricated bushings were machined in

k)

Thru-flow type inlet valve and its servomotor

l)

By-pass valve

m)

Pressure relief valve (PRV)

shop and some parts were replaced with the new ones. The PRV liners were repaired and especially the outlets of liners were patched with steel liners.

Items Drain valves and pipes for n) spiral case, draft tube and penstock Instruments, and piping devices, cables

Unit 1

Unit 2

Descriptions The drain valves and pipes for spiral case, draft tube and penstock were replaced with the new ones. All existing instruments, device, cables and pipes

o)

except the embedded pipes were replaced with the new ones.

(2) Governor and Turbine Control System a) b) c) d) Governor actuator Governor regulator Turbine control panel Speed Signal Generator (SSG) R R R R R R R R The governor systems were replaced with the new type governor system with the latest technology, which is the digital PID electro-hydraulic type governor. The governor regulator functions were accommodated in the Main Control Boards.

(3) Oil Pressure Supply System a) Oil pump with motor R R The oil pumps with motors were replaced with the new ones and the oil pump motors are controlled by Motor b) Oil pressure tank, oil piping and valves Control Center (MCC). All oil pressure tanks with R R accessories, oil pipes and valves were replaced with the new ones. (4) Air Compressed Supply System Two (2) sets of air compressor with motor were a) Air compressor with motor R replaced with the new ones and the motors are controlled by Motor Control Center (MCC). (5) Cooling Water Supply System a) Water head tank O The water head tank were cleaned and repaired.

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The exposed pipes and valves were replaced with the new ones. The strainers were replaced with a motor operated automatic strainer controlled by Motor Control Center (MCC). Four (4) sets of automatic b) Water piping and valves R R strainers were supplied for the cooling water supply system. Two (2) strainers were installed on the line between the penstock and the water head tank and others were on the line between the water head tank and the generating units. The water flow relays were replaced with the new c) Water flow relays R R magnetic flow meters installed at drainage side of bearing coolers & generator air coolers (6) Dewatering & Drainage System a) Submersible water pump with motor Water level switches with R Two (2) submersible pumps were installed for dewatering and drainage and their operation is R R controlled automatically by Motor Control Center (MCC) through detecting the water level.

b) c)

accessories Necessary piping and valves

(7) Auxiliary Machine Control a) b) Motor Control Center (MCC) Necessary wiring and cables R R R R Including auxiliary control

(8) Water Depression System a) (9) All devices, equipment, pipes and valves Items for Mechanical X X All existing devices, equipment, pipes and valves for the system were removed.

Other

Equipment Level monitoring devices for intake & tailrace water level Spare parts and special tools The float type level monitoring devices were installed R R on the intake and tailrace and all level data is transmitted to the powerhouse. R

a)

b)

R: Replacement item with new one

O: Overhauling and repairing item X: Removal

Items
2. Electrical Equipment (1) Generator and Its Auxiliary a) b) c) Stator core Stator winding with accessories Stator winding main and neutral leads Rotor winding and excitation leads Rotor pole piece with damper winding

Unit 1

Unit 2

Descriptions

R R R

R R R

The stator core and the stator winding were replaced with new ones for both units. The existing stator frame was reused because it is fixed on the concrete foundation. The following parts were replaced with new ones: a) Rotor winding and excitation leads for both units b) Rotor pole pieces with damper winding for both

d)

e)

units

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R: Replacement item with new one

O: Overhauling and repairing item X: Removal

Items

Unit 1

Unit 2

Descriptions

The brake ring was replaced with new one for both Brake ring & brake /jack system units. R R All the brakes and jacks were replaced with double cylinder type brake/jack system that used as brake by compressed air injection and as jack by pressurized oil for both units. g) Upper bearing bracket O O The upper bearing bracket was overhauled for both units. The thrust bearings were replaced with new ones for both units. The guide bearings were replaced with segment type R R bearings and the oil coolers were also replaced with new one for both units. O O The lower bearing bracket was overhauled for both units. The guide bearings were replaced with segment type R R bearings and the oil coolers were also replaced with new one for both units. X X The collector ring was removed because of application of brush-less type excitation system The brush and brush holder were removed because of application of brush-less type excitation system All air coolers for both units were replaced with vertical flow type air coolers.

f)

h)

Thrust bearing pads

i)

Segment

type

upper

guide

bearing and oil cooler

j)

Lower bearing bracket

k)

Segment

type

lower

guide

bearing and oil cooler

l)

Collector ring

m)

Brush and brush holder

n) o) p) q) r) s)

Air coolers Pipes and valves Instruments and relays Operation lamp Generator housing Terminal boxes

R R R R O R

R R R R O R

Painting For instrument, control & alarm cables

(2) Excitation System a) b) c) Brush-less type AC exciter Rotating rectifier Protection relays for brush-less exciter Automatic voltage regulator R R R R R R The existing exciters were replaced with brush-less type excitation system for both units.

d)

and excitation cubicle Epoxy resin molded self-cooled

e)

excitation transformer equipped with thermometer with alarm contacts and adjustable wheels

(3) Main Control Boards

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R: Replacement item with new one

O: Overhauling and repairing item X: Removal

Items
a) b) Main control board Automatic control, recorder and protection relay boards

Unit 1
R

Unit 2
R

Descriptions
The generator-transformer panels for both units were replaced with new designed ones. New main control boards have sequence controller,

automatic synchronizer and HMI (Human Machine Interface).

c)

Supervisory control boards

The supervisory control panel was removed, because it was not used. The 132kV control boards were replaced with new ones. The synchronizer & synchro-scope were replaced with new ones.

d)

132kV control boards

e)

Synchronizer & Synchroscope

(4) 11kV Metal-Enclosed Cubicles 11kV Metal-enclosed cubicles with accessories The existing 11kV cubicles were replaced with new R R designed 11kV cubicle equipped with vacuum circuit breakers for generators.

a)

(5) Main Transformer a) b) Outdoor-use three phase ON transformer with accessories Terminal boxes R R R R The main transformers were replaced with new designed ones. For instrument, control & alarm cables

(6) Station Transformer Epoxy resin molded self-cooled a) station accessories Vacuum circuit breaker for station service transformers transformer with R R The transformers were replaced with new designed dry type or resin molded type ones and those were installed in the new 11kV cubicle. The vacuum circuit breakers were installed on station R R service isolators. transformers circuit instead of existing

b)

(7) Station Service Low Voltage AC & DC Circuit Boards a) Station service low voltage AC Circuit Boards Station service low voltage DC Circuit Boards R Common use

b)

Common use

(8) Electrical Cable a) b) c) 11kV power cables Power cables for low voltage Control cables R R R R R R Including common cables Including common cables

(9) Station Battery a) Station battery with accessories R The station battery was replaced with new one. (Common use) The battery charger was replaced with new one and it R was equipped with auto changeover function that DC supplies to emergency light at AC power failure.

b)

Battery accessories

charger

with

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R: Replacement item with new one

O: Overhauling and repairing item X: Removal

Items
(10) Other Items for Electrical

Unit 1

Unit 2

Descriptions

Equipment All paints, sealing materials, a) bolts and nuts necessary for overhauling works b) Spare parts and special tools R Including common use R R Including common use

Annexure II

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During R&M

After R&M

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During R&M

After R&M

before

after

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before

after

before

after

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before

after

before

after

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before

after

before

after

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before

after

before

after

Mechanical type

Digital type

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before

after

11KV,10.6 MVA

11KV, 12MVA

before

after

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before

after

before

after

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before

after

before

after

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before

after

Before

After

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before

after

before

after

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before

after

before

after

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before

after

before

after

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before

after

before

after

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before

after

Before repair

After repair

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before

after

before

after

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before

after

before

after

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before

after

before

after

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before

after

before

after

11/132KV, 10.6 MVA

11/132KV, 12 MVA

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