New Hydro Power Projects Under Construction in India

New hydropower projects under construction
in India
ČKD Blansko Engineering, a.s.
Karel Kyzlink, Ladislav Štégner – ČKD Blansko Engineering, Czech Republic

Chokka Rao Godavari Lift Irrigation Scheme – Phase II – India, Andhra Pradesh
Location:
Andhra Pradesh
State of India
New hydropower projects under construction in India , HydroVision India 2012 - New Delhi
Organizational Chart
Government of Andhra Pradesh

Irrigation and Water Resources Department
Investor
Hindustan Construction Company, Nagarjuna

Construction Company (India)
Contractor and civil companies
Jyoti (India)
Contractor for technology E&M equipment
ČKD Blansko Engineering ČKD Nové Energo

(Czech Republic) (Czech Republic)
Hydraulic and mechanical Supplier of motors
design of pump units
ČKD Blansko Engineering (member of Litostroj Power group) concluded contract with Jyoti in 2006
Chokka Rao Godavari Lift Irrigation Scheme – Phase II – India, Andhra Pradesh
• after completion a total of 7 pump stations (14 pump units)
• pumping up to Bomakur area – 150 km
• total delivery head – 480 m
• total pump water quantity – 1210 mil. l/day
Number Delivery head/ Delivery Rated Impeller

Pump station (PS) Rated input
of units delivery piping quantity speed diameter
name at PS [kW]
length [m] [m3s-1] [min-1] [mm]
GANGARAM 2 10 850 131 / 38 090 7 500 Ø1912

BHIMGANAPURAM 2 9 850 123 / 47 728 7 500 Ø1875
SALIVAGU 2 10 550 130 / 40 517 7 500 Ø1907
DHARMASAGAR 2 11 350 138 / 23 000 7 500 Ø1945
Pump conception and design solution
Pump conception:
• radial centrifugal pump
• one hydraulic design
• pump motors above flood level
• radial-axial bearing on pump cover
• synchronous motor – ČKD Nové Energo,CR
PS GANGARAM
• pump rotor length – 25 m
• 4 guide bearings
• 3pcs hollow shaft ø880/ø800mm
(2pcs - 5600mm, 1pcs - 4900mm)
• 1pc pump shaft ø400mm
• 3pcs connecting shaft ø400mm
PS BHIMGANAPURAM, SALIVAGU,
DHARMASAGAR
• pump rotor length – 14,5 m
• 2 guide bearings
• 1pc hollow shaft ø880/ø800mm – 6800mm
• 1pc pump shaft ø400mm
• 1pc connecting shaft ø400mm
Pump components manufacturing - Europe
B. HILFRICH GmBH – hollow shafts
Žďas, CR – pump shafts, connecting shafts, coupling, impellers
Eagle Burgmann – shaft seal
RENK – guide bearings, flexible
gear coupling
Pump components manufacturing - India
GWALIOR TANKS (Bhopal) – draft tube assembly
VIMAL ALLOYS (Mandri Gobindgarh) – pump lower cover
Rhine Engineering (Vadodara) – pump spiral casing with diffuser
- inlet dia – 2000 mm

- outer dimensions – c.4700x8055x2450
- weigth – c. 20 000 kg
Special impeller manufacturing technology
Impeller manufacturing technology
- used new, so far not applied manufacturing technology
- this technology has been patented by ČKD Blansko Engineering, CR
- Impeller is welded from two halves
Hub
Weld boundry
Crown Weld boundry
Special impeller manufacturing technology
The main advantages of the applied technology
- weld is located outside the points of stress concentration
- the welding metal consumption and input heat quantity for welding is also
substantially lower than with the so far applied technologies
- hydraulic shape of the hub, crown and blades is very good accessible during
NC machining, all surfaces are finished before welding
- the weld deformation are minimized due to using just one weld for each blade
- weld is good accessible for polishing and NDT checking
Impeller manufacturing
Casting of the impeller crown
NC machining of the impeller crown
Impeller welding – position during main welding
Final acceptance test of the impellers
Pump assembly on PS GANGARAM site
Pump assembly on PS GANGARAM site
Pump putting in operation
- Currently, two pumps of Gangaram pump station are in operation
- Six pumps of Bhimganapuram, Salivagu and Dharamasagar pump stations

were completely assembled , tested and commissioned, however, the
complex test of pump units was not yet performed due to shortage of water
on pump stations sites
- The existing experience in the pump operation at Gangaram pump station

confirms the correctness of both hydraulic and mechanical design elaborated
by the ČKD Blansko Engineering, CR
Koyna Left Bank Power Station
Location:
Maharashtra
State of India
Organizational Chart of the KLBPS project
Government of Maharashtra
Water Resources Department
Investor
IVRCL (India) Vendors for local fabrication

of P-T components as
Contractor and local manufacturing company
Jyoti Ltd. and others
Litostroj Power (Slovenia)

Supplier of E&M technology equipment
ČKD Blansko Engineering Končar (Croatia)

(Czech Republic)
Supplier of motor-generator
Hydraulic and mechanical and electrical equipment
design of pump-turbine
Litostroj Power concluded contract with IVRCL in December 2010
Water Ways Solution
Existing dam with Francis turbines at right bank of Koyna river
Civil works of new Koyna left bank power station started in 2008
Concrete lined headrace tunnel – length 450m – 7.6m dia
Steel lined bifurcation for two pump-turbines – length 20m
Concrete lined tailrace tunnel – length 290 – 6.5m dia
Underground Power House Arrangement
2xDeriaz pump-turbine - D=3,9m , n=187,5rpm
Butterfly inlet valve with diameter 3,9 m
Draft tube flap valve - 5,35 m to 2,5 m
Unit rotor seated in three bearings
Each unit is equipped with independent cooling
Blow down air system for condenser operation
PUMP OPERATION
Head range: 33,5 ÷ 83m
Power Input: 40 ÷ 52 MW
TURBINE OPERATION
Head range: 27,5 ÷ 77m
Power Output: 10 ÷ 52 MW
Pump Turbine Type Selection
LOW head pump turbines = HIGH head variations (Koyna level variation is 30 ÷ 80 m)
Operation range in pump mode generally limited by cavitation and operation stability
Operation range in turbine mode generally limited by pressure pulsations
Reasonable pump-turbine setting is advised (machine axis under tail water level)
Dériaz pump-turbine with adjustable runner blades at constant speed = FINAL SOLUTION
Head and power variation
Dériaz pump-turbines with

variable speed
Dériaz pump-turbines with
constant speed
Francis pump-turbines
with variable speed
Francis pump-turbines
with constant speed Investors price
Hydraulic design procedure
Experience from older projects for heads up to 60 meters (Lipt.Mara, Czorsztyn, Kadana)
Number of runner blades = 10, Number of guide vanes = 20, Number of stay vanes = 16
Simultaneous hydraulic and mechanical design was applied
Ansys CFX software was used for numerical CFD analysis
Optimization of the runner geometry improved efficiency and cavitation features
Operation range was extended in both operational modes
Mode Operational point Requirements
Pump mode Best efficiency point at rated delivery head Efficiency
Pump mode Maximum delivery head Efficiency, Cavitation and Stability
Pump mode Minimum delivery head Efficiency and Cavitation
Turbine mode Best efficiency point at rated head Efficiency
Turbine mode Maximum output at maximum head Efficiency and Cavitation
Turbine mode Maximum output at minimal head Efficiency and Cavitation
Hydraulic design – pump operation
Flow in the pump-turbine runner in pump operation mode
Some amount of cavitation at leading edge (blue colour) is unavoidable
maximum delivery head minimum delivery head
Hydraulic design – turbine mode
Flow in the pump-turbine runner in turbine operation mode
Some amount of cavitation at minimal head (blue colour) is unavoidable
maximum net head minimum net head
Hydraulic design – model manufacturing
Model Witnessed Tests
Development tests were carried out from April to May 2011
Hydraulic laboratory of ČKD Blansko Litostroj Power in Blansko (Czech Republic)
Two testing rigs are in operation since the end of 2011 Parameters of universal testing
rig No.1:
Max. test head 120 m
Max. Discharge 1.20 m3s-1
Max. rotation speed 2000 min-1
Max.model power 300 kW
Max. shaft torque 1000 N.m
Min. NPSH 1.5 m
New hydropower projects under construction in India , HydroVision India 2012- New Delhi
Model Witnessed Tests
Performance guarantees were successfully fulfilled at model witnessed tests (June 2011)
Measurement of axial thrust and blade and guide vane loading was carried out as well
Final hydraulic solution was confirmed as applicable for Koyna power station
Model pump-turbine runner Model witnessed tests
Mechanical design
Detail stress analysis of all parts using Ansys
Dimensions of important components were

optimized
Mechanical design
Detail stress analysis of all parts using Ansys
Dimensions of important components were optimized
Mechanical design
Summary
New Deriaz pump-turbine for wide head variation was successfully designed
The hydraulic and mechanical design proceeded simultaneously
Guaranteed performance parameters were verified by model witnessed test
ČKD Blansko Enginnering is now in final stage of completing documentation
The manufacturing in Litostroj Power workshops started
Project runs successfully and putting into operation is planed for year 2015
Thank you for your attention …
ČKD Blansko Engineering, a.s.
Čapkova 2357/5
678 01 Blansko
Czech Republic
info@cbeng.cz
www.cbeas.com

New Hydro Power Projects Under Construction in India

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New Hydro Power Projects Under Construction in India

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New hydropower projects under construction

ČKD Blansko Engineering, a.s.

Karel Kyzlink, Ladislav Štégner – ČKD Blansko Engineering, Czech Republic

Government of Andhra Pradesh

Hindustan Construction Company, Nagarjuna

ČKD Blansko Engineering ČKD Nové Energo

Number Delivery head/ Delivery Rated Impeller

GANGARAM 2 10 850 131 / 38 090 7 500 Ø1912

B. HILFRICH GmBH – hollow shafts

VIMAL ALLOYS (Mandri Gobindgarh) – pump lower cover

- inlet dia – 2000 mm

Crown Weld boundry

Casting of the impeller crown

NC machining of the impeller crown

- Currently, two pumps of Gangaram pump station are in operation

- Six pumps of Bhimganapuram, Salivagu and Dharamasagar pump stations

- The existing experience in the pump operation at Gangaram pump station

IVRCL (India) Vendors for local fabrication

Litostroj Power (Slovenia)

ČKD Blansko Engineering Končar (Croatia)

Litostroj Power concluded contract with IVRCL in December 2010

Existing dam with Francis turbines at right bank of Koyna river

Concrete lined headrace tunnel – length 450m – 7.6m dia

Steel lined bifurcation for two pump-turbines – length 20m

Concrete lined tailrace tunnel – length 290 – 6.5m dia

2xDeriaz pump-turbine - D=3,9m , n=187,5rpm

Butterfly inlet valve with diameter 3,9 m

Draft tube flap valve - 5,35 m to 2,5 m

Unit rotor seated in three bearings

Each unit is equipped with independent cooling

Blow down air system for condenser operation

Operation range in turbine mode generally limited by pressure pulsations

Dériaz pump-turbines with

Simultaneous hydraulic and mechanical design was applied

Ansys CFX software was used for numerical CFD analysis

Optimization of the runner geometry improved efficiency and cavitation features

Operation range was extended in both operational modes

Mode Operational point Requirements

Pump mode Best efficiency point at rated delivery head Efficiency

Pump mode Maximum delivery head Efficiency, Cavitation and Stability

Pump mode Minimum delivery head Efficiency and Cavitation

Turbine mode Best efficiency point at rated head Efficiency

Turbine mode Maximum output at maximum head Efficiency and Cavitation

Turbine mode Maximum output at minimal head Efficiency and Cavitation

Flow in the pump-turbine runner in pump operation mode

Some amount of cavitation at leading edge (blue colour) is unavoidable

maximum delivery head minimum delivery head

Flow in the pump-turbine runner in turbine operation mode

Some amount of cavitation at minimal head (blue colour) is unavoidable

maximum net head minimum net head

Development tests were carried out from April to May 2011

Hydraulic laboratory of ČKD Blansko Litostroj Power in Blansko (Czech Republic)

Model pump-turbine runner Model witnessed tests

Detail stress analysis of all parts using Ansys

Dimensions of important components were

Detail stress analysis of all parts using Ansys

Dimensions of important components were optimized

The hydraulic and mechanical design proceeded simultaneously

Guaranteed performance parameters were verified by model witnessed test

ČKD Blansko Enginnering is now in final stage of completing documentation

The manufacturing in Litostroj Power workshops started

ČKD Blansko Engineering, a.s.

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