A Report of Industrial Visit to
“Ukai Hydro Power Station, Ukai.”
Organized by
Mechanical Engineering Department (19)
For
th 7 Semester B.E. Mechanical Engineering 56 No. of Students
On
th 4 October 2017
Faculties accompanied: Prof. Krunal A. Hathiwala,
Prof. Dhaval S. Chaudhary
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 1
-:Acknowledgement:-
The industrial visit at Ukai Hydro Power Station, Ukai was impossible to us without the efforts and valuable inputs from collage and faculties. We are here extending to our great acknowledgement and appreciation to following persons with their memorial inputs that are not limited only those mentioned below. The first and the most acknowledged is Shri Dr.K.N.Mistry, Principal Sir who was very helpful to us. As a principal, he has inspired us to arrange industrial visit to Final year students. He has injected us the familiarity and methodology of planning of visit. Not only that as giving the permission of industrial visit, his academic guidance, fairness and responsiveness to kind of queries remains him as a role model, there of we are extending our gratitude to Shri Dr.K.N.Mistry, Principal Sir.
We owe a deep sense of gratitude to Shri Dr. H.S.Patil Sir, Head of Mechanical Engineering Department, always supports and provides all the facilities and guides at each and every stage and solves all the problems regarding the Industrial visit. His constants encouragement , timely suggetion helped to complete industrial visit and conclude it, ascertaining him a commemorative plaque at deep of our heart.
We are extremely Thankful to Chief Engineer for providing all information about Hydro Power Plant and its advantages and makes possible this visit. It is privillge to thank Ukai Hydro Power Station, Ukai to give us Permission for Industrial Visit.
We thank profusely to all the students for kind behavior and support at every stage during Industrial visit.
Again thanks for valuable collaborations
Prof. Krunal A. Hathiwala
Prof. Dhaval S. Chaudhary
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 2
1.Introduction
The river Tapi is the second largest west flowing river in India. The Tapi river has its origin at Mulati in Betul District of Madhya Pradesh. The river has a total length of 720 km out of which 208 km lies in the Madhya Pradesh, 323 km in the Maharashtra and 189 km in Gujarat. It ultimately meets the Arabian Sea approximately 19.2 km west of surat in Gujarat.
Ukai is the largest Multipurpose Project undertaken by the state and is only next to Narmada Project, so far as benefits are concerned. The Ukai Hydro Power Station is located at Ukai Dam on Tapi river in Tapi district. There are 4 units of hydro turbine each of 75MW with a total installed capacity of 300MW. All the above units are of BHEL make. Commissioning dates of unit no. 1to 4 are 08/07/1974, 13/12/1974, 22/04/1975 and 04/03/1976 respectively.
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 3 The Ukai Left Bank Canal (LBC) Hydro Power Station is located at Left Bank Cannel of Ukai Dam on Tapi River in Tapi District. There are two units of hydro turbine each of 2.5 MW with a total installed capacity of 5 MW. All the above units are of BHEL make. Commissioning dates of unit no. 1 and 2 are 08.12.1987 and 19.02.1988 respectively.
The functions of the project are:-
1. Irrigation
2. Power Generation
3. Flood Protection
4. Fisheries Development
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 4 2.About Ukai Dam
The Ukai Dam, constructed across the Tapi River is the largest reservoir in Gujarat. It is also known as Vallabh Sagar. Constructed in 1972, the dam is meant for irrigation, power generation and flood control. Having a catchment area of about 62,255 2 and a water spread of about 52,000 hectares, its capacity is almost same as that of the Bhakra Nangal Dam. The site is located 94 km from Surat. The storage capacity of Ukai dam is almost 46% of the total capacity of all the other existing dams in Gujarat if put together. Thus it can be concluded that the rest of the dams have as little as 0.1% average storage capacity. During the last 40 years, the actual irrigation potential is attained through all the major and medium water resources projects in the State, which comprises only 14 million hectares. The dam is an earth-cum-masonry dam. Its embankment wall is 4,927m long. Its earth dam is 80.77m high, whereas the masonry dam is 68.68m high. The dam's left bank canal feeds water to an area of 1,522 2 and its right canal provides water to 2,275km2 of land.
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 5 2.1.Salient Features:
DAM
Construction cost of DAM 180.74 Cr
Max. Dam Level 1990-91 346.17 Feet
Min. Dam Level 1979-80 268.30 Feet
MAIN HYDRO
Main Hydro Total Cost 22.87 Cr
Commissioning date of Main Hydro Units
Unit # 1 (75 MW) 08-07-1974
Unit # 2 (75 MW) 13-12-1974
Unit # 3 (75 MW) 22-04-1975
Unit # 4 (75 MW) 04-03-1976
Max. Generation (for Monsoon Year) 1976-77 1261.217 Mus
Max. Generation (Monthly) Sept-2013 221.267 Mus
Max. Generation (Daily) 25-09-1998 7.689 Mus
Ukai hydro power station has been declared 3rd best performing station in India during 2006-2007 year and awarded Bronze shield for the same by Ministry of Power, New Delhi.
Previous record of generation (210.100 Mus) is break in September 2013 by 221.267 Mus.
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 6
3.Ukai Hydro Power Station
There are three basic stages of hydro power station to generate electricity.
1. Spillway
2. Turbine
3. Generator
3.1.Spill Way:
Specification of Spill Way is given below
1 Spill Way Channel Length = 1524 Meter, Width = 259 Meter Depth = 18.29 Meter
2 Spill Way Gates 1) Numbers = 22 nos 2) Types = Redial Gates. 3) Area = 15.545 m × 14.783 m. 4) Weight = 100 Tones Each.
3 Discharge Capacity 49490 m3/sec. Maximum=59920 m3/sec
4 Over all Crest Length 425.195 m.
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 7 3.2.Turbine:
Specification of turbine is given below
1 Type Reaction Type, Kaplan, Vertical Shaft, Feathering
propeller type.
2 Make Bharat Heavy Electricals LTD.
3 Head 1) 47.8 m (156.82 ft.) Rated Head.
2) 57.2 m (18.66 ft.) Max head.
3)34.4 m (112.86 ft.) Min head.
4 Output power 1) 1,05,000 Metric HP
2) 1,20,750 Metric HP Max
5 Speed 150 RPM (clockwise rotation)
6 Run away Speed 1) 300 RPM with cam
2) 350 RPM Without Cam
7 Water Discharge 6000 cusec (101 m3/sec) at 75 MW.
8 Nos. of guide Vanes 24 nos.
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 8
9 Size of guide vanes 6660 mm × 19.4 mm
10 Main shaft dia. 900 mm
11 Runner hub dia. 3160mm
12 Runner blades 6 nos. Each having Weight of 5 tones & design to withstand 1700 tones hydraulic.
13 Spiral inlet dia. 6500 mm
14 Largest transport item of turbine Inner top cover half size 6.1m × 3.5m × 3.0m
15 Efficiency 98 % at the full water level.
16 Weight of turbine with shaft 140 MT And runner disc
17 Bearing Turbine guide bearing 1 no having 8 nos. pads.
3.3.Generator:
Specification of generator is given below
1 Nos. of Generator 4 Nos
2 Sr. no. of Generator 3000107, 3000108, 3000109, 3000110 respectively
3 Type G25 Vertical Umbrella Type Salient Pole Rated 83333 KVA, 0.9 p.f., 11KV (± 5%) 3 phase, 4370 AMPS. Rated KVAR 56000 at Zero leading P.F.
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 9 4 Make Bharat Heavy Electrical Ltd.
5 Stator Windings: Slots 384, winding coils 384
Joint 1) Series joint 264
2) Pole to pole joint 108
3) Bus Bar joints 12
Stator resistance per phase at 200=0.003415 ohm. Field resistance at 200 C=0.15 ohm. Rotor excitation at no load & 100% voltage= 608 amp. Rotor excitation at rated output & voltage = 1052 Amp. Excitation voltage = 180 v.
6 Speed 150 RPM
7 Overall dia. 4127.5 ×2 =8255.0 mm
8 Heaviest package for shipment
Thrust bearing housing size 04.34m long × 4.12 m width × 2.6 m high having weight 55 tones.
9 Weight of generator side 275 MT
10 Heaviest assembly to be lifted by crane weighting 220 tones.
11 Bearing 1 no – thrust bearing having 12 pads. 1 no – Generator guide bearing having 24 pads.
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 10
4.Activities on the day of Visit
With an aim to go beyond academics, Mechanical Engineering Department of GDEC had th organized an industrial visit to Ukai Hydro Power Plant, Tapi District, Ukai; on 4 October 2017. th Total 56 students from 7 Semester, Mechanical engineering department, 2 faculties from Mechanical Engineering Department visited the Ukai Hydro Power Plant.
The purpose of this Industrial visit was to provide an excellent opportunity to all the students & faculties, to interact and know more about industrial environment. The intention was to help the students to create a practical perspective on the World of Engineering.
The bus had reached around 3:00 pm at the Ukai site. We took entry for our visit at 3:15 pm. In the visit, authorities welcomed us on the Gate-Pass section. We all moved to the main site of the plant. After that, we moved to the Control Department of hydro power plant. Then, Prof. Krunal A. Hathiwala explained the working of Hydro power plant with the help of Schematic Diagram of the plant. The questioning was also being taken by us and the satisfactory answers were given by them.
Control Department At Ukai Hydro Power Station, Ukai
Chief Control Engineer explained all the component of control room. They give brief information regarding monitoring, controlling, observing.There we had observed different control rooms for different turbine sections. All the control of the whole generation system was controlled by that control room containing different control switches and digital panels. Later they discussed about the various activities about plant in nearby areas.
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 11 Then we were study about the generation of power with Hydro turbine and seen the turbine generator coupling for power generation and learn about generator generation capacity of 75 MW. There are 4 units of hydro turbine each of 75MW with a total installed capacity of 300MW. All the above units are of BHEL make.
One of the engineers had given overview of the working of the Hydro Turbine, Generator and the other units. The water was taken to the turbines and turbines were caused to generate the electricity which was generated by the generator. Though these much equipments were there the plant was very neat and tidy.This way, the complete information regarding each and every section of the plant was given by the allotted engineers and they also briefly explained regarding how this power generation was actually taking place.
Switch Yard & Disribution System At Ukai Hydro Power Station, Ukai
Then a whole grid system containing generators, transformers, electricity transfer cables were observed. After this complete explanation we had went to the exit and then we had thanked the all authorities and left the plant. On the way back to college the photo of visit had been taken and all the students finally left for the college.
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 12 5.Glimpse of Visit
At Ukai Hydro Power Station, Ukai
Group Photograph At Ukai Hydro Power Station, Ukai
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 13 Conclusion
As Students visited and looked at all the operations, Processes of Ukai Hydro Power Plant. We have learnt the proper management criteria of the production process of electric energy from water and had an chance to extract more knowledge of functioning and working of an Power Plant.
Also,We saw the working of Turbine and Generator too. The water was taken to the turbines and turbines were caused to generate the electricity which was generated by the generator. We were also given the demo of the power plant.
Industry saw the Hydro Power Plant Types ,Constuction ,Function of elements, Working and came to know the actual concept of how the Hydro Power Plant has Work , What they have learned in theoretical subject.
It is pleasure that Ukai Hydro Power Station, Ukai has open the door for Industrial Training of students of GDEC, Navsari for anytime and Industry-Institution relation has been developed. If the performance of the students will be satisfactory during training period they will likely to give a chance to place the students of their esteemed industries.
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 14 Feedbacks
1. Prof. Krunal A. Hathiwala (Faculty of GIDC Degree Engineering,Navsari)
It is great experience of Ukai Hydro Power Station, Ukai. It is very useful to students because students can observe working of HPP and its various components like, Catchment area, Reservior, Dam, Surge Tank. They can understand working of Spillway, Turbine, Electric Generator, Power House, Draft Tube, Control room etc.
2. Prof. Dhaval S. Chaudhary (Faculty of GIDC Degree Engineering, Navsari)
It is nice industrial visit at Ukai Hydro Power Station, Ukai. It will help to students in their studies also. I have gather lot of information about working of Hydro Power Plant and its different working operations .
3. Student
It was great experience to visit Ukai Hydro Power Station, Ukai. I got lot of information about Hydro Power Plants and its working. We see whatever we learn theoretically. It is helpful to get practical information beyond the textbook. We see new technologies use in Hydro Power Plant.
4. Student
I want to thank our faculties and Institute for organizing such a wonderful visit. It was great opportunity to develop skill, Improve technical knowledge. This kind of visit useful to students for Industry experience. We hope we get further more chances to have such wonderful and informative experiences of visiting different Industry.
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 15 Annexture-1
Permission / Undertaking by Teachers / Students / Parents / Gaurdian
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 16 Annexture-2
List of Student for Industrial Visit
Sr.No. Enrollment No. Name of the Student
1 131100119044 RATHOD DHAVALKUMAR RAMESHBHAI
2 141100119005 BHALARA UDAYKUMAR ASHWINBHAI
3 141100119014 CHINTAN ASHVIN SURATI
4 141100119015 DESAI DEEP M
5 141100119020 GAUTAM SUNEETKUMAR VINODKUMAR
6 141100119021 GANDHI NISARG DHARMESHKUMAR
7 141100119024 INTWALA ADITYA KISHORCHANDRA
8 141100119027 KHALIFA BILAL SALIMBHAI
9 141100119030 LAD BHAVIN PRAKASHBHAI 1 10 141100119033 MANGUKIYA JAYMIN BHUPENDERABHAI
11 141100119034 MARATHE RAKESHKUMAR ASHOKBHAI
12 141100119035 MEHTA TEJASKUMAR UDESHBHAI
13 141100119037 NAIR RAHUL RAJAN
14 141100119043 PATEL AKHILKUMAR BALUBHAI
15 141100119067 PATEL JIMIKUMAR DINESHBHAI
16 141100119068 PATEL KARTIK BALUBHAI
17 141100119069 PATEL KAVANKUMAR MAHENDRABHAI
18 141100119071 PATEL KEYUR BHUPENDRABHAI
19 141100119076 PATEL NILAYKUMAR PRAVINCHANDRA
20 141100119078 PATEL PARTH HARSHADBHAI
21 141100119079 PATEL PRANAV SATISHBHAI
22 141100119082 PATEL RAVINDRAKUMAR DHANJIBHAI
23 141100119086 PATEL SHREYAL RANJITBHAI
24 141100119088 PATEL TEJASH NALINBHAI
25 141100119096 PATEL YUGAL SUMANBHAI
26 141100119099 RAVIKUMAR BALVANTBHAI PATEL
27 141100119100 SATYAM RAJENDRASINGH BHADORIA
Page Mechanical Engineering, GIDC Degree Engineering College Navsari. 17 28 141100119101 SHAH AKSHAYKUMAR ASHOKBHAI
29 141100119108 SOLANKI HERI GIRISHBHAI
30 141100119109 SONI AKSHAYBHAI DINESHBHAI
31 141100119114 TANDEL KARANKUMAR SOMABHAI
32 141100119121 VAGHANI PARTH KISHORBHAI
33 141100119123 VASHI TEJAS CHETANBHAI
34 141100119125 YAGNIK LATHIYA
35 141100119127 SIMBINE TERCIO FILIPE
36 151103119001 BARODIYA PRITESHKUMAR SURESHBHAI
37 151103119003 BHATT ATULKUMAR KANTILAL
38 151103119004 DESAI PARTHKUMAR BHARATBHAI
39 151103119005 DESAI PRIYANK ANILKUMAR
40 151103119006 DUSHANE MITESH ASHOKBHAI
41 151103119007 GAJERA SHYAMKUMAR HIMMATBHAI
42 151103119008 GHAYAL MITANG DHARMESHKUMAR
43 151103119011 KANSARA NISHANT BHARAT
44 151103119013 KEVAT HEMANG ANILKUMAR
45 151103119014 LAD KRUNAL BALVANTBHAI
46 151103119015 MAROLIA JAY BHARATBHAI
47 151103119016 MISTRY PRATIK BHARATKUMAR
48 151103119017 NAIK VATSAL PRAKASHBHAI
49 151103119018 NIKAM NITEENKUMAR BALAKDAS
50 151103119020 PATEL BHAVIKKUMAR MUKESHBHAI
51 151103119022 PATEL HIREN RAMESHBHAI
52 151103119023 PATEL JAY DINESHBHAI
53 151103119028 PATEL TEJASKUMAR DHANSUKHBHAI
54 151103119032 SANDAPA MILANKUMAR RAMJIBHAI
55 151103119034 THORIYA PAYALBEN BABUBHAI
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 18 Report Prepared by:
th 7 Semester Students,
Mechanical Engineering Department,
GIDC Degree Engineering College, Abrama, Navsari.
Report Prepared & Compiled by:
Krunal A. Hathiwala
Asst. Professor,
Mechanical Engineering Department,
GIDC Degree Engineering College, Abrama, Navsari.
Dhaval S. Chaudhary
Asst. Professor,
Mechanical Engineering Department,
GIDC Degree Engineering College, Abrama, Navsari.
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 19
Thank You
Department of Mechanical Engineering
Mechanical Engineering, GIDC Degree Engineering College Navsari. Page 20