ONE MONTH TRAINING
AT
CENTRAL WATER COMMISSION, NEW DELHI
(August - September, 2016)
Under the guidance of :-
1.) Er. R. K Gupta, IES (Chief Engineer, Design (E&NE) CWC)
2.) Er. A.K Shukla, IES (Director, HCD (E&NE) Directorate)
3.) Er. Amrish Pal Singh, IES (Deputy Director, HCD (E&NE) Directorate)
4.) Er. Abhijeet Kashliwal, IES (Asstt. Director, HCD (E&NE) Directorate)
5.) Er. Abhinav Shrivastav, IES (Asstt. Director, HCD (E&NE) Directorate)
Submitted by :-
Er. Vivek Kumar
Dy. Manager, P&D (Civil) II
Designs Cell, HPPCL, Sundernagar (H.P)
Outline of the Report:
1. Training Certificate
2. Design of Power Intake
3. Training on Staad Pro
4. Hydraulic Design of Surge Shaft
o Using IS Code IS
o Using Water Hammer Software
2. DESIGN OF POWER INTAKE
1. Introduction:
An intake is an arrangement by which water is satisfactorily diverted for the required use.
A Power Intake structure is an arrangement which is placed in a surface water source to facilitate
the regulated discharge as well as to ensure smooth flow to the water conductor system for
Power Generation. The functional objectives of intake are:
a) To divert required discharge into the water conductor system.
b) To divert relatively clean water into the water conductor system, which is free from
floating debris and having minimum silt content.
The position and location of intake would generally depend upon the type of
development & may be broadly classified as under:-
a) Run of the river type:- Run of the river type intakes are those which draw water from
the fresh continuous river inflows without any pondage upstream of the diversion
structure.
b) Reservoir type:- Reservoir type intakes are provided where discharges for power
generation are drawn from storage built up for the purpose.
2. Typical Layout of Intake Structure:
a) Bell mouth entrance and transition from rectangular to circular opening.
b) Trash rack supporting Structure.
c) Gate slot enclosures with air vents.
d) Anti-vortex devices.
3. Conditions for location and layout of intake structure:
a) Type of development, that is, run-of-the river or storage dam project.
b) Location of power house vis-a-vis the dam.
c) Type of water conductor system, that is, tunnel, canal or penstock.
d) Topographical features of area.
e) In cases where there is a considerable movement of boulders, stones and sand in the
downstream direction, the intake should be arranged so that the effect of such
movement will not lead to a partial restriction or blockage of the intake; in respect of
storage reservoir intakes the sill level of the intake should be aimed to be kept above
the sedimentation level at or near the dam face arrived.
f) The intake can often be located so as to enable it to be constructed before the level of
the reservoir is raised.
4. Hydraulic Design of Intake Structures:
Design Criteria
An intake is provided in a hydroelectric development to let water into the water
conductor system. The intake design should be such as to:
a. Give minimum hydraulic losses;
b. Prevent formation of air entraining vortices;
c. Minimize sediment entry, especially in the case of run-of-the river schemes; and
d. Prevent floating material from entering the conduit.
5. Hydraulic Design of Components of Intake:
A. Bell Mouth Opening & Transition.
i. Shape & Size of Opening:
The inlet should be streamlined to minimize the losses. The profile of the roof and
floor should approximate to that of a jet from the horizontal slot. The profile is
generally an ellipse given by the following equation:
x2 y2
1
(1.1D) 2 (0.291D) 2
Following fig. shows the bell mouth details for Lower & Upper Nappe.
Fig. 2: Detail of Entry Plan
ii. Opening Area, Height & width of Opening
AS per IS: 9761:1995 the Opening area of Intake tunnel is as follows:
Opening Area = Penstock Area/(Cc x Cos)
Where
Angle of inclination of penstock centre line to horizontal
Cc Coefficient of Contraction
Also, Width of Opening be = Area of Opening/Height of Opening (he)
iii. Transition
In order to obtain hydraulically efficient design of Intake Transition from
rectangular section to a circular section conduit, the transition should be designed in
such a manner so that, transition should be made about the centre line of mass flow
& should be gradual, side walls should not expand at the rate 50 from the centre
lone of mass flow and all slots or other necessary departures from the neat outline
should normally be outside the transition zone.
B. Centre Line of Intake
The geometry of the approach to the power intake should be such that it can ensure
economy, and better hydraulic uniform flow condition. The flow lines should be
parallel, having no return flow zone and having no stagnation. Velocity distribution
in front of penstock should be uniform.
To prevent vortices, the centre line of intake should be so located as to ensure
submergence requirements given in Fig. 18 which has been developed by an
evaluation of minimum design submergence at operating satisfactorily.
For large size intake plants:
v
Fr= 1/3
gd
Where,
Fr = Froude Number and h = 1 to 1.5 times the intake height or diameter
recommended.
For medium and small size installations Fr 1/3 ) the submergence requirement
is calculated as:
h
=0.5+2Fr
D
However, requirement of water cover may be reduced with provision of anti vortex
device such as:
1. Parallel vertical fins of RCC on the U/s face of the power dam.
2. Dinorwic louvered type.
3. Perforated breast-wall.
C. Trash Rack Structure
The entry of undesirable floating debris to the water conductor system can be
controlled through trash racks provided in the intake structure. The trash rack
supporting structure also supports necessary auxiliary appurtenances such as trash
rack cleaning machine and gate hoisting arrangements.
i. A trash rack structure should be provided in front of a penstock or conduit to
prevent the entrance of any trash that would not pass easily through the smallest
opening in the turbine runner.
ii. The shape of trash rack structure may be adopted to meet the requirements of the
headworks layout and head loss. For instance, for high dams with nearly vertical
upstream face, semi-circular trash rack structure is usually preferred to provide
the required trash rack area economically.
iii. No part of the trash rack structure should fall within 80 percent of the intake
height, he, from the centre point of intake.
iv. The piers and beams of the trash rack supporting structure should be sharp nosed
and should be streamlined about the required structural section.
v. The normal velocity of flow through the rack structure is indicated below:
For units with hand raking, V = 0.75 m/s
For units with mechanical raking, V = 1.5 m/s
vi. Trash bars should be so spaced that the net opening between them should be at
least 5 mm less than the minimum opening between turbine runner blades.
vii. The trash rack should also be designed to withstand the effect of submerged jets
in the case of pumped storage scheme. The spacing of the bars should be adjusted
so that the ratio of forcing frequency to natural frequency of bar is less than 0.6.
viii. For the design of trash rack piers, ribs and trash rack screens, a minimum
differential head of 3-6 m may be adopted depending upon the efficiency of the
cleaning of trash racks being adopted.
D. Intake Gate & Air Vent
i. The intake gate slot should be enclosed in a structure designed to guide the water
into the rectangular opening without side contraction.
ii. The upstream edge of the gate slot should be at least 0.40 b, from the nose, where
b, is the width of opening.
iii. Where gates are located in a gate shaft, suitable transition from circular to
rectangular gate slot should be provided.
iv. An air vent downstream of intake gate should be provided. The air vent should be
so designed as to admit air at the rate the turbine is discharging water under full
gate conditions.
v. The area of air vent may be fixed by the following formula:
Q s (D/t)3/2
F=
750000 c
F = Area of air vent pipe in m2
Q = Max. discharge through penstock. Discharge of air through penstock is taken
as 21 to 22 percent of penstock discharge.
S = Factor of Safety against cllapse of pipe (normally assumed between 3 & 4)
D = Diameter of penstock in m
t = thickness of penstock in m
c = coefficient of discharge through inlet (0.5 for ordinary type of intake valve
and 0.7 for short air inlet pipes)
E. Approach Apron
The approach apron should not be placed closer than 30 percent of the intake height
h, from the lower edge of the intake orifice.
2.1 Preliminary Hydraulic Design Done at CWC
1. Introduction
Hydraulic Design of Power Intake of Karuma HEP was given. The power intake consists of
six independent intakes and is located on the left bank of the Kyoga Nile River, aligned in
N46W S46E direction and making 112 angle with the dam axis (S24W N24E). The
northwestern end of the structure will be anchored with the non flow blocks of the Concrete
Dam.
The centre line of the first power intake is placed at a distance of 44.0 m from the dam axis.
The intake is placed sufficiently close to the dam in order to facilitate cleaning of silt
deposited in front of the intake. .A silt flushing channel has been provided in front of the
intakes.
The intake is located on the outside of a river bend (towards the end of the bend). This is to
benefit from the spiral current in the river that moves clean surface water towards the intake
and bed load away from the intake towards the centre of the river.
2. Spacing Of Intakes
The width of the power intake has been fixed keeping in view the area required to have
acceptable flow velocity through trash rack. The centre to centre spacing of pressure shafts is
26m, which is equal to the centre to centre spacing of machines in the power house. The
penstocks enter the powerhouse at an angle of 600 giving the spacing of pressure shafts as
22.516m. By keeping width of each power intake as 22.516m, sufficient area at intake is
available for smooth entry of flow at acceptable velocity. Hence, six intakes have been
spaced at centre to centre spacing of 22.516m. This spacing also avoids bends in the pressure
shafts.
3. Minimum Submergence Requirment
The entrance of the intake structure should be sufficiently submerged below MDDL so as to
avoid vortex formations in front of the inlet section. Vortices intruding into the pressure shaft
may adversely affect the turbines and the operation of the plant.
Submergence requirement has been calculated carried out as per Bureau of Indian standards,
IS: 9761-1995, Hydro Power Intakes Criteria for Hydraulic Design . As per code,
submergence is calculated from the following equation:
h
0.5 2 Fr
D
( for Fr 1/3)
( where h is Submergence above centre line of the intake; D and Fr are the height of
opening and Froude number at gate sill level)
To prevent formation of air entraining vortices, Fr 0.5.
The following basic parameters have been considered in the hydraulic design of Power
Intake structure.
a) Full Reservoir Level at El. 1030.00m
b) Minimum Draw down Level at El.1028.00m
c) Design discharge with 10% over load as 1240.82cumecs
e) Diameter of the Pressure shaft as 7.70m.
If the height of opening at gate is kept equal to the diameter of the pressure shaft, the
submergence becomes quite large, which in turn requires the placement of intake openings at
a very low level. Hence the depth of opening at gate is fixed such as to minimize the
submergence requirements.
For Fr = 0.5
h
0.5 2 0.5 1.5
D Therefore h=1.5 D
The centre line of intake is fixed at EL. 1020.30m. Hence,
submergence below MDDL = 1028-1020.30 = 7.7m
Therefore D = 7.7/1.5 = 5.133.
Fixing D= 5.2m
v
FroudeNo. 0.5
gD
Width of opening required at gate to satisfy the above equation works out to
be= 11.4m
As it is practically not possible to have a single opening of size 11.4m(W) x 5.2m(H),
therefore, 2 openings of size 5.2m(H) x 5.7m (W) are provided with a 3.5m wide pier in
between to support the gates and gate hoisting arrangements.
The intake sill is proposed at El.1012.0m to have sufficient submergence to avoid vortex
formations in the Intake structure. The detailed calculations are placed as Annexure 1.
4. Bellmouth Shape:
The four sided Bell-Mouth Shaped Entrance is proposed for the Intake structure to ensure the
stream line flow and minimum losses. The Bell-Mouth entrance consists of Roof & Floor
Profile and Side profile.
The profile of roof and floor of the entrance should approximate to that of a jet from the
horizontal slot. The profile is an ellipse given by the following equations
In Elevation
x2 y2
1
(1.1D) 2 (0.291D) 2
x2 y2
Equation 1
(5.72) 2 (1.513) 2 Where D = 5.2m is the Depth of the tunnel at the gate
location.
x2 y2
1
(0.55be) 2 (0.2143be) 2 In Plan
Where be is the width of opening = 11.4m
x2 y2
Equation 1
(6.27) 2 (2.443) 2
where D is the diameter of the tunnel
5. Transition
A Transition is provided before entering to the pressure shaft as the shape of the intake at the
gate slot is in the form of two rectangles. In order to have hydraulically efficient intake, the
transition must be smooth. A transition from 2 rectangles of size 5.2m(H) x 5.7m(W) to a
7.7m diameter circular shape has been provided. The length of the transition is kept as 15m
The overt at the transition has been kept horizontal and the invert gradually lowers to
increase the 5.2m depth at gate to 7.7m diameter of the pressure shaft.
6. Trash Rack Structure
The entry of undesirable floating debris to the water conductor system can be controlled
through trash racks provided in the intake structure. The trash rack supporting structure also
supports necessary auxiliary appurtenances such as trash rack cleaning machine and gate
hoisting arrangements.
A trash rack structure should be provided in front of the water conductor system to prevent
the entrance from floating debris that would not pass through the smallest opening in the
turbine runner. The requirement of the trash rack panels control the width of the intake
structure. In Kyoga Nile the floating plants are quite high, so inclined type trash rack
arrangement with cleaning machine is proposed for Karuma Hydro Power Project.
The trash rack arrangement should comply to the following conditions,
a) Minimum Head loss.
b) No vibration.
c) Arrangements for removal of floating debris.
Keeping in view the above conditions, an inclined trash rack of 770 to the horizontal is
proposed for Karuma Hydro Power Project. Each intake structure consists of 20 trash rack
panels of 4.579m width. The trash rack panels are placed between 1.8m end piers and 1.2m
intermediate piers so as to provide sufficient anchorage for the trash rack grooves. The intake
structures are placed side by side to have common trash rack cleaning machine and gantry for
emergency gate.
The width of the panels are designed in such a way that to control the flow velocity within
the limits. As per the standards, 25% clogging of trash rack has been considered as critical
condition for the panel design. The detailed calculation for velocity through trash rack is
placed at Annexure 2.
The velocity of the flow through trash rack without clogging is 0.96 m/s. With 25% clogging
the flow velocity through trash rack is 1.2 m/s. Thus the velocity at the trash rack is within
the permissible limit.
3. Training on STAAD Pro V8i:
During the training at CWC, I got a chance to attend the Two Days training on Staad Pro.
This training was organized by CWC. STAAD Pro V8i is the most popular structural
engineering software product for 3D model generation, analysis and multi-material design. It
has an intuitive, user-friendly GUI, visualization tools, powerful analysis and design facilities
and seamless integration to several other modeling and design software products.
In this training usage of STAAD Pro in Civil Engineering design was explained. Design
done in the STAAD Pro training is placed below as Annexure 3.
4. Design of Surge Shaft Using IS Code & Software
4.1 Introduction
Surge Shaft is a structure provided at the end of head race tunnel to account for water
hammering effect in the tunnel at its downstream and also to supply/store additional water
during load acceptance/rejection during load demand/rejection until the conduit velocity has
accelerated/decelerated to the new steady state value. Surges or mass oscillations occur in the
surge tanks, the hydraulic design of which is so done as to keep the surges within reasonable
limits. The pendulation of water levels (small or large load variations) are quenched by
damping effect of frictional resistance. Surge shaft serves following functions:-
1. Flow regulation
2. Water hammer relief or pressure regulation
3. Improvement in speed regulation.
A surge shaft is always located as close as possible to the power house in order to reduce
the length of penstock to a minimum and preferably on high ground to reduce the height of
tower
4.2 Type of Surge Shaft
4.2.1 Simple Surge Shaft
A simple surge tank is a shaft connected to pressure tunnel directly or by a short
connection of cross-sectional area not less than the area of the head race tunnel.
4.2.2 Restricted Orifice Type Surge Shaft
A simple surge tank in which the inlet is throttled to improve damping of oscillations
by offering greater resistance and connected to the head race tunnel with or without a
connecting/communicating shaft. During the training, hydraulic design of restricted
Orifice type surge shaft was done using IS Code & WHAMO (Annexure 4)
4.2.3 Differential Surge Shaft
Differential surge tank is a throttled surge tank with an addition of a riser pipe may be
inside the main shaft, connected to main shaft by orifice or ports as shown in Fig. 3A.
The riser may also be arranged on one side of throttled shaft as shown in Fig. 3B. In case
of type shown in Fig. 3A port holes are generally at the bottom of the riser at the sides.
4.3 About WHAMO
The WHAMO is a computer program developed to assist engineers in mitigating
water hammer by simulating Water Hammer And Mass Oscillation in networks that
convey fluids such as water or fuel. Some typical applications for WHAMO include
analysis of hydropower plants, pumping facilities, jet fueling systems, and wastewater
collection systems. The program determines time varying flow and head (transients) in a
network which may include pipes, valves, pumps, turbines, pump-turbines, surge tanks,
and junctions arranged in any reasonable configuration. Such transients are generated due
to any variation in the operation of a turbomachine or valve within the network, or due to
changes in the head or discharge at boundaries of the network. The rotational speed,
torque, and power of machines are computed along with the system hydraulic variables.
The basic physical elements considered by WHAMO fall into four main
categories: flow elements, turbomachines, boundary elements, and junctions. In
WHANO, all the data entered in FPS system of unit. WHAMO follows certain basic
steps during a simulation run. These are:
1. Read and check input data The user's commands and associated data
are read in. The data are processed as necessary and checked for errors.
2. Build system connectivity The user's specifications of the system
structure are reinterpreted to a form compatible with computation. The
resulting system is checked to insure that it is physically reasonable
3. Display input data and system structure All data input as well as the
system structure and other information determined by the program are
printed in tabular form. This allows easy verification of the input data by
the user.
4. Steady state generation An initial, steady state condition compatible
with the specified boundary and operating conditions is determined for the
system.
5. Transient simulation System response to specified transient machine
operation or boundary condition is simulated. Computational difficulties
are monitored by the program's self-checking algorithms.
6. Output The simulation results are printed or stored for later processing
according to the user's instructions.
