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Design: 280 m head plant, 66 kV

Short answer

Power output at Q45% is 15.233 MW. Two 7.7 MW units provide 15.4 MW installed capacity. Recommended turbines are 4-jet Pelton, 500 rpm, for good part-load efficiency and sediment handling.

A typical hydro power plant has the following details.

MonthDischarge (m³/s)Flow durationDischarge (m³/s)
January5.2Qmax (Q0)211.00 m³/s
February3.86Q25%18.24 m³/s
March3.58Q45%7.00 m³/s
April4.55Q65%4.70 m³/s
May3.20Q85%3.10 m³/s
June12.77Q95%2.17 m³/s
July32.95Qmin0.64 m³/s
August40.26
September31.23
October15.05
November7.38
December4.85
Turbine typeHead range (m)
Kaplan2 < H < 40
Francis10 < H < 350
Pelton50 < H < 1300
ParameterValue
Gross head280 m
Turbine efficiency91%
Generator efficiency97%
Transformer efficiency99%
Head loss5%
Riparian release10%
Generator sub-transient reactance21%
Transformer reactance9.15%
Transmission line inductance0.92 mH/km
Transmission line length30 km
Transmission voltage level66 kV
Generator voltage level11 kV
Transmission circuitDouble circuit

Design a power plant so as to obtain the following parameters: a) Electrical power output taking design discharge as Q45% [2] b) Select the numbers of units and installed capacity [2] c) Select and Recommend suitable turbine [4] d) Draw the single line diagram showing generators, power transformers, station transformer and diesel generator for black start [4] e) Calculate the rating of generator circuit breaker to be used in your design [4] (Assume suitable data if necessary and necessary graph is attached herewith) [Chart attached: turbine efficiency (%) against Q/Q0 for Full Kaplan, Pelton, Francis, Crossflow and Fixed propeller]

Assumptions: riparian release = 10% of the driest monthly mean flow; net head = gross head minus 5% loss; ρg=9.81\rho g = 9.81 kN/m³; generator power factor 0.85; base = 100 MVA. For fault levels the grid is taken as a source of 1,000 MVA at the 66 kV grid substation at the far end of the line (an assumed typical value, since grid data is not given).

a) Electrical power output at Q45%Q_{45\%}

Driest month = May (3.2 m³/s), so riparian release Qr=0.1×3.2=0.32Q_r = 0.1 \times 3.2 = 0.32 m³/s.

Qd=Q45%−Qr=7−0.32=6.680 m3/sHn=Hg(1−0.05)=280−14.00=266.00 mPhyd=ρgQdHn=9.81×6.680×266.00=17.431 MWPshaft=ηtPhyd=0.91×17.431=15.862 MWPgen=ηgPshaft=0.97×15.862=15.387 MWPout=ηtrPgen=0.99×15.387=15.233 MW\begin{aligned} Q_d &= Q_{45\%} - Q_r = 7 - 0.32 = 6.680\ \text{m}^3/\text{s} \\ H_n &= H_g(1 - 0.05) = 280 - 14.00 = 266.00\ \text{m} \\ P_{hyd} &= \rho g Q_d H_n = 9.81 \times 6.680 \times 266.00 = 17.431\ \text{MW} \\ P_{shaft} &= \eta_t P_{hyd} = 0.91 \times 17.431 = 15.862\ \text{MW} \\ P_{gen} &= \eta_g P_{shaft} = 0.97 \times 15.862 = 15.387\ \text{MW} \\ P_{out} &= \eta_{tr} P_{gen} = 0.99 \times 15.387 = 15.233\ \text{MW} \end{aligned}

Answer: generator output = 15.387 MW; power delivered to the 66 kV bus = 15.233 MW.

b) Number of units and installed capacity

  • Choose 2 units. With a run-of-river flow that falls well below the design flow in the dry months, one unit can run near full load on half the design flow, so efficiency stays high in winter.
  • One unit can be maintained while the other runs, and two units keep the number of machines (and cost) low for a plant of this size.
  • Per unit: Q=6.680/2=3.340Q = 6.680/2 = 3.340 m³/s, generator output =15.387/2=7.693= 15.387/2 = 7.693 MW → rate each unit at 7.7 MW.
  • Generator rating: S=7.7/0.85=9.06S = 7.7/0.85 = 9.06 MVA → 9.5 MVA, 11 kV, 0.85 pf, 50 Hz.
  • Step-up transformer, one per unit: 10 MVA, 11/66 kV, YNd11 (next standard size above 9.5 MVA).

Answer: installed capacity = 2 × 7.7 MW = 15.4 MW.

c) Selection and recommendation of turbine

Hn=266.00H_n = 266.00 m lies in the Francis (10–350 m) and Pelton (50–1300 m) ranges, so the specific speed decides.

Shaft power per unit P=15.862/2=7931.2P = 15.862/2 = 7931.2 kW. With N=120f/pN = 120f/p (synchronous speeds) and Ns=NP/Hn5/4N_s = N\sqrt{P}/H_n^{5/4}, where Hn5/4=1074.2H_n^{5/4} = 1074.2:

NN (rpm)PolesNsN_s (metric, kW)
1000682.9
750862.2
6001049.7
5001241.5
428.61435.5
3751631.1
333.31827.6

Usual ranges: Pelton about 10–30 per jet (multi-jet Ns=Ns,jetzN_s = N_{s,jet}\sqrt{z}), Francis about 60–300, Kaplan 300–1000.

Choose N=500N = 500 rpm (12 poles): Ns=41.5N_s = 41.5. With 4 jets, Ns,jet=41.5/4=20.7N_{s,jet} = 41.5/\sqrt{4} = 20.7, inside the Pelton range.

Check of jet ratio: jet velocity Vj=0.982gHn=70.8V_j = 0.98\sqrt{2gH_n} = 70.8 m/s; bucket speed u=0.46Vju = 0.46V_j; runner diameter D=60u/(πN)=1.24D = 60u/(\pi N) = 1.24 m; jet diameter d=4(Q/z)/(πVj)=0.123d = \sqrt{4(Q/z)/(\pi V_j)} = 0.123 m; D/d=10.2>10D/d = 10.2 > 10, acceptable.

A Francis at 1000 rpm (Ns=82.9N_s = 82.9) is also possible, but the Pelton is preferred because (i) its efficiency stays nearly flat from about 20% to 100% load (jets can be switched off), which suits a run-of-river plant whose flow falls far below the design flow in the dry season, and (ii) it tolerates the heavy sediment of Himalayan rivers better, and worn buckets and needles are easier to repair.

Answer: 2 × vertical-axis 4-jet Pelton turbines, 500 rpm, about 7.93 MW each.

From the efficiency versus Q/Q0Q/Q_0 curves: Pelton and full Kaplan stay above about 85% down to 20–30% flow, while Francis drops sharply below about 40–50% flow and a fixed propeller is the worst. Since this plant runs at part flow for much of the year, the flat Pelton curve supports the choice.

d) Single line diagram

 Line-1          Line-2  (66 kV, 30 km)
    |               |
  [CB]            [CB]
    |               |
 ===+=====+=========+===+=== 66 kV bus
          |             |
        [CB]          [CB]
          |             |
        (T1)          (T2)
          |             |
        [CB]          [CB]
          |             |
 =========+====[BS]=====+=========+=== 11 kV bus
          |             |         |
        [GCB]         [GCB]     [CB]
          |             |         |
        (G1)          (G2)      (ST)
                                  |
 =================================+===+ 0.4 kV
                                      |
                                    [ACB]
                                      |
                                    (DG) black start
ItemRating
Generators G1–G29.5 MVA, 11 kV, 0.85 pf, 500 rpm, Xd′′X''_d = 21%
Step-up transformers T1–T210 MVA each, 11/66 kV, YNd11, XX = 9.15%
Station transformer ST250 kVA, 11/0.4 kV, Dyn11, 4.5% (aux load about 1.5% of capacity)
Diesel generator DG160 kVA, 0.4 kV (essential auxiliaries for black start)
Line66 kV, double circuit, 30 km to grid substation
NGRneutral grounding resistor (low-resistance earthing, one generator earthed at a time if preferred)

BS = bus section breaker, GCB = generator circuit breaker, ACB = air circuit breaker. Black start: with the grid dead, the DG energises the 0.4 kV auxiliary bus (governor oil pumps, cooling water, excitation field flashing, lighting and battery chargers), one unit is started and runs in island mode, and it then energises the step-up transformer and the line.

e) Rating of generator circuit breaker

Per-unit reactances on 100 MVA base:

xg=0.21×1009.5=2.2105 pu,xt=0.0915×10010=0.9150 puXL=2πfLl=2π×50×0.92×10−3×30=8.671 Ω per circuit; two in parallel=4.335 Ωxl=XL×100662=4.33543.56=0.0995 pu,xgrid=1001000=0.1000 puxgrid path=0.1000+0.0995=0.1995 pu\begin{aligned} x_g &= 0.21 \times \frac{100}{9.5} = 2.2105\ \text{pu}, \quad x_t = 0.0915 \times \frac{100}{10} = 0.9150\ \text{pu} \\ X_L &= 2\pi f L l = 2\pi \times 50 \times 0.92\times10^{-3} \times 30 = 8.671\ \Omega \text{ per circuit; two in parallel} = 4.335\ \Omega \\ x_l &= \frac{X_L \times 100}{66^2} = \frac{4.335}{43.56} = 0.0995\ \text{pu}, \quad x_{grid} = \frac{100}{1000} = 0.1000\ \text{pu} \\ x_{grid\ path} &= 0.1000 + 0.0995 = 0.1995\ \text{pu} \end{aligned}

All generators feed the common 11 kV bus, so the GCB is rated for the full 11 kV bus fault level (generators plus the grid through the step-up transformers):

Sgen=2×1002.2105=90.5 MVASgrid=100xt/2+xgrid path=1000.4575+0.1995=152.2 MVAS11kV=90.5+152.2=242.7 MVA\begin{aligned} S_{gen} &= 2 \times \frac{100}{2.2105} = 90.5\ \text{MVA} \\ S_{grid} &= \frac{100}{x_t/2 + x_{grid\ path}} = \frac{100}{0.4575 + 0.1995} = 152.2\ \text{MVA} \\ S_{11kV} &= 90.5 + 152.2 = 242.7\ \text{MVA} \end{aligned} Isc=242.73×11=12.74 kA,Imake=2.55×12.74=32.48 kA peakIFL=9.53×11=499 A,1.25IFL=623 A\begin{aligned} I_{sc} &= \frac{242.7}{\sqrt{3} \times 11} = 12.74\ \text{kA}, \quad I_{make} = 2.55 \times 12.74 = 32.48\ \text{kA peak} \\ I_{FL} &= \frac{9.5}{\sqrt{3} \times 11} = 499\ \text{A}, \quad 1.25 I_{FL} = 623\ \text{A} \end{aligned}
ParameterRequiredSelected
Rated voltage11 kV system12 kV
Rated normal current≥ 623 A630 A
Breaking capacity242.7 MVA (12.74 kA)25 kA (520 MVA at 12 kV)
Making capacity32.48 kA peak63 kA peak
Short-time current–25 kA, 3 s
Type–Vacuum (or SF6), generator-duty tested (IEEE C37.013)

Answer: GCB fault level = 242.7 MVA; select a 12 kV, 630 A, 25 kA generator circuit breaker. The margin covers the DC component and delayed current zeros of generator faults; surge arresters and surge capacitors are fitted at the generator terminals when a VCB is used.

✓ Answer checked by Claude Opus 5.5 (high effort)

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