M.p.p.g.c.l Gandhi sagar Dam, Mandsaur M.P

A
INDUSTRIAL TRAINING REPORT
ON
M.P.P.G.C.L GANDHI SAGAR DAM, MANDSAUR (M.P)
Submitted in partial fulfillment of the requirement for the award of
Degree of
BACHELOR OF ENGINEERING
MECHANICAL ENGINEERING 2013-2017
Submitted to
RAJIV GANDHI PROUDYOGIKI VISHWAVIDHYALAYA
BHOPAL (M.P)
Submitted by
SHUBHAM DHANESHREE
Enrollment No. 0712ME131049
Department of MECHANICAL Engineering
Mahakal Institute of Technology & Science, Ujjain

Industrial training report,
Mahakal Institute of Technology and Science, Ujjain (M.P)
Page 1
ACKNOWLEDGEMENT
An engineer with only theoretical knowledge is not a complete
engineer practical knowledge is very important to develop and apply
engineering skills. Its gives me great pleasure to have an opportunity to
acknowledge and to express gratitude to those who were associated
with me during my training at M.P.P.G.C.L, Gandhi Sagar Mandsaur,
(M.P).
I express my sincere thanks and gratitude to M.P.P.G.C.L,
authorities for allowing me to undergo the training in this prestigious
organization. I will always remain indebted to them for constant
interest and excellent guidance in my training work. More over for
providing me with an opportunity to work and gain experience.
SHUBHAM DHANESHREE

Page 2
CONTENT
Certificate
Acknowledgement
Gandhi Sagar Dam Overview
Introduction of hydro power plant
Hydraulic Turbines
 Reaction Turbines
1. Axial flow reaction turbines
2. Radial flow turbines
 Impulse turbines
Appurtenant structure for reaction turbine
Power house layouts
Conclusion

Page 3
Gandhi Sagar Dam Overview
The Gandhi Sagar Dam is one of the four major dams built on India's
Chambal River. The dam is located in the Mandsaur district of the state
of Madhya Pradesh. It is a masonry gravity dam, standing 62.17 meters
(204.0 ft.) high,[1]
with a gross storage capacity of 7.322 billion cubic
meters from a catchment area of 22,584 km2
(8,720 sq. mi). The dam's
foundation stone was laid by Prime Minister of India Pandit Jawaharlal
Nehru on 7 March 1954,[2]
and construction of the main dam was
completed in 1960. Additional dam structures were completed
downstream in the 1970s.

Page 4
The dam sports a 115-MW hydroelectric power station at its toe, with
five 23-MW generating units each providing a total energy generation
of about 564 GWh.[3]
The water released after power generation is
utilized for the irrigation of 427,000 hectares (1,060,000 acres) by the
Kota Barrage, which is located 104 kilometers (65 mi) downstream of
the dam, near the city of Kota in the state of Rajasthan.[2][4][5]
The dam's reservoir area is the second-largest in India (after the
Hirakud Reservoir), and attracts a large number of migratory and non-
migratory birds throughout the year. The International Bird Life Agency
(IBA) has qualified the reservoir under "A4iii" criteria, as the
congregation of water birds is reported to exceed 20,000 at some
points.

Page 5
Official name
Bhadra
Location Mandsaur District, Madhya Pradesh
Coordinates
24°42′24″N 75°33′12″ECoordinates: 24°42′24″N
75°33′12″E
Opening date 1960 (Stage I)
1970 (Stage II)
Construction cost Rs. 2.32 billion
Operator(s) Water Resources Department, Madhya Pradesh and
Madhya Pradesh Power Corporation
Dam and
spillways
Impounds Chambal River, a tributary of Yamuna River
Height 62.17 metres (204.0 ft)
Length 514 metres (1,686 ft)
Reservoir
Creates Multipurpose
Total capacity 7,322,000,000 m3
(5,936,000 acre·ft)
Catchment area 22,584 km2
(8,720 sq mi)
Surface area 723 km2
(279 sq mi)
Power station
Hydraulic head 44 metres (144 ft)

Page 6
Introduction of hydro power plant: -
Hydro-power or water power is power derived from the energy of
falling water and running water, which may be harnessed for useful
purposes. Since ancient times, hydro-power has been used
for irrigation and the operation of various mechanical devices, such
as water mills, sawmills, textile mills, dock cranes, domestic lifts,
power houses and paint making.
Since the early 20th century, the term has been used
almost exclusively in conjunction with the modern development
of hydro-electric power, which allowed use of distant energy
sources. Another method used to transmit energy used a trompe,
which produces compressed air from falling water. Compressed air
could then be piped to power other machinery at a distance from
the waterfall. Hydro power is a renewable energy source.
Water's power is manifested in hydrology, by the forces
of water on the riverbed and banks of a river. When a river is in
flood, it is at its most powerful, and moves the greatest amount
of sediment. This higher force results in the removal of sediment
and other material from the riverbed and banks of the river, locally
causing erosion, transport and, with lower
flow, sedimentation downstream.

Page 7
Hydraulic Turbines:- These form the prime mover which
transforms the energy of water into mechanical energy of rotation and
whose prime function is to drive a hydroelectric generator. The turbine
runner and the rotor of the generator are usually mounted on the same
shaft, and thus the entire assembly is frequently referred to as the
turbo-generator.
Hydroelectric plants utilize the energy of water falling through a certain
difference in levels which may range from a few meters to 1500m or
even 2000m. To handle such a wide range of pressure heads, various
turbines differing in design of their working is employed. Modern
hydraulic turbines are divided into two class - impulse and reaction. An
impulse turbine is one in which the driving energy is supplied by the
water in kinetic form, and a reaction turbine is one in which the driving
energy is provided by the water partly in kinetic and partly in pressure
form.

Page 8
Turbines are classified according to several considerations as indicated
below.
i) Based on working principle
a) Impulse turbine
b) Reaction turbine
ii) Based on working media
a) Hydraulic turbine
b) Steam turbine
c) Gas turbine
d) Wind Turbine
iii) Based on head
Head is the elevation difference of reservoir water level and
D/S water level.
a) High head turbine (Above 250 m) Pelton Turbine
b) Medium head turbine (60 – 250 m) Francis
Turbine
c) Low head turbine (Below 60 m) Kaplan
Turbine
iv) Based on specific speed
Turbines can be classified based on Specific Speed. Specific
speed is defined as the speed in rpm of a geometrically similar turbine,
which is identical in shape, dimensions, blade angles and gate openings
with the actual turbine working under unit head and developing unit

Page 9
power. Specific speed is used to compare the turbines and is denoted by
Ns.
Specific speed Ns = N √P / H5/4
a) Low specific speed (8.5 – 30) - Pelton Turbine
b) Medium specific speed (50 – 340) - Francis Turbine
c) High specific speed (255 – 860) - Kaplan
Turbine
The basic types of impulse and reaction turbines are given in the
following table.
Turbine types Class Head range
Propeller turbines:
Fixed blade turbines
Adjustable blade ( Kaplan turbine)
Reaction
Reaction
10-60m
10-60m
Diagonal flow turbines Reaction 50-150m
Francis turbine Reaction 30-400m (even up to
500 to 600m)
Pelton turbine Impulse Above 300m

Page 10
Reaction turbines: - Reaction turbine operates with their
runners fully flooded and develops torque because of the reaction of
water pressure against runner blades
Reaction turbines are classified as Francis (mixed flow)
or axial flow. Axial flow turbines are available with both fixed blades
(Propeller) and variable pitch blades (Kaplan). Both axial flow (Propeller
& Kaplan) and Francis turbines may be mounted either horizontally or
vertically. Additionally, Propeller turbines may be slant mounted.
A turbine has stationary as well as rotating members. The stationary
components of a reaction turbine with vertical axis are shown in Figure.

Page 11
1.Axial flow reaction turbines: - The axial
flow turbine resembles the propeller of a ship and hence is also
termed as the propeller turbine. The runner of such a turbine
has three to eight blades, cantilever-mounted on a spherical or
cylindrical hub equipped with a cone (Figure 3c). In a fixed
blade propeller turbine, the blades are rigidly fastened to the
hub at a permanent angle. In the adjustable-blade propeller (or
Kaplan) turbine, the blade angles can be adjusted by an
hydraulic operated piston located within the hub (Figure 3d).
The advantage of having an adjustable-blade for a propeller
turbine, as for the Kaplan turbine, is that the fixed blade
wheels show peak efficiency at only a small range of load. If
load is slightly higher or smaller than this range, its efficiency
drastically decreases. On the other hand, the blade adjustable
turbines can be operated in such a way that their efficiency
remains high over a very large range of load.

Page 12
2. Radial flow reaction turbines: - The
runner of a Francis turbine, where the flow of water from the
stationary part into the turbine runner is in a radial direction. Once
inside the runners, the flow direction changes and gets directed
downward. The runners of a Francis turbine are attached at their upper
ends to a conical crown and the lower ends to a circular band. The
shrouded buckets make an angle with the radial planes and bend at the
bottom. The number of blades usually ranges from 14 to 19 (Figure 4c).
As with the propeller turbine, the runner shape depends upon the
head, as shown in Figure 4d.

Page 13
Impulse turbines: - The Pelton turbine is an impulse
turbine that is used commonly in hydro power projects world wide for
very high head installations. The runner of a Pelton turbine (Figure 8)
consists of a disk with buckets attached around its periphery. The
buckets can be integrally cast with the disk or welded or bolted to the
wheel centre. The buckets may vary in details of their construction but
in general they are bowl-shaped and have a central dividing wall, or
splitter, extending radially outward from the shaft. The runner is
enclosed in a housing and is mounted on the same shaft with the rotor
of the water-wheel generator, placed either vertically or, more
frequently, horizontally. The water is supplied from the upper pool
through penstocks which end with one or several tapering nozzles. The
water jet escaping from the nozzles hit the dividing wall which splits it
into two streams, and the bowl-shaped portions of the buckets turn the
water back, imparting the full effect of the jet to the runner. The
quantity of water through the nozzle is controlled with the help of a
spear-valve. The used water flows down a conduit into the lower pool.

Page 14
Appurtenant structures for reaction
turbines: - The power output of a reaction turbine depends upon
the hydro-net pressure head, that is, the effective head available for
power generation. This is calculated by deducting the losses in the
water conductor system (including penstocks) from the gross head
evaluated between the head water or reservoir level and the tail water
level. Further, the entire water passage from the intake to the outlet is
completely filled with water. In fact, there should not be any water nor
the water pressure be so low that it turns into vapor, which may create
cavitation damage to the turbine and the water passage. Hence, it is
important to design the path of water from its distribution to the
runner at the periphery of the stationary part to the existing passage.

Page 15
In Figure 10, a three dimensional cut-out view through the power
house of a reaction turbine has been shown. The turbine and
generator units have been removed to give a better view of the
water passage. It may be observed that the penstock, which is a
uniform diameter tube shapes in to a spiraling pipe near the
turbine that reduces in size towards its tail end. This section,
called the Spiral or Scroll Casing, is provided to distribute the
conveyed water all around the periphery of the turbine runner
through the stay rings and wicket gates as uniformly as possible. At
the bottom, the water passage bends up from vertical to a horizontal
alignment, and this passage is known as the draft tube. The functions of
a Draft Tube are two-fold: (a) Achieves the recovery of velocity head at
runner outlet, which otherwise would have wasted as exit loss, and (b)
Allows the turbine to be set at a higher elevation without losing
advantage of the elevation difference. The second objective allows
easier inspection and maintenance of the turbine runners.
Figure 11 explains the reason why a reaction turbine enjoys the energy
available between the runner end and the tail water level (Hs
) with the
help of a draft tube (Figure11b). In the absence of a draft tube

Page 16
(Figure11a), the head difference (Hs
) would have simply been lost. As
shown in Figure11b, in the presence of a draft tube, therefore, there
exits a sub- atmospheric pressure at the bottom of the runner. It may
be noted that though Figure11 shows a typical Francis turbine in place,
the draft tube is not very different in case of a propeller or Kaplan
turbine, as shown in Figure 12.

Page 17
circular but gradually changes to a rectangular section as it becomes
horizontal. This is because at the end of the draft tube, there is usually
a rectangular shaped gate that is sometimes required to shut off tail
water during maintenance. However, the change in shape of the elbow
increases the turbulent losses in the draft tube. The magnitude of this
loss depends upon the magnitude of flow.
A sectional view through the water passage and turbine of the power
house shown in Figure 10 would be as shown in Figure 11, which shows
a typical Francis runner installed.
Of course, one may replace the runner with a Propeller or Kaplan unit
without changing much of the inlet and exit water passages, the spiral
casing and draft tubes.
Both the spiral casing and draft tubes have to be designed carefully, in
order reduce the head loss as far as possible and also to avoid
cavitations. The following Bureau of Indian Standards codes can be
referred to for carrying out a detailed design of these units:
IS: 7418-1991 “Criteria for design of spiral casing (concrete and steel)”
IS: 5496-1969 “Guide for preliminary dimensioning and layout of elbow
type draft tubes for surface
hydel power stations”

Page 18
Power house layouts: -
Classifying by the way the water from the head water pond or reservoir
is applied to the turbine, one may differentiate powerhouses as
belonging to one of the following categories:
1. In-stream, as for low-head run-of river plants (Figures 13 ). Here, the
intake head works are incorporated as a part of the power house.

Page 19
2. Detached, as for turbines receiving water through an intake from the
head water via a penstock (Figure 15).

Page 20
The length of a power house mainly depends upon the unit spacing,
length of erection bay and the length required for the overhead crane
to handle the last unit. The total length (L) of the power houses may be
determined from the following formula:
L = N0
× (unit spacing) + Ls
+ K
where
N0
= Number of units
Ls
= Length of erection bay
K = Length required for overhead gantry crane to handle the last unit
The length of erection bay may be taken as 1.0 to 1.5 times the unit bay
size as per erection requirement. The width of the power house
depends on the dimensions of the spiral casing and the hydro
generator. Superstructure columns which are required to carry the
weight of the rails supporting the overhead gantry crane are usually
spaced at about 2.0 to 2.5 metres.
The height of the power house from the bottom of the draft-tube to
the centerline of spiral casing (H1
in Figure 20) has to be determined
from the dimensions of elbow type draft tube. The thickness of the
concrete below the lowest point of draft-tube may be taken from 1.0 to
2.0m depending upon the type of foundation strata, backfill conditions
and size of the power house. The height from the center line of the
spiral casing up to the top of the generator (H2
in Figure 20) can be
determined from the height of the generator’s stator frame and that of
the load bearing bracket.
The height of the machine hall above the top bracket of the generator
depends upon the overhead cranes hook level, corresponding crane rail
level, and the clearance required between the ceiling and the top of the
crane.

Page 21
IS: 12800-1993 “Guidelines for selection of turbines, preliminary
dimensioning and layout of surface hydro-electric power houses”
Part 1: Medium and large power houses
Part 2: Pumped storage power houses
Part 3: Small, mini and micro hydroelectric power houses

Page 22
Conclusion: -
The objective of industrial training is to provide work experience so that
students’ engineering knowledge enhance and employment prospects
are improve. The student should take this course are a window to the
real world of work and should try to learn as much as possible from real
life experience by involving and interaction with interaction with
industry staff. Industrial training also provide an opportunity to
students to select an engineering problems and possibly and industry
guide for major projects in final semester.
Industrial training of the student is essential to bridge to
wide gap between the classroom and industrial environment. This will
enrich their practical learning and they will be better equipped to
integrate the practical experience with the classroom learning process.

Page 23
REFERENCE:-
1. www.wikipedia.com
2. Google.co.in
3. Bansal R. K; Fluid Mechanics & Fluid Machines
4. Venkanna BK; turbomachinary; PHI
5. NPTEL m5l03.pdf
6. www.Slideshare.net

M.p.p.g.c.l Gandhi sagar Dam, Mandsaur M.P

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