You are on page 1of 58

SAMARA UNIVERSITY

College of Engineering and Technology


Department of Electrical and Computer Engineering

Stream Power System Engineering

Host Company:

Ethipian Electric Power

Report On Internship Work at: Tana Beles Multipurpose Project

Prepared By:

Aschalew Mekete

Advisor: Milky

January/……

Samara, Afar, Ethiopia


Declaration
I am 5th year Electrical and computer Engineering student have undertaken our internship
experience in Beles hydro Electric power plant for a period of October to January under the
guidance of mentor Mr.Milky, Mr.Yigermal, and Mr welde mariam.I clarify that my work is
original and compiled according to the internship report writing guide line given by the
department.
Intern Name IDNO Signature
Aschalew mekete……………242/06………………….
As the student academic advisor, I clarify that the internship report prepared by the student is
original work and compiled according to the guide line provided by the department as far as our
knowledge’s is concerned.
Name of advisor Signature Date
Mr.Milky …………… …………..

I
Acknowledgements
I am numerously thankful Samara University and UIL office for giving this opportunity of being
parts of the internship program. I am also want to say special thanks for the following persons
and organizations that contributes great role in our four month internship program achieving
without any ambiguity who acts as not only teacher, supervisor, mentors and workers but also
like father, mother and friends. I want to give grateful thanks to my mentor Mr.yigermal he
gave us moral support and guided us in different matters regarding to the internship program. I
would like to thank our company supervisor Mr. Daniel, Ms.Abeba, Mr.Anbachew, Ms.Adey,
and Mr.Woldemariam who helped me a lot in gathering different information, giving data and
guides from time to time in making internship program. Generally, I want to say special thanks
to all Tana Beles hydropower plant workers starting from site manager to everyone else.

II
ABSTRACT
The importance of internship program is obviously known in education, because it gives the
student chance to link his/her theoretical batch ground to the real world application. It also helps
the student to develop different personal skill and take glimpse at the real world experience that
waits after graduation. During the past four month, we are working in Beles hydroelectric power
plant in the first semester fifth year of study on electrical and computer engineering. This
company is responsible for generating an electrical energy. During this intern we know general
idea about hydro power plant and basic components of this generation, like intake, power house,
and switch yard and out let and also how to control system analyze, measure, inspect, and how to
maintain temporary as well as permanent faults. This report document includes over views and
back ground of the company, objective, work, responsibility and assignment, technical aspect
and problem solving problem like manually carbon brush replacement in excitation system.
Excitation system is provided for synchronous machine which is operated both as a motor and
generator. Field excitation is provided by a DC batteries source which is connected as a brush
exciter. This mechanism is to change the polarity of brush to equalize the wearing rate of brush
and slip ring. By means of automatic polarity charger circuit this uses LDR as a sensor and
Principal operation of hydro power plant and their component, general problem,
recommendation and reference.

III
Table of Contents
Acknowledgements ......................................................................................................................... II

ABSTRACT .................................................................................................................................. III

Acronyms ...................................................................................................................................... IX

CHAPTER I .................................................................................................................................... 1

1.1. Company background and overviews .................................................................................. 1

1.1.1. Historical Background ................................................................................................... 1

1.2 Vision .................................................................................................................................... 2

1.3 Mission .................................................................................................................................. 2

1.4 Objectives of the company .................................................................................................... 2

1.5 Main customers (key stake holders) of company .................................................................. 2

1.6 Production process of the company ...................................................................................... 3

1.7 Main products or services ..................................................................................................... 3

1.8. Organization structure .......................................................................................................... 4

1.9 Work flow ............................................................................................................................. 4

CHAPTER TWO ............................................................................................................................ 6

Over all about internship ................................................................................................................. 6

2.1 Objectives of the internship................................................................................................... 6

2.1.1 General objective ............................................................................................................ 6

2.1.2 Specific objectives .......................................................................................................... 6

2.2 How we did get the company ................................................................................................ 6

2.2 Overall system components .................................................................................................. 7

2.2.1 Inlet structure .................................................................................................................. 7

2.2.2 Intake structure ............................................................................................................... 7

2.2.3. The low pressure headrace tunnel ............................................................................... 10

2.2.4. Surge shaft ................................................................................................................... 10


IV
2.2.5. Penstock ....................................................................................................................... 10

2.2.6. High pressure headrace tunnel ..................................................................................... 11

2.2.7. Power house ................................................................................................................. 11

2.2.8. Main inlet valve .......................................................................................................... 11

2.2.9. The speed governor ..................................................................................................... 12

2.2.10. Synchronous generators ............................................................................................. 13

2.2.11. Field excitation .......................................................................................................... 15

2.2.12. Transformers .............................................................................................................. 16

2.2.13. Draft tube gate ........................................................................................................... 20

2.2.14 cooling water system .................................................................................................. 20

2.2.15 Power house firefighting system ................................................................................ 21

2.2.16 Supervisory control and data acquisition (SCADA) system ...................................... 22

2.2.17 Control panel .............................................................................................................. 23

2.2.18. Protection ................................................................................................................... 24

2.2.19 Irrigation by-pass ........................................................................................................ 24

2.2.20. Switch yard ................................................................................................................ 25

2.2.21 Tail race tunnel ........................................................................................................... 30

2.2.22 Tail race portal ............................................................................................................ 30

2.2.23 Outlet .......................................................................................................................... 30

2.2.24communication system ................................................................................................ 30

2.3 Work section ....................................................................................................................... 30

2.4 Performing work tasks ........................................................................................................ 31

2.4.1 Took inspection ............................................................................................................ 31

2.4.2 Battery inspection ......................................................................................................... 32

2.4.3 Diesel inspection.......................................................................................................... 33

V
2.4.4 Breakdown maintenance............................................................................................... 33

2.5 Procedures and methods ...................................................................................................... 34

2.6 Challenges and problems .................................................................................................... 34

CHAPTER THREE ...................................................................................................................... 36

Overall internship experience ....................................................................................................... 36

3.1 Theoretical knowledge and practical skills ......................................................................... 36

3.2 Team playing skill ............................................................................................................... 36

3.3 Interpersonal communication skill ...................................................................................... 37

3.4 Leadership skills.................................................................................................................. 37

3.5 Entrepreneurship skills ........................................................................................................ 38

3.6 Work ethics ......................................................................................................................... 38

3.6.1 Personal ethics .............................................................................................................. 39

3.6.2 Professional ethics ........................................................................................................ 39

CHAPTER FOUR ......................................................................................................................... 40

Projects and Contributions ............................................................................................................ 40

CHAPTER FIVE .......................................................................................................................... 44

Conclusions and Recommendation ........................................................................................... 44

5.1 Conclusions ......................................................................................................................... 44

5.2 Recommendation ................................................................................................................. 44

5.2.1 Recommendation to the company ................................................................................ 44

5.2.2 Recommendation for university linkage....................................................................... 45

5.2.3 Recommendation for school ......................................................................................... 45

References ..................................................................................................................................... 46

VI
List of Figures
Figure 1. 1Production process of power plant ................................................................................ 3
Figure 1. 2 Organizational structure of Beles HPP ......................................................................... 4
Figure 2. 1The general overview of Beles hydropower plant ......................................................... 7
Figure 2. 2 General intake structure ................................................................................................ 8
Figure 2. 3 Rack cleaning machine ................................................................................................. 9
Figure 2. 4 Entrance of the power house and machine hall floor ................................................. 11
Figure 2. 5 Main inlet valve .......................................................................................................... 12
Figure 2. 6 Overview generator and turbine connection............................................................... 14
Figure 2. 7 power transformer ...................................................................................................... 17
Figure 2. 8 Principal function of excitation .................................................................................. 19
Figure 2. 9 Station service transformer ......................................................................................... 20
Figure 2. 10 cooling water system ................................................................................................ 21
Figure 2. 11 Firefighting system ................................................................................................... 22
Figure 2. 12 Over view of SCADA .............................................................................................. 23
Figure 2. 13 Switch yard ............................................................................................................... 25
Figure 2. 14 voltage transformer ................................................................................................... 26
Figure 2. 15 current transformer ................................................................................................... 27
Figure 2. 16 Pantograph ................................................................................................................ 29
Figure 2. 17 Backup battery .......................................................................................................... 33
Figure 4. 1 diagram of excitation current polarity changer of the brush ...................................... 43

VII
List of Table

Table 2, 1 Characteristics of low pressure tunnel ......................................................................... 10


Table 2, 2 generator rating ............................................................................................................ 14
Table 2, 3 Characteristic of the transformer ................................................................................. 17

VIII
Acronyms
A Ampere

AC Alternating current

ACS Aluminum conductor steel reinforced

BHPP Beles Hydro Power Plant

BMPP Beles Multipurpose Project

CB Circuit breaker

CCTV Closed circuit television

CT Current Transformer

o
C Degree Celsius

DC Direct Current

DIA Data Integrity Assurance

DRS Digital Relay System

Ear Armature Voltage

EELPA Ethiopian Electric Light and Power Authority

EEP Ethiopian Electric Power

EMF Electromotive force

EEU Ethiopian Electric Utility

F/N Force per Newton

g gravitational acceleration

GCB Generator Circuit Breaker

IX
GWh/y Gega Watt Hour per year

H Height

Ha Hectare

HV High Voltage

HVAC Heat Ventilation and Air Conditioning

Ia Armature Current

Kg/m Kilogram Per meter

KN Kilo Newton

kV Kilo Volt

KVA Kilo Volt Ampere

LCP Local Control panel

mA milli Ampere

MIV Main Inlet Valve

MVA Mega Volt Ampere

MW Mega Watt

M&D Monitoring and Diagnostics

OFWF Oil Forced Water Forced

P Power

PID Proportional Integrator and Differentiator

PLC Programmable Logic Control

PT Potential Transformer

X
Q flow rate of water

SCADA Supervisory Control and data Acquisition

SF6 Sulphur hexa fluoride

UIL University industrial linkage

V Voltage

VT Voltage Transformer

XI
CHAPTER I
1.1. Company background and overviews
1.1.1. Historical Background
The Ethiopian Electric Power (EEP) is a fully government-owned public enterprise established to
develop and provide electric power. EEP supplies power in bulk mainly to the Ethiopian Electric
Utility (EEU), which is responsible for distribution of electricity to customers throughout the
country. EEP's mandate is to generate and transmit electric power and develop these facilities
and infrastructures.

EEP is also mandated to export electric power to neighboring countries through high-voltage
transmission systems and to domestic large consumers directly. While some neighboring
countries are already importing electricity from Ethiopia, others have signed PPAs for future
trade.
Ethiopia strives to be the hub of renewably sourced energy in the region and beyond. Ethiopian
Electric Power (EEP) is instrumental to this ambitious plan.

EEP is a sole provider of bulk electricity to users, mainly to the Ethiopian Electric Utility (EEU);
direct industrial customers; and exports to neighboring countries. Djibouti and the Sudan are
connected to Ethiopia by a high-voltage power line. A 400MW energy purchase agreement was
signed; and a 500 kilovolt (kV) HVDC line between Kenya and Ethiopia is under construction

EEP operates and maintains more than 12 hydropower and three wind power plants distributed in
different parts of the country with installed capacity of more than 4290MW, including the Gibe
III plant (1870MW) which is under commissioning. There are two major hydropower projects
under construction, namely the Grand Ethiopian Renaissance Dam (6000MW) and Genale Dawa
3 (254MW).

EEP operates and maintains all high-voltage transmission lines across the country, which covers
more than 9,000km with varying voltage levels ranging from 500kV to 132kV; and more than 90
substations with the above mentioned voltage levels. Huge transmission line expansion is
planned to extend the system and cover the whole country including border crossing power lines.

1
EEP has its own transmission & substation construction unit task force, which has more than 30
years of experience and developed construction and commissioning capacity of high-voltage
lines up to 230 KV and substations.

The Beles Hydroelectric Power Plant sometimes referred to as Beles II or Tana Beles, is a run-
of-the-river power plant in Ethiopia near Lake Tana. The power plant receives water from the
lake and after utilizing it to produce electricity the water is then discharged into the Belles River.
The plant has an installed capacity of 460 MW and it is the second largest power plant in the
country. It is also expected to help provide water for the irrigation of 140,000 hectars.In 1992;
the first feasibility study was complete for the project, a 200 MW power station. A later study
and final design was completed in 2005 by Studio Pietrangeli for the current 460 MW plant.
1.2 Vision
“By 2025 to be a first-class provider of quality electric power for the whole country, and a
competitive exporter of energy in the region.”

1.3 Mission
“To provide adequate and quality electricity generation, transmission through continuous
improvement of management practice responsive to the socio-economic development and
environmental protection need of the public.”

1.4 Objectives of the company


To provide a major link to deliver the power generated from beles power plant to the load centers
of the northwest region of the country which is connected to the grid. This improves the power
supply reliability and system stability of the national grid.

1.5 Main customers (key stake holders) of company


The main stakeholders of EEP are the government, which is the owner of the corporation, the
employees and customers. The major customers of EEP are householders, governmental and
nongovernmental organizations, industries, small scale enterprises and business institutes are
customers and beneficiaries of EEP. The corporation in general provides service to the public.
EEP is the big corporation that control and monitor the country energy source monopoly as a
whole. That is why it is hold by the government only monopoly.

2
1.6 Production process of the company
The Production process of the company starts at the natural reservoir, i.e. lake Tana where
water is drained to passes through the tunnel and fall over the turbine .The turbine rotates and
generates AC power by using generator (alternator). The generated electricity is then getting in
to step up transformer for being transmitted over the transmission line.

Figure1. 1Production process of power plant

1.7 Main products or services


EEP manages and operate power generating facilities, the national transmission and distribution
grids, and is also responsible for the supply of electricity to more than 28,700,000 customers
with a total of 5163 towns. The development of BMPP has increased the generation capacity of
the country and makes the power export viable. These power plant generate 460MW as
previously described and supply an electrical power for different governmental and
nongovernmental industries, for lighting of towns such as BahirDar, Debremarkos, Slulta and
some parts of Addis Ababa. In addition to the direct benefit it has created job opportunity during
constriction improved access to the local transport and created trade link between project area
and nearby towns. Under this project some public service facility have been constructed or
repaired by the contractor for the community. These include High school, health center, police
station, administrative office and religious center.

3
1.8. Organization structure
The work flow in generation operation of Beles hydro power plant has the following branches.
From these branch in the intern period of BHPP, we are worked in the maintenance and
operation team section.

Management board

Chief executive

Officer

General manager Administration


and finance team

Maintenance Operation leader Administration Finance and


leader casher

Maintenance team Operation team

Figure1. 2Organizational structure of Beles HPP

1.9 Work flow


Maintenance is the process by which any equipment or machinery can be maintained in a proper
and efficient condition.

The electrical equipment or apparatus like any other electric machines requires carefully planned
program of checking or inspecting to give satisfactory and trouble-free service for a long time.

4
The periodic inspection and maintenance details may vary with the type of machine and its
working condition but planning and inspection of different items at regular intervals will meet
most of the requirements of the time.

The performance of any equipment or machine or apparatus must be particularly observed


immediately after commissioning it in respect of its operating voltage, current, starting device
and unusual vibrations and noise.

BMPP has two main work groups. These are the maintenance and operation groups.

Work flow in maintenance:

 Discus the day work according to the plan except sudden emergency appears

 Then perform their task within group

 Report their data to maintenance leader.

Work flow in operation:

 Within their shift recording over all plant conditions hourly from SCADA system

 report to operation leader

Then the two leaders collect data and give to the plant manager

5
CHAPTER TWO
Over all about internship
2.1 Objectives of the internship
The four-month internship program comprises of general and specific objectives, both added to
produce skilled man power in engineering aspects.

2.1.1 General objective


Samara University college of engineering aims that this internship program enables engineering
students under the institute:-

 To analyze the theoretical back ground with related practical situation

2.1.2 Specific objectives


The interns, during the internship, are aimed to;-

 improve their practical, theoretical and interpersonal communications

 develop team playing, entrepreneurship and leadership skills

 understand about work ethics related issues, responsibility

 To understand how to check and maintain devices

 To relate the interns with the common obstacles who those must straggle

 To show interns what interface is there when they conduct in such area after graduation
are the specific objectives.

2.2 How we did get the company


First of all I was ask different industrial company especially in Kombolcha and Dessie but I have
not any acceptance. Then I am get the chance from our department to send ELPA five students.
Our department send us with thanks letter to ELPA. Then when we reach we get Mr.cheru he
accept our acceptance paper and he write for tana beles generation and give for us to contact the
company. I am wait two days in Addis Ababa because there is no transportation due to riot.
When I was reach in bahr dar I am calling to Mr. Mulugeta to accept us. But he said me there is
no guest house. He order us to wait for one week until arranged the guest house. I am calling

6
reputedly to him then he arranged in three day. Then I am reach and he accept introduce himself
and he order Mr. Daniel to introduce all about the company. He introduce all about company
such as documentation class, safety during we get power house, time that we contact and
arranged in group.

2.2 Overall system components


In The BMPP water from Lake Tana is taken via the intake structures. These structures are the
main gates for the water to enter the whole system. Hence we have tried to explain the flow of
water from this intake structures to the outlet where the water is finally combined with the
Johanna River after finishing its journey through the tunnel and goes to give yet another use for
irrigation in the surrounding area.

Figure 2. 1 The general overview of Beles hydropower plant

2.2.1 Inlet structure


This structure is one of the components of the water conveyance system in which the design flow
160m3/s passes through. It is equipped with stop log gates to five respective bays. The upper
parts of the inlet gate are bridge structure used as road way to pass vehicles.

2.2.2 Intake structure


This is the main structure of BMPP has spillway, trash rack, gates (bulk head, roller gate and air
vent), geometrical adaptation transition, dismantling chamber, transition/connector to low
pressure tunnel. The water when pass through the intake structure has a velocity 0.48m/s.

7
Figure 2. 2 General intake structure

2.2.2.1 Approach channel


The approach channel draws the water from the Lake Tana and conveys it to the headrace tunnel.
It subdivided in two sections, upstream and downstream of the channel inlet structure. Upstream
section is a channel structure which provides water from Lake Tana to stop logs. Downstream
side covers from stop logs to track rash machine.
2.2.2.2 Inlet stop logs
At the beginning of the inlet channel a set of stop logs (a total of 15 stop logs), including the
lifting beam. It is operated by manorial crane of capacity 150KN.The inlet monorail crane will
be used for the erection, operation and maintenance of the inlet stop logs. The mono rail crane
trolley mounted is used like any gantry crane operating gate for routine open close operation, for
maintenance support, and transferring to storage place of the gate. The lifting beam has locking
and unlocking mechanism by manually unlatching the latching device.

8
2.2.2.3. Trash rack
A horizontal beam which is used to support the panels and is free from vibration during all
operating condition and is sufficiently sturdy to limit as much as possible any deformation. It is
used to prevent the passage of debris which might damage the turbine.

2.2.2.4 Rack cleaning machine


The machine is used to clean the trash rack screen panels by removing floating debris, that is
coming with water and to facilitate the passage of water to the tunnel.

Figure 2. 3 Rack cleaning machine

2.2.2.5 Bulkhead Gate


The bulkhead gate operates only in balanced conditions and with the downstream wheel gate in
closed position. The gate structure is endowed of an internal by pass system in order to balance
the pressure levels upstream and downstream. When opening the bulkhead gate, the fixed gantry
crane operates a stroke to open the bypass plug (less than 60 mm) and let the water fill the
intermediate tunnel; the lifting is prevented until the pressure levels upstream and downstream
the bulkhead gate are balanced (filling time is 20 min for lifting operation). When the filling is
completed, the gantry crane operates the complete opening. The control operation of bulkhead
gate opening and closing are performed by the action of the fixed hoist. Control of operations
will be done from the local control panel installed on the hoist support structure.

9
2.2.2.6. Intake gate (wheel gates)
The main purpose of these gate are to allow maintenance and inspection of the power tunnel. The
gates will normally be in open position. The control panel foresees the terminal boards for
remote control signals and therefore the gate operation could be also possible from the control
room. Each gate is operated by a hydraulic system able to raise the gate leaf even under
unbalanced pressure conditions closure is guaranteed the leaf weight, the cylinder acting as a
brake.

2.2.2.7. Control room


Inside the control room of the intake step down transformer, standby diesel generator for
emergency (100KVA) 110V DC batteries are present.
2.2.3. The low pressure headrace tunnel
A tunnel which is used to carry water from intake to surge shaft. It has characteristics of low
pressure tunnel is shown below.

Length 11.823km
Excavated diameter 8.1m
Finished diameter 7.2m
Invert slope 3.00 m/km
Table 2, 1 Characteristics of low pressure tunnel

2.2.4. Surge shaft


A structure found right before the penstock shaft. Its main purpose is to provide space for the
water to reside whenever the main inlet valve is closed and hence preventing back flow of the
water. It is 91.2m high and 18m internal diameter.

2.2.5. Penstock
Penstocks are open or closed conduits which carry water to the turbines. They are generally
made of reinforced concrete or steel. Concrete penstocks are suitable for low heads (< 30m) as
greater pressure causes rapid deterioration of concrete. The steel penstocks can be designed for
any head, the thickness of the penstock increases with the head or working pressure. TheTana
Beles hydro power plant penstock has the following characteristics:-
 7.2 to 6m diameter and 297m long.

10
2.2.6. High pressure headrace tunnel
It is high pressure penstock where the water is taken from the surge shaft and directed to the
main inlet valves. Here it had bifurcates and irrigation bypass. The bifurcate is a structure used to
divide the incoming water from the penstock to the main inlet valve. The irrigation bypass is
used to direct the water from the penstock to the tail race tunnel when the power house is under
maintenance, or when the main inlet valve is closed and no water will flow to the bifurcate.

2.2.7. Power house


Depending up on the topography and the geology of the surface the power house can be located
on the surface, underground or semi underground. Fully underground and Excavated with Drill
and Blast Technology In which many electromechanical equipment, Control buildings, Offices,
medium store, Power Transformer and soon Work shop are situated .It has the 96.5m length,
18m wide and 39.5m height. There are different floors in the powerhouse those are; machine hall
floor, generator floor, spiral case floor, turbine floor, MIV floor, control room and office and
backup battery room. In each floor there are different electrical and mechanical materials or
machines which are used for generating and transmitting an electrical power.

Figure2. 4Entrance of the power house and machine hall floor

2.2.8. Main inlet valve


Main inlet valve is used for controlling the flow of water to the turbine by fully close or full open
state. In Beles project spherical valve was designed and used based on the advantage of the head

11
and their cost. It is operated by hydraulic servo motors and controlled by their own governor.
One valve, for each unit is used.
By pass

Figure 2. 5 Main inlet valve

2.2.9. The speed governor


It’s composed of electrical and mechanical components working in collaboration. The electrical
components mainly include the PLC which measures the speed and calculates the opening of the
wicket gates for a given load condition, there by instructing the hydraulic governor to open the
gates. The electrical system uses a PID (proportional, integral and differential) control system.
The speed governor is used to maintain a constant frequency, for emergency device in case of
over speeding and adjustment of load (speed droop).It has different operating conditions
depending on the opening and closing of the GCB. When the GCB is open the governor sets a
parameter from the PID system where the speed is proportional to the opening. There by
increasing the speed to a given amount. When the speed reaches about 90% of the maximum
speed, the speed on wards starts to increase gradually towards 100% of the final value. When
the GCB is closed i.e. when synchronism is attained, we’ll have a no load condition. In this case

12
we have bearing losses, stator copper loss, friction loses and others. For this compensation the
governor increases the opening at the same time regulating the speed constantly. Finally when
the load is added to the system, we have a loaded condition. During this condition the governor
uses by supplying the needed power. In the BMPP the speed governor sets the initial opening
condition from the rated head.The speed droop curve (power speed curve) to maintain the given
sed.

2.2.10. Synchronous generators


Synchronous generator is a device which converts mechanical power to AC electric power.
Water turbine is the source of mechanical power, the prime mover. Synchronous generators
usually operate together (or in parallel), forming a large power system supplying electrical
energy to the loads or consumers. In BMPP the Generator consist of stator weighing 147 ton
(stator frame with heat exchanger, stator core and stator bar), rotor weighing 200ton (pole, spider
rim sheets damper winding, driver end fan, non-drive end fan etc.), combined bearing complete
(thrust pad, upper guide bearing pad, 6 cooler, collar, oils pump, upper bracket etc.), lower guide
bearing (lower guide pad, sump, cooler, lower brake device etc.), generator shaft. The four
Generator (4*115MW) are located in underground power house at elevation of 1461masl.

Let as illustrate from the fundamental energy formula:

𝑃 = 𝜌𝑔ℎ𝑄

Where

Q-discharge=40 m3/s

h- Head=315m

𝑔- Gravity=9.81m/s2

ρ- Density of water=1000kg/m3

p- Generated power

P=1000kg/m3*9.81m/s2*315m*40 m3/s

P=123.6MW

13
Figure 2. 6 Overview generator and turbine connection
In BMPP wounded rotor synchronous generator was selected to control the power factor
according to electrical load condition, regulate the voltage, reactive power and to inject the
reactive power to compensate loads’ reactive power consumption. Later we see principal
operation of excitation system and protection of the generator. The plant is designed with four
generators each having the following characteristics.

Rated out put 133kv


Rated voltage 15+_10%
Power factor 0.9
Synchronous speed 375rpm
Number of pole 16 pole
Rated frequency 50Hz+_2.5%
Run away speed 590rpm

Table 2, 2 generator rating


From the turbine manufacturer we are given a speed of 375 rpm. Using this value we can get the
no. of poles using the formula:

14
𝑃 = 120𝐹/𝑁

Where

P=number of poles

F=frequency constant=50Hz

N=synchronous speed=375 rpm

Hence

𝑃 = 120 ∗ 50/375=16 poles

2.2.11. Field excitation


DC field excitation is an important part of the overall design of a synchronous generator. The
field excitation must ensure not only a stable AC terminal voltage, but must also respond to
sudden load changes. Rapid field excitation response is important. The field exciters in this
station are slip ring.

Principal operation and excitation of generator

From an external source, the rotor field winding is supplied with a DC current excitation.
Rotor (field) winding is mechanically turned (rotated) at synchronous speed. DC current in the
field winding produces the main flux,∅ which induces an emf Eg in the outer stator (armature)
winding. The frequency of these voltages is insynchronism with the rotor speed.Depending on
the load condition, the armature current Ia is established. Ia produces its own flux and due to
armature reaction, Ear is the induced Emf by∅ar. The available induced Emf is the sum of the
two(i.e emf=Eg +Ear).

Generator protection

Generators are protected from voltage, frequency, reverse power, over current, loss of field, over
excitation, phase fault, ground fault,loss of excitation, over excitation, over voltages, unbalanced
current, abnormal frequency, breaker failures by using DRS(digital relay system).

15
The protection panels are placed at generator floor at elevation of 1461m. In addition to the
above control cubicles and equipment, In power house there exist : Generator local control panel
(LCP),Turbine Local control panel, main inlet valve control panel, Drainage pit control panel,
Draft tube LCP, Irrigation by pass Spherical valve and Howell bunger LCP, Cooling pump LCP,
Fire fitting LCP, Lighting &Socket.

2.2.12. Transformers
A transformer is an electrical device that transfer electrical energy between two or more circuits
through magnetic induction. Commonly transformers are used to increase or decrease the voltage
of alternating current in electric power application. A varying current in the transformers primary
winding creates a varying magnetic flux in the transformer core and a varying magnetic field on
the transformers secondary winding. This varying magnetic field at the secondary winding
induces a varying electromotive force (EMF) or voltage in the secondary winding.

I. Power transformer

The transformers are located in a cavern downstream of the power house. The cavern is 51m
long, 13.5m wide and 10m height. It accommodates four step up transformers, which is used to
step up the voltage from 15kv to 400kv in turn by lowering the current from 5119A to 192A for
ease of transmitting power through transmission lines with minimum power loss. The types of
connection for these transformers are star with neutral on the primary side and delta on the
secondary side since they are step up transformers, and their cooling systems are oil forced water
forced (OFWF) type because it has high voltage.

Charaterstics of the transformer Types and values


Cooling system OFWF
Primery connection Star with neutral
Secondary connection Delta
Rated power 133MVA
Nominal voltage H.V 400000+2.5%V
Nominal voltage M.V 15000V
Nominal current H.V 192A
Nominal current M.V 5119.2A

16
Tap charger Off load
ICE Group YND11

Table 2, 3 Characteristic of the transformer

Figure 2. 7 power transformer


Case of transformer failures and their protection

 Transformer may be fail due to;

 overheating

 over load

 insulation issues

 Electrical connection, loose or high resistance and

17
 Maintenance issues

 The above failures are protected by;

 Keep the porcelain bushings and insulators clean

 On liquid-cooled units, check the radiators for leaks, rust, accumulation of dirt,
and any mechanical damage that would restrict the oil flow

 Keep electrical connections tight

 Inspect tap changes on a regular basis, check the contacts for tightness, burning,
pitting, freedom of movement, and alignment.

 The transformer windings, bushings, and arresters should have a Power Factor
test on a three-year basis.

 Check the ground connection on the surge arrester annually. The connection
should be tight, and the lead should be as short as possible. The earth resistance
should be checked during the dry season, and should not exceed 5 ohms.

II. Excitation transformer

Excitation system for the operation of a synchronous generator a magnetic rotor field is required
which is produced by a DC current flowing in the rotor windings. This DC current is generated
by the excitation system. Fully static excitation for the generator via excitation transformer
which step down voltage from 15kv to 740v is required for each unit. The source for the
excitation transformer is from the generator stator itself, we are referring to a “shunt field
excitation system”. The output voltage of the excitation transformer is rectified by a fully bridge
thyristor and controlled by AVR, and feeds the field winding via brushes and slip rings.
Temperature sensors are provided for temperature detection and wired to trip or indication
modules in the excitation system control cubicle.

18
Figure 2. 8 Principal function of excitation

III. Auxiliary transformer

Each unit has its own auxiliary transformer which is used for supply power to auxiliary devices
by step down the generated (15kv) voltage to 400v. It is three winding transformer. One primary
winding receives 15kv from generator and the two secondary windings ; one is used to step down
to 400v and supply to auxiliary device and the other used to pass15kv to switch gear which feeds
station service transformer.

IV. Station service transformer

In power house and switchyard there are two station service transformer the one is on duty and
the other standby used to step down voltage 15kv comes from switch gear to 400v to feed the
general power center which supply power to essential and non essential AC distributions and unit
MCC when one or all units stop generating.

19
Figure 2. 9 Station service transformer

V. Ground transformers

Each unit has ground transformer. This transformer is important to generator protection and also
for maintenance purpose.

2.2.13. Draft tube gate


The main purpose of the draft tubes gate (slide gates) is to control the flow of discharge water
through the draft tube. The gates will normally be in open position and will be closed to allow
inspection and maintenance of turbines. Remote control is provided and therefore the gates
operations are possible also from the control room

2.2.14 cooling water system


The cooling system for BMPP supplies cool water to the following users:

1) Turbine shaft seal

2) Unit Step up transformer oil/water heat exchangers

3) Turbine governor oil/water heat exchanger

20
4) Generator thrust bearing oil/water heat exchangers

5) Generator air/water heat exchangers

6) Generator guide bearing oil/water heat exchangers

7) Turbine guide bearing oil/water heat exchangers

The cooling water system consists, for each unit, of independent closed circuit filled with
demineralised water. The closed circuit is cooled by heat exchanger supplied with raw water
with the inlet and outlet located in the tailrace downstream the draft tube gate.

Figure 2. 10 cooling water system

2.2.15 Power house firefighting system


 Water-Foam firefighting on Generators and Transformers.
 150 m3 of water are stored in the access tunnel 85 m above the machines level.
 Water discharges by gravity.
 The water tank is refilled by using a pumping station in the powerhouse

21
Figure 2. 11 Firefighting system

2.2.16 Supervisory control and data acquisition (SCADA) system

Basically SCADA can perform four functions. These are

 Data collection/data acquisition


 Data communication
 Data presentation and control

The above functions can perform by 4 kinds of SCADA component

Sensors: - either digital or analog and control relays that directly interface the managed
system

Remote terminal unit: - small computerized unit deployed in the field

Gathering report from the sensor and delivering command to the control relay

SCADA master unit: - it is a large computerized unit and serves as

The central processing unit for the SCADA system

Provides human interface for the system

Automatically regulate the managed system in response to the sensor input

The communication network that connects the SCADA master unit to the remote terminal unit
in the field

22
Figure 2. 12 Over view of SCADA

2.2.17 Control panel


The control panels are contains the following elements, some of them are:-

 Breakers, relays, meters signaling instruments

 Auxiliary relays, Miniature ,fuse

 Time delay, contactors

 Thermostat, single line diagram on the combo box

 Connectors

 Emergency lighting

 Push buttons

 Power supply

23
2.2.18. Protection
Generally Beleshave provided with different types of electrical protection systems both at the
power house and the switch yard. we try to list and briefly explain some of protection systems.

 Under voltage protection

 Over current protection

 Breaker failure protection

 Over voltage protection

 Rotor earth fault protection

 Stator earth fault protection

 Earth fault protection and Bus bar protection

The above protection system emplaced works using different principles. Unlike other power
stations in Ethiopia, BHPP uses the combination of DIA TECH and DRS the latest and advanced
technology of protection system. They are differing from others by its high capability to analyze
data by using microprocessors. The digital protective relay or numeric relay is protective relay
that uses a microprocessor to analyze power system voltages, currents or other process quantities
for the purpose of detection of faults in the plant.

2.2.19 Irrigation by-pass


BMPP as the name indicates is designed for utilization of both hydroelectric power generation
and for irrigation in the downstream basin. The project includes in its design a diversion tunnel
for the irrigation water requirement for upstream of Beles catchment .Tunnel is designed to by-
pass water from the penstock shaft to the draft tube without passing through the turbines. This
tunnel will function when the power house is under maintenance. It consist of a by-pass made by
an approx.120m long penstock rising from the high pressure head race tunnel, immediately
downstream the vertical penstock shaft, running across the access adit up to the valve chamber
where a guard spherical valve and Howell bunger valve are installed. The by-pass tunnel has a
total length of 406m.

24
2.2.20. Switch yard
The switch yard consists of two bus bar systems with seven bays, four for four unit transformers,
one bus bar coupler andthree outgoing lines to Bahir Dar and recenace dam. Each bay consists of
the following Equipment: Lightening Arrestors, Disconnector with earth blades, Current
Transformers, SF6 Breakers, Pantograph disconnectors, voltage transformers on outgoing lines
of Bahir Dar I and II and Bus bars and earthling blades on bus bars of both sides. In order to
protect the switch yards from thunder strike and lightning there are eight earth mast which surges
the voltage, four of them have also projections and rotary cameras at four corners of the yard.
The rotary cameras are connected with CCTV (Closed Circuit Television) system that is
placed at operators’ panel of control room. The camera shows the status of the equipment and
any movement in the switch yard.

Figure 2. 13 Switch yard

i. Lightening arrestors

These are designed to limit the line - to - ground voltage in the event of lightning or other
excessiv transient voltage conditions. Some of the older gap-type lightning arrestors actually
short circuited the line or equipment, causing the circuit breaker to trip.

25
ii. Voltage transformers

Are transformers which have primary and secondary windings but they don’t step up or down
simply they use their primary part for reading or measurement and they use their secondary part
to pass to the next material since they are interconnected. At theentrance we will read 400kv on
the primary side and it will be passing to the material by using their secondary part protection
of voltage transformers. It is possible to protect a voltage transformer from secondary short-
circuit by incorporating fuses in the secondary circuits. voltage transformer are used for;

 Reading

 Protection

 measuring

Figure 2. 14 voltage transformer

iii. Current transformers

It is an instrument transformer used for measuring the amount of current passing through the
system. Works on the principle of induction to measure the level of line current which can be
adjusted according to the conversion needed and also used for control and safety purposes. This
is the same as voltage transformers the only difference here is we can read only current.

26
Figure 2. 15 current transformer

iv. Bus bar

Bus bars are low resistance path for current flow used to connect the four generating units with
three outgoing lines. In addition it is used to;

 Carry normal currents and over load current continuously with temperature rise
within specified limits

 Withstand normal system voltage; specified transient over voltage without


flashover

 To withstand mechanical stresses due to wind, icing, short circuit

v. Bus bar coupler

Bus bar coupler is used to connect/disconnect the two bus bars to provide reliable power
transmission ,coupling circuit breaker (CB) associated with isolators is provided between the two
bus bars. By closing the isolators and the bus coupler CB, the transfer bus is energized. Then the
unit photography isolators charged over from bus bar A to B or viseversa.

vi. SF6 gas circuit breakers

27
This breaker have their contacts enclosed in a sealed interrupting chamber filled with SF6
gas.SF6 gas is nonflammable inert gas that has a very high dielectric strength, much greater than
oil.

vii. Switchgear

Is the combination of electrical disconnects switches, fuses or circuit breakers used to control,
protect and isolate electrical equipment. Switchgear is used to energize/de-energize equipment
to allow work to be done and to clear faults downstream.This type of equipment is important
because it is directly linked to the reliability of the electricity supply. This is also automatic like
the control room. This is the place where the feeder and the outgoing lines can be controlled.

viii. Pantograph disconnections (isolator)

Pantograph is spring-loaded and pushes a contact shoe up against the contact wire to connect and
to disconnect bus bar and line voltage, it is possible to operate under load condition due to that it
has arc removing part. The pantograph isolators open and close in vertical plane. They bridge
the vertical isolating distance between two bus bars in different horizontal levels. The
pantograph arms collapse in vertical plane and isolation is obtained between the upper bus bar
and lower bus bar.

Functions of pantograph

 to transmit power without disconnecting the supply

 to free one bus bar for maintenance purpose

 to transmit power supply system from one bus bar to other bus bar system.

28
Figure 2. 16 Pantograph
Equipments in switch yard control building;

 110V lead acid batteries and Chargers for control voltages of the system

 Switch gear

 Two transformers capacity of 250kVA for Switch yard auxiliary supply

 Two Emergency Diesel generators of 800kVA capacity with two step up


transformers 0.4/15kV which is used for supplying during total shut down of the
plant (to feed the main essential feeders for starting up one unit)

 Low voltage 400V AC auxiliary supply

 Telecommunication panels

 Protection device (DRS) for bays equipment’s

 Operators panels (SCADA)

The switch yard building also consists of Mechanical work shop equipped with as lathe machine,
drilling machine, welding machine and store.

29
2.2.21 Tail race tunnel
The high pressure tunnel where all the water collected from the draft tube is collected finally
directed to the outlet.

2.2.22 Tail race portal


It is the outlet structure used to diffuse the incoming water to meet Johanna River which is
constructed under the tunnel so that it cannot damage the ecological system of the area.

2.2.23 Outlet
The outlet of BMPP is consisting of river diversion, outlet structure, and pedestrian crossing and
regulation weirs (two of them with pedestrian crossing).

2.2.24communication system
In BMPP fiber optic multiplexer equipment are installed for telecommunication service between
Beles power plant, Bahir Dar and load dispatch center, and also the internal communication
between the power plant, switch yard, housing compound, intake and outlet.

2.3 Work section


We are mainly participated in the maintenance group and sometimes worked in the operation
group. The planning of maintenance activities can be categorized in the following ways:

1. Routine maintenance

2. Overhauling maintenance

3. Preventive maintenance

Routine maintenance.:-Visual inspection, minor repairs, replacement of small parts and


adjustment of the equipment’s, cleaning the electrical equipment of dust and dirt, cleaning of
fittings, fixed and moving contacts of starters, cleaning of carbon deposits, fuse metal, changing
of burnt contacts, lubrication of bearings etc. are covered under the routine maintenance
program. Checking of oil level, inspection the current, voltage and indicating lamps’ lighting is
also covered under the routine maintenance .it should be carried over daily if possible or on
alternate days.

30
Overhauling maintenance:-The replacement or renewal of the main units, parts of electrical
equipment and assemblies, rewinding of motor stators and rotors etc.bushing, changing of
starters is covered under overhauling. It should be carried out twice a year.

Preventive maintenance:-Under preventive maintenance inspecting, Testing, Engineering


Analysis, recording, organization and tools and tackles are carried out. In the operation section
control over all generation station on the SCADA system, locally &automatically. If an accident
happen in the generation station the alarm signal comes in the SCADA; they made measurement
otherwise announcing to the maintenance group to make a fast response. They also communicate
with the grids or LDC system.

2.4 Performing work tasks


When we had been in BHPP, our work task were maintenance and inspection of equipments
basically in Powerhouse and switch yard some times in outlet and intake. The aim of
maintenance is identification of problem/fault, repair, and improving plant availability.

To know the various problems occurring in the power plant, maintenance and inspection are
important plans. The advantage is its low cost, to collect extensive information, and low risk of
failures. Information about the power generating unit condition is the most important aspect and
absolute necessity for any maintenance activity.

Basically there are three crucial aspects of maintenance and inspection.-

 The control system, which records the operating data


 The monitoring system enables operating and generating conditions to be recorded
 Inspection serves to determine the present condition of each generating units and other
components

In BHPP there was a repetition of work’s maintenance and inspection. We actively participated
in the following works’ in our internship duration.

2.4.1 Took inspection


Inspection is one part of maintenance to observe and take data of the sensors, oil level of
different hydraulic devices, measuring voltage and specific gravity of each DC supply batteries

31
and observation of the device. In the present of this it supports to maintain failed devices in the
system.

Objective of the task

 Help to fix the problem at the beginning


 To prevent common mistakes being repeatedly
 Save time and effort of the final maintenance

The method to achieve the above objectives, first we collect some information by informal
review from different technical staff members about how to take inspections in power house,
switch yard as well as intake and outlet. Then we read documents to know in detail about
equipments from the plant manuals. After this every Friday we took inspections of different
appliances with maintenance employees, such as:

 transformers winding and core temperature


 Condition of current and voltage measuring instrument
 Governor hydraulic system operating pressure and oil level
 incoming and outgoing water Pressure
 Oil linkage around the compressor, main transformer ,turbine and generator pit
 size of carbon brushes to replace the damaged one

2.4.2 Battery inspection


Check the voltage of battery- each battery cell has rated capacity given by the manufacturer,
but after charging the battery must have greater or equal to this value unless it must be changed.

Check the specific gravity of battery- specific gravity of battery is the ratio of distilled water to
electrolyte. This ratio is measured by using hydrometer which has red, yellow and green colors
indicator, The yellow color (range 1.23 to 1.27v) indicates good specific gravity. The red color
(range greater than 1.27) indicates the distilled water is greater than electrolyte so it needs
additional electrolyte. The green color (range up to 1.23v) indicates electrolyte is greater than
distilled water, so it requires additional water

32
Figure2.17 Backup battery

2.4.3 Diesel inspection


Two diesel generators are used to generate voltage to give power for the station when black out
occurs or the station cannot obtain power from the grid.

Procedure to check operation of diesel generator:-

 Check starting battery


 Check the water and fuel level
 Place the selector switch local position
 Start the diesel and run for 10 minutes
 Finally stop and place the switch to auto position

2.4.4 Breakdown maintenance


Breakdown maintenance is defined as the repairs or replacement process, When alarm actuated
on the SCADA system from a failed device or machine in order to bring it back to its functional
state or working condition. Such a thing could be used when the equipment failure does not

33
significantly affect the operation or generate any significant loss other than repair cost. Among
that maintenance few are listed below:

 Heat exchanger cleaning


 Primary, self-cleaner and shift seal filter cleaning
 Carbon Brush replacement
 HVAC air cleaning
 Maintaining injection pump in water treatment

2.5 Procedures and methods


The method we used during intern period to achieve our objective:

 Reading manuals and the related textbook


 Asking the company employees
 Working together with the maintenance and operation team

The procedure we followed:

 Taking the report from the control room that is the SCADA system which gives each and
every relevant information all about the system functions and their status. Additionally
took inspection in each machine to maintain or to take action on the system. More over:
 Identify the problem
 Coined the problem area name
 Collect data to solve the problem using full information
 Show our day to day activities to our advisor to get basic comments
 Take the comment & correct ourselves when told the advisor
 Give proposed solution to the given problem

Finally set all the necessary data & comment that we collected in a written document

2.6 Challenges and problems


 The sounds of the machine limit communication of the worker with us to discuss about
that machine
 there is lack of computer

34
 When power off or black out occurred the plant use diesel. This cases high economic
crises in the company
 ventilation problem in the control panals instead heaters are provided in design
 placement of compressors bellow Colling water filter and heat exchanger causes water to
fall on motors during maintenance
 lack of spare parts for all each equipment in store

35
CHAPTER THREE
Overall internship experience
We get different skills and knowledge in four month internship program. From this we get
numerous benefits listed below:

3.1 Theoretical knowledge and practical skills


Internship program gives us the opportunity to apply our theoretical knowledge in real world
environment in addition to the practical skill from this internship program; we have got a good
chance to improve our practical skill highly. We can develop our skill by participating our self
into different part as we had learned theoretically in our department course. Among them:

 Machine maintenance:-There are activities which are maintained daily, weekly,


monthly, & yearly according to the maintenance plan.
 Inspection:- daily, weekly such as turbine cooling, generator cooling, transformer
cooling, cooling pumps, DC batteries are checked & inspected.

In working area we were acquired practical skills and knowledge by different methods such as:

 By observation
 By practical analysis
 By learning process
 By presentation and demonstration
 By theoretical analysis and etc.

3.2 Team playing skill


Team work is becoming more commonly used and widely accepted as way to increase
productivity in the work place. The most important point in team playing skill is just reach an
agreement from different points on the work to be done. We learn much how to coordinate with a
team in organization. We were ready to respect and governed by work ethics and interacting and
working with the technicians for the common goal. Ideas were much diversified as it comes from
different people. This has helped us to improve our skill to explain and solve problems, to be
opening minded and to have global thoughts. From their perspective, we have been observing
methods to handle challenges and failures that might happen in different aspects. we usually

36
come together to handle an issue that's difficult, for people to do on their ow and when we works
together, creativity levels were higher, as we tap into one another's strengths. This often leads to
increase our creativity, and an inspiring sense of collaboration and cooperation.

Achieving good team playing skill is essential for:

 effective completion of tasks


 increasing productivity

3.3 Interpersonal communication skill


Interpersonal communication skill is the process of sending and receiving information between
two or more peoples. For any individual, communication is an important way of learning, which
can be defined formally as the act, process, or experience of gaining knowledge or skills.
Communication and the subsequent learning help individual specially engineers move from
novices to experts and allow them to gain new professional knowledge and abilities. Good
communication is the life blood of the engineering profession. It takes many forms, such as
speaking, writing and listening. The advantages we get from the internship include:

 handling information,
 persuading people, and
 Improve relationships with people.

We have no idea about job environment, at all, until we have been work on this internship
program. But then we have understood that an interpersonal communication skill is the basic
need beside professionalism. Because it is the way to enrich good service, up to date information,
experience sharing and most of all to create good environment fo his/her work. We have passed
our luxury time with them. We have been helping some of them with their academics. Generally,
our relationship with the technicians and staff members were very fine and can be said well.

3.4 Leadership skills


Leadership is a process of leading the carrier of the company. Leading a team or an organization
holds the most basic and key place of profession, hence requires well trained person. Some of
leadership skills we have grasped can be explained as follows; to be responsible for our work, to
trust, to recognize and tell mistakes, to admit mistakes, to share our problems openly and get the

37
team involved in solutions whenever there is a setback, Respect peoples differences and needs,
their weaknesses and their strengths, Use people for their skills, and provide teamwork where
experience is lacking, stimulate teamwork without blame, to inspire support and best efforts. The
following terms are used for to become a good leadership

 Effective communication
 Motivation and Planning

3.5 Entrepreneurship skills


Entrepreneurship skill may be defined in different ways but it can be generally defined as the
ability of a person to create business or an enterprise of his/her own. This internship program
develops our creativity and we detect that the private sector is better than the public sector to get
better business. To be good entrepreneur, the following abilities or skills are needed.

 Risk management
 Self confidence
 Innovative skills
 Market understanding ability
 Educational background

3.6 Work ethics


Ethics is a branch of philosophy that defines morality and determines the meaning and rational
justification of the right way to live, correct values as well as correct ways of treating others. As
workers wear made to specialize in different fields, specific codes of conduct were expected
from each worker. In today’s complex world, Ethical conduct of workers is very important for
developing healthy working environment and increasing productivity. Ethical work conduct
enables workers to possess‟ appropriate behaviors in their work and so as to develop proper
relationships with co-workers and it helps them to create good industrial environment. There are
two common types of ethics. These are Personal ethics and Professional ethics. There are two
common types of ethics.

 Personal ethics and


 Professional ethics

38
3.6.1 Personal ethics
All human beings as rational creatures are expected to exhibit certain personal principles of
ethics. These principles of personal ethics are values which are expected to be possessed by all
individuals in their life, and contribute a lot for a smooth interaction among individuals and
peaceful coexistence of a society. These principles of personal ethics include:

 Honesty
 Fairness
 Concern for the wellbeing of others
 Compliant to the law
 Doing good
 Refusing to take un fair advantage
 Respecting the autonomy etc.

3.6.2 Professional ethics


Professional ethics refers to the standards or a set of moral principles for regulating behaviors of
a certain defined profession. In order to consider that an activity to be a profession, it should be
carried out by one who has advanced education, knowledge, and skills. Thus, for developing
healthy working environment and increase productivity, ethical work conducts are important
medium. The following are some of common professional ethical principles which are apply in
the construction environment.

 Impartiality
 Transparency and openness
 Integrity

39
CHAPTER FOUR
Projects and Contributions
INTERNSHIP PROJECT ON BELES MULTI PURPOSE PROJECT ON THE
EXCITATION SYSTEM OF THE PLANT
PROJECT TITLE: AUTOMATIC BRUSH POLARITY CHANGER
Project Background
Introduction
Generator require direct current to energize the magnetic field. The DC is obtained from a
separate source called an exciter. The exciter is the backbone of the generator control system. It
is the power source to the field windings of a synchronous generator there by ultimately inducing
AC voltage and current in the generator armature. The rotors magnetic field may be produced by
induction (as a brushless alternator), by permanent magnets (as in very small machine), or by a
rotor winding energizing with direct current through slip rings and brushes.
The modern excitation systems are applied in:-
 Static and
 Brushless version

The static type excitation system produces the field current using a thyristor converter and
conducts the current to the field through slip rings. The power converter is feed from auxiliary
grid of the power plant or the generator terminals through excitation transformer.

Whereas the effects of current polarity on the wear rate and contact voltage drops of the
composites were investigated using a brush on slip ring. Basically the wearing are electrical,
mechanical and both.The electrical wear is due to the high arc temperature and discharge of the
role of factors such as the surface material damage case. Because electrical wear affects the face,
so it will have influence on the mechanical. Due to the current through the brush and slip ring
assembly contact surface and the conductive part is some point temperature is very high, and due
to the high temperature arc will make both sides polar partial melting, shedding, metal in to
metal vapor, carbon brush structure loose, affected by oxidative corrosion and exfoliation the
electrical wear performance of. Although positive brush possesses a high wear rate compared
with the negative brush in the air atmosphere since the electrical field direction activates
oxidation at the positive brush surface while inhibits oxidation at the negative brush surface.

40
Except for the regular wear looses. The combined effect of molten metal bridge erosion and arc
erosion cause the positive brush to lose extra material and the negative brush to gain extra
material so the positive brush shows a higher wear rate than the negative brush.

Problem Statement
This project is developed to improve the weakness of manually changing of the brush
polarity.Manually changing of the brush polarity is a traditional method was used to equalize the
graze of the slip rings. In the configuration of manually polarity changer, the rate of wearing
accuracy size is poor and cannot be changed frequently. The weakness of manually change of
polarity, which affect the:-

 The size of slip ring


 Rate of temperature on one side.
 Unexpected dusts will be creating in the slip ring.

Objectives
Main objective
The main objective of the proposed system is to equalize the abrasion of slip rings by
interchanging the polarity of excitation voltage through electromagnetic relay using comparing
the voltage by comparator or (by pic - microcontroller chip or by DRS).

Specific objective
 Apply consistent Measuring & Verification methodology to quantify and identify the size
of brush.
 Identify the short and long brush size and accordingly inter change the polarity and get
alarm.
 To prevent unnecessary maintenance cost.

Scope of the Project

This project is conceder the excitation system of tana beles hydro power generation. Specifically
it concerned with the manual brush polarity changing to change in to automatic system, based on
comparing the brush size using LDR sensor.

41
METHODOLOGIES
I am read different text book and manual employed for this project the circuitry design which
take up light dependent resistor (LDR), relays, comparator, LED, and other active and passive
elements [4]. The LDR sense the light intensity of the LED with respect to their distance. Where
the LDR is fixe on the brush and the LED is placed separately and parallel to it [5]. The
comparator compares the voltage coming from the preset with regard to the reference selected
voltage value. The inputs of the comparator depend up on the distance between the LED, LDR
and preset adjusted value. Then the relay will be takes action to inter change the polarity or
obtain alarm depend on the comparator output (that means 1 or 0) at the transistor triggered
point[2].

A comparator is a device that accepts two analog in puts, compares the inputs and produces
output that is a function of which input is higher. That is comparator compares the voltages at the
+ and – inputs. If the + input is at a higher voltage than the – input the comparator output will be
high. If the – input is at a higher voltage than the + input the comparator output will be low. To
use operational amplifiers in open loop as comparators is quite common[6].

But in my project working of the circuit is separated in to two stages. The first stage is to
interchange the polarity of brush and the second stage is for alarming and to start the time
counter. This uses two LDR for detecting the light intensity and to adjusted the brush size
independently and feds voltage signal to the #1 and #2 LM324 comparator ICs by the help of
potentiometer #1 and #2 respectively. At full light the resistance of the LDR will be few ohms
and at darkness it will rise toseveral hundred ohms. The ICs LM324 is wired as a comparator
here. At darkness the resistance of the LDR increases and so the voltage at inverting input of the
IC #1 will be less than the reference voltage at the non inverting input. The output of IC #1 to
activate the double pole relay contact and at the same time the polarity of the brush will be
changed.

The second stage is for alarming and time counting, which are work after the polarity of the
brush changed that means after completed the first stage action until the adjusted brush size will
be reached. So the voltage in the inverting input will be greater than the non inverting input,
which switch on the transistor Q1 and Q3 to connect the buzzer to grounding for alarming and
the 555 IC gats input voltage signal for oscillating and to start the digital watch respectively.

42
The block diagram contains the following sections

Sensor
Alarm

Excitation
Compara Comparat
DC or
tor
pow
er
sup Switching
ply circiut

Figure 4. 1diagram of excitation current polarity changer of the brush

Expected out come

The following results are expected to be demonstrated at the end of the design and
implementation automatic polarity changer.

 The two brush size will relatively finish equally.


 The slip ring will be prevented from unnecessary wearing.
 And system will be safe from other unwanted hazards through the
application of automatic brush polarity changer ordering to excitation field
current.

43
CHAPTER FIVE
Conclusions and Recommendation
5.1 Conclusions
Generation is a process of generating an electrical energy from sources such as water; sun light,
wind, geothermal, steam etc. A generating station which utilizes the potential energy of water at
a high level for the generation of electrical energy is known as a hydro-electric power station.
After generating an electrical energy, it steps up by transformer and transmit it from generation
substation (switch yard) to residences dam and Bahir Dar substations.
In our intern period we got practical knowledge about the machines in the company and their
working principles, how to control, how to maintain and how to electrical energy produced. We
also know the general characteristics and component of hydro power plant.
Our task during the internship was to observe electrical equipment’s and understand their
methods of operation. Based on the major findings presented above its easy to understand that
internship has a great significant in up grading student’s theoretical knowledge and improving
practical skill.
The project work is an attempt to design automatic brush polarity changer using LDR sensor.
LDR senses the light intensity with respect to the wearing of brush, and then according to the
expected brush size of each pole due to wearing it performs the control action through a proper
adjustment of the comparator inverting input of the preset by interchanging the polarity and
alarming through different transistors. This project gives more reliable and user-friendly brush
polarity change controlling system by continuously monitoring the brush size and improves
weakness of the system.

5.2 Recommendation
5.2.1 Recommendation to the company
Tana Beles hydroelectric power plant station has the following basic problems:
 Design of turbine oil extraction fan
 Annually maintain of plant
 Computer access
 Service like transportation, pure water and shopping.
 The HC documentation of the plant was not arranged properly.

44
 To have good relation with the local peoples and give the right of gating the services
from the government to the citizen (i.e. when the power plant was constructed they give
their land which is used for agriculture) the TBHPP must give electricity and pure water
to the local peoples.
 To have safe house for the cars of the company which prevents them from rain and sun
that may result in shorting the life time of the cars.
 Insert the project in the SCADA system by means of PIC microcontroller algorithm
programming interfacing through DIA tech. whereas no one can’t be take an action to
change the wearied brush the unit will be go to stop step by step.
 For good accuracy of switching and communication system of the station use DRS
instead of transistor.
So we strongly suggest and recommend that the company must fulfill the entire necessary thing
above.
5.2.2 Recommendation for university linkage
First of all, the university industrial linkage office should request or announce to the companies
earlier to the internship period so that the company will have reserve place tothe intern to host
him/her. The university industry linkage has low communication skill with the companies and
students, so the university industry linkage must improve this skill.
5.2.3 Recommendation for school
We also recommend to the school to know the specific companies of the intern students
with short period of time and check the mentor (advisor) to get the student at that specific
company with proper time interval.

 It is better to have good relation to company

 Shall give the students good laboratory before the internship courses like power system,
machine and energy conversion.

45
References
[1]. Myanmar, ’’International Journal of Scientific Engineering and Technology Research’’
Volume.03, IssueNo.11, Pages: 2481-2486, June-2014.
[2].D. Zorbas, ‘’Electric Machines-Principles, Applications, and Control Schematics’’,
West,2ndend,t 1989.
[3].G. pietrangeli, ’’Vatech Hydro (2011) operation and maintenance control system’’, Rome -
ITALY, 1st , 2004.
[5]. Matousek ‘’operation & maintenance manual excitation system’’, Modification acc.lettter,
Rome – ITAL, 2010.
[4].Wang and L.JinJun , ’’A method of online analyzing excitation system performance based on
PUM measurement ‘’ 2011.
[6] V. DelToro, Electric Machines and Power Systems. Prentice Hall, 1985
[7]. G. pietrangeli,’’ Hydro painting specification of component’’, Vatech, Rome-ITALY, 2011.
[8]. G. pietrangeli, ‘’Hydro calculation notes’’, Vatech, Rome – ITALY, 2011.
[9]. Metallurgy, ‘’Mineral & Energy Photovoltaic Solar Pane’’, solar PV manufacture, page1 and
2, 2015.
[10]. http://www.electronicsclub.cjb.net

46

You might also like