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MECH ENG 4100 Aerospace Engineering
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MECH ENG 4100 Aerospace Engineering
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Course Code: MECHENG4100
University: The University Of Adelaide
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Country: Australia
Question:
Feasibility study of Hydropower plant in You need to do the case study for that specific hydropower site. Here we attached the example of how to do the assignment. In this brief we didn’t mention any specific province and specific hydropower site, now you have to select a specific province and specific hydropower site and proceed to do the assignment.
Answer:
Introduction:
India is one of the states with the largest generation of energy from the renewable energy sources. However, apart from the hydropower, the other two abundant sources of energy are the solar and wind which has remained untapped for the past 70 years majorly as a result of the unavailability of relevant technologies and lack of political will. India is known by anyone that it is the fourth largest emitter of carbon globally with its population of 1.3 billion with the major contributor to this emotion being the power sector. However, in the recent decade, India has made significant steps towards the development of the renewable energy.
The changes in the climatic conditions have been a great concern across the world hence promoting the decision makers and government to establish a detailed blueprint for sustainable and clean power for the entire population of India. Despite numerous efficiency improvements needed are cost-effective, currently, there has not been a good quantification of the value streams that the hydro plant can provide. Hence it is impossible to provide cost effective analysis when making the upgrades. Some of the techniques that can be implemented in Koyna Hydropower plant so as to improve its efficiency and performance include electricity market opportunities, new technologies, and operational improvements. The modification and replacement of the three major components of hydro unit namely wicket gates, wear plates, and seal rings can improve the efficiency of Koyna Hydropower plant by approximately 2% and the capacity of the plant can also be increased by 3 percent to 5 percent.
Renewable Energies in India
The energy used in India can be categorized as either nonrenewable energy sources or renewable energy sources. Renewable energy by definition is the energy sources that can naturally be reproduced within the environment. The renewable sources of energy include hydropower, wind energy, solar energy, and tidal energy. Solar energy is one of the most used sources of renewable energy in India with an alarming growth rate of 50% annually. For the conversion of solar energy into electrical energy, a device known as the photovoltaic cell is used (Bansal, 2010). The ten machines in Gujarat province near Okha were some of the first wind turbines installed in the country.
India has the 5th largest installed capacity of wind energy of 3595MW and the estimated potential of wind energy being 45,000MW in the country. There are two categories of hydropower plants in India, these include small and large plants. The small hydro plants have an installed capacity less than 25MW and these projects are under the New and Renewable Energy Ministry. The large hydro projects are the responsibility of the Ministry of Power (Bhatia, 2014). The depletion of resources is an economic term which denotes the exhaustion of raw materials within an area. The use of natural resources beyond their rate of replacement is considered to be natural resources depletion [1].
Currently, the most significant source of energy used by the population in India is the non-renewable energy sources. The value of these resources due to their demand despite the decrease in their supply. Energy is the primary necessity for the development of the economy as well as every sector in India. Therefore, it is necessary for the country to consider all the emerging and new energy efficiency technologies and renewable energy and also implement the laws of energy conservation (Boyle, 2012). With an exclusion of the hydropower energy, the renewable energy in India accounts for a total installed capacity of 12,610MW of energy which is equivalent to 9%.
The total installed capacity of power stations in India is 303, 083MW as of June 2016. The table below shows the type wise and sector wise breakup of the list of power stations in India:
India is the 7th largest hydropower producer globally with an installed capacity 44,594MW which is equivalent to 13.5% of the total installed capacity. The other smaller units of hydropower have a total capacity of 4.380MW which is equivalent to 1.3% of the total installed capacity. The estimated potential hydropower is estimated to be at 140,700MW at a load factor of 60% (Gupta, 2009). The figure below shows the potential hydropower plants in India:
In central India, the potential hydropower has been identified from the Narmada, Vamsadhara, Nagavali, Mahanadi, and Godavari river basins which are yet to be established on the primary scale because of the potential opposition from the locals. The public sector contributes to 92.5% of the produced hydropower in India (Hossain, 2014). The public sector companies involved in the generation of hydroelectric power plants in India include NTPC-Hydro, THDC, Satluj Jal Vidyut Nigam (SJVNL), Northeast Electric Power Company (NEEPCO), and National Hydroelectric Power Corporation (NHPC). The private sector is also anticipated to develop with the hydroelectric energy development in the northeast and Himalayan mountain ranges in India. India has changed from a state that has the deficiency of electricity to a state that has the surplus electrical energy [4].
The shortages caused by peak loads can be met by using the schemes of pumped storage which store extra power to meet the demands of peak load. The schemes of pumped storage also contribute seasonal and secondary power at no extra cost when the rivers are flooded with additional water. The units of pumped storage can also be used as the station of pumping to supply river water for drinking water, industrial needs, and irrigation. The quantity of water needed to meet the various demand can be attained from the pumped river units of storage and rivers. Hydroelectric power plays a significant role in the energy security and sustainable development in India since it attains the criteria of reliability, availability, and sustainability. The techno-economic viability of the projects of hydroelectric energy depends on accessibility, hydrology, topology, and geology of the region [5].
The techno-economic viability of the projects of hydroelectric energy depends on accessibility, hydrology, topology, and geology of the region which in this case is the Satara District. The technical background of the hydropower in Satara District evaluates the technical performance and background of the Koyna Hydroelectric power plant which is a large plant with four dams. The power is acquired from the fast running water or falling water and then use it to rotate the turbines [6]. The figure below shows the technologies involved in the generation of hydropower system:
During the past decades, hydropower technology was being implemented through watermills to assist in irrigation as well as operating many mechanical systems such as ore mills, domestic lifts, dock cranes, trip hammers, textile mills, sawmills, gristmills. Hydropower became a source of electricity generation in the late 19th century. Watermills and water wheels were constructed as early as the 4th century in India, despite records of the era are patterned. The water wave power released from a tank used for the purposes of extracting a metal ore through a process known as hushing which was used in the mining of gold during 75AD in Wales (Leyland, 2014).
During canal building in 1830 in the US, hydropower provided the energy to convey barge traffic down and up steep hills by the use of inclined plane railroads which were then changed to be hydropower systems. The technical progress has changed the open water wheel into a water mater or enclosed turbine which led to the improvement of the efficiency of a turbine to 90%. An engineer in the Locks and Canals Company by the name James Francis applied testing methods and principles to design turbines by using graphical and mathematical calculations which led to the improvement of efficiency to match exactly the condition of the specific flow of any site. The hydraulic power networks used pipes to convey water pressurized and for the purposes of mechanical power transmission from the source to the terminal consumers. The hydroelectric power systems used for the purpose of electricity generation can be grouped into pumped-storage hydropower, conduit hydroelectricity, micro-hydro, small hydro, and conventional hydroelectricity (Mishra, 2012).
Underground Power Station
This is a type of hydropower station build by the excavation of the primary components such as tailrace, penstock, and machine hall from the rock and not the common methods of surface-based construction. There are numerous factors that determine if the power plant is built underground or not. The geology or terrain around the dam is determined since steep or gorges valleys may not support a surface hydropower plant. A hydro-station within bedrock may be less costly to erect compared to a surface hydropower plant on loose soil. Huge hydropower plants have been positioned underground frequently after the World War II so as to protect the plants from airstrikes.
Normally, the underground power stations form part of the pumped storage hydropower projects whose primary functionality is the levelling of the electrical energy required. The pumped hydropower is effective since it uses cheap or surplus off-peak energy to be used in pumping water to the upper reservoir from a lower lake (Varma, 2010). When the underground power station is used with the pumped storage hydroelectric project, the pumped hydro-project stores’ energy pumped from a reservoir of lower elevation in the form of gravitational potential energy to a higher elevation. The extra off-peak energy is normally used to propel the pumps. When there is a high demand for electrical energy, the water stored is released through the turbines to generate electricity [9].
During the periods of low demand for electrical energy, the excess capacity generated is used in pumping water into the upper reservoir and when the demand is higher, the water stored is released back through a turbine into the lower reservoir to produce electrical energy.
Thermodynamics plays a significant role when designing and analyzing systems of thermal design. During the analysis of the energy balance, the major consideration made is te process where the environment and system come to equilibrium. The energy balance for the entire system can be observed in equation below which includes the internal, potential, and kinetic energies of the system.
ΔE = Q – W; where W is the power generated by the system, Q is the amount of heat generated, and ΔE is the change in energy on the system. The analysis of how the energy is lost in the entire system assist in understanding the entire energy balance of the system.
The electrical energy is still concentrated, however, not every mechanical energy is converted to electrical energy. Some of the electrical energy is lost through friction and heat which is lost through very mechanical component. The wires in the generator are heated up by internal friction as electrons flow through them. The cooling fan of the generator heats up additional air by blowing it over the generator to maintain coldness within the area. Averagely, a generator can convert approximately 90% to 985 of the received mechanical energy into electricity or electrical energy. The remaining 2% to 10% of the electrical energy is lost becomes a less effective form of energy or low grade energy [7].
As the electricity flows through the transmission lines into the substation or to consumers, the wires are heated by the electrons flowing. This result into more lost energy. Finally, when the electricity reaches consumers, the energy is converted into mechanical energy or heat. The Thermodynamics second law states that the change in the quantity of entropy contained with the system during some interval is equivalent to the difference between the amount of entropy generated within the system during the time interval, and the net amount of entropy transferred in across the boundary of the system during the time interval. By considering the hydropower unit of generation, the second and first law of thermodynamics can be applied in numerous distinctive manner [8].
Koyna Hydropower station, is both peak hydropower and regulating production plant, hence the units do not run at a constant mode. Koyna station is changing its output power frequently varying the quantity of water intake. The output power of the plant is varied based on the needs of the consumers and also based on the desired downstream water flow and capacity that the Koyna dam. The typical parameters used for the Koyna hydropower analysis is shown below:
The results of the electrical energy analysis of the Koyna Power Plant before overhaul and the expected results after overhaul of the hydro units are shows in the table below. The wear plate and seal ring clearances, and the wicket gate guide vein of the Koyna Hydropower plant can be modified to attain a higher plant capacity and efficiency.
The Koyna Hydropower Project is located in Satara district near Patan near the village of Helwak. The people of Helwak are the major beneficiaries of this hydropower project. This project is the largest power plant that has been completed so far in India with a total of four dams on the Koyna River with a capacity of 1960MW. This hydropower project is composed of four phases of power production. All the generators are situated in the underground powerhouses excavated inside the Western Mountains. The powerhouse in the dam foot also contributes to the generation of electrical energy. This hydropower project is considered as the lifeline of Maharashtra due to the electrical energy generation potential of Koyna Hydropower Project. The project is composed of a total of four dams with the primary contributor being Kolkewadi Dam and Koyna Dam [14].
To ensure that the Koyna Hydropower project performs its stipulated functions effectively, there is need of identification of the limitation and potentials of the power plants and then proposing on the ways through which the performance of the project can be improved to benefit the locals in Satara district. This case study analyzes some of the techniques that can be implemented in the Koyna Hydropower project so to increase efficiency and electrical generation of the Koyna Hydropower project. Despite the generation efficiency of 56%, the Koyna hydropower plants remains the major source of energy in Satara District. Research shows that the improvement in efficiency of the existing plant may result in more flexibility on the power grid [15].
Despite numerous efficiency improvements needed are cost-effective, currently, there has not been a good quantification of the value streams that the hydro plant can provide. Hence it is impossible to provide cost effective analysis when making the upgrades. Some of the techniques that can be implemented in Koyna Hydropower plant so as to improve its efficiency and performance include electricity market opportunities, new technologies, and operational improvements [16]. These factors are explained below:
The current state of Koyna Hydropower plant is eligible for numerous operational changes so as to improve its efficiency and performance. The optimization of its performance may result in an increased revenue for the power plant operators by 1 to 3%. Markets should be adjusted to enable the Koyna hydropower plant to compete as a flexible reserve to manage variability and reduce cycling of thermal plants. Another operational change that can be done on the plant is the compensation of hydropower for providing security and reliability to the grid, which would promote income to the Koyna plant by 40% [9].
Optimization of the Koyna Hydropower plant covers a broad factors when considering the performance and efficiency of the power plant. The daily river flow analysis of the Koyna River is an essential step towards optimization of the power plant. This analysis will help in the process of decision making during the determination of the water storage in the Koyna dam in the course of ensuring reliable and optimal operational policy. There is need of evaluating the river flow, temperature, and daily rainfall of the region so as to predict the River Koyna. This daily river flow analysis will help in determining the optimal hydropower generation scheduling so as to fit the demand of power with the supply for a given week or day while attaining numerous constraints within the system [12].
The daily river flow analysis of River Koyna is significant step towards performance and efficiency improvement of Koyna Power plant, its purpose is to asset the process of decision making of determining the storage of water in the Koyna Dam in the course of ensuring reliable and optimal policy of operation. The management of Koyna Power plant should also implement performance measurement program which contains an adaptive management process that enables participants to develop performance expectations as well as tracking results. Numerous initial indicators of performance are quite operational and basic, while other are to advanced measure such as the attempt to determine immediately the physical and fiscal; effects of a forced generator outage without marketing or transmission results [2].
The performance measurement program recognizes the three factors that form any system if power generation, namely the multiple agencies involved in the management operation, the individual Koyna power generation plant, and the power system as whole. Each entity should have operational goals, targets, and strategies that are focused on the improvement of efficiency and performance of Koyna power plant. Some of the strategies that can be adopted by the management include the reliability analysis, risk analysis, equipment condition assessment, work management, and availability of generation resources [15].
The changes in the management of the Koyna power plant as well as its electricity market management would result in more opportunities for hydropower. Scheduling after every hour promotes flexibility compensation and wider participation. The power plant would receive compensation for scheduling in forward markets. It has also been proved that bringing extra demand response to the market would assist in enabling the hydropower station to receive ancillary service prices and competitive energy. These changes are expected to reduce the electricity prices by 5% which will positively affect the people of Satara district. Scheduling of the Koyna generation station over numerous days or hours would also enable the performance optimization of Koyna hydropower plant in the context of other resources [9].
The approach of fixed-scheduling may increase the profit from the Koyna power station between 63% and 77%. This is because the current structure of market benefits fossil fuel sources of energy whose output is time independent and can burn fuel to produce electrical energy during any day, month, or hour. The Koyna power plant does not have this advantage and approximately at the highest price time to sell and lowest cost time to refuel. The figure below shows the high and low prices of the power station:
Another way in which the performance of the Koyna hydropower plant can be optimized is through liking this hydropower plant with wind power station so as to optimize bother the energy sources. As a corollary, markets would also treat the Koyna hydropower plant as a new class of storage asset since the power plant provides transmission support as well as the production, financial compensation could be issued for these services [17].
There is also need of making numerous changes in technological and mechanical systems of the Koyna Hydropower station so as to improve the efficiency and performance of the plant. One of the major technical changes that can be implemented is the expansion of operating range of the plant which has been approximated to have the capability of improving the income of the station by 61%. The expansion of the operating range can be implemented in this plant by changing the technological systems so as to serve higher peaks and lower loads as a percentage of capacity. These changes can improve the income of Koyna power plant by 85% [8].
The accurate estimation of velocity head correction factor could also improve the efficiency and performance of Koyna power plant. The correction factor also provides potential for improving designs of turbine-draft tube or the modification of fish passage, both in terms of environmental and performance conditions. The efficiency of the power station can also be improved through design modification and the use of innovative processes and current choices of materials. One of the significant alteration in the generator design is the method of control of circulating current losses in the stator winding. The new system of transposition has bottom-bottom or top-top strand transposition as all coil connections [13].
The segment of core lamination replacement which can be manufactured from a magnetic steel grade is also a significant technology which will provide a reduction in losses by 10% compared to the initial machine design that is currently being used Koyna Hydropower plant. Thro tor field coils should also be stripped and reinsulated with Class F exciter so as to improve the field forcing to 200% from 150% [10].
Another strategy of improving the efficiency and performance of Koyna Hydropower station is the improvement in the hydro unit operating efficiencies. The current turbines used in the power generation have been there since the construction and installation of this project. An appropriate seal on the seal rings does not permit water to flow through, hence conserving extra water and resulting in energy wastage. The leakage of water past work wear plates results in an extra load on the turbine runner during operation in condense mode. The leakage of water past work plates additionally decreases the efficiency of the Francis turbine specifically when wicket gates are closed and operating at partial loads [5].
Another way of improving the power capacity is through stroking the wicket gates. Over stroking the wicket gates entails the modification of the current mechanics of existing gate, by prolonging the wicket gate servo motor linear travel by 1inch to 4inches of travel. This slight alteration of wicket gates entails moving or machining the wicket gate servo motor stop nuts back further [19]. The figure below shows the proposed wicket gate linkage system which operates the gates to close and open:
The major benefit of this proposed wicket gate modification and profile include less cultivation of turbine at the leading edges of the turbine runners due to the uniform velocities across the proposed wicket dates design. This proposed wicket gates prevent the wear plates to experience less damage from leakage compared to the initial design of wicket gates that are currently used in Koyna Hydropower plant. Overhauling of the generation station if Koyna plant involves replacing and modification of the three primary components of hydro-machinery system namely wicket gates, wear plates, and seal rings [20].
This case study focuses on the technological improvements analyzed in the case study review above which can be implemented in Koyna Hydropower Plant so as to improve the performance and efficiency of the Koyna Dam and the Koyna Power plant. The capacity and performance improvements at Koyna Hydropower Plant are focused on permitting an increase in the optimum quantity of water allowed to flow into the turbines at low level of the lake. Additional flow of water will result in additional capacity of the horsepower at the turbine and it enables for extra electrical energy capacity for the entire plant. The guide vanes or wicket gates are huge gates of steel which can be closed or opened to regulate the flow of water of high pressure to the hydropower turbines [20].
The system of wicket gate is composed of 24 huge gates of steel organized like a cylindrical venetian blinds around the turbines. The approach that can be utilized in the improvement in the flow capacity to the turbines, and the output power capacity of the plant is to replace the current old cast steel wicket gates that are presently being used in the Koyna hydropower plant with the new stainless steel wicket gates to permit additional water to flow through the turbines. These proposed stainless steel wicket gates possess a more streamlined flow profile than the present old cast steel wicket gates, and are designed with a huge optimum opening [15].
The significance of these proposed stainless steel wicket gates is that thy provide payback of the project investments after few years of their implementation. By the use of the conservative wholesale price of the market for the $2660 per MW-month capacity, the value of 70MW of the new capacity can be added to the current Koyna Hydropower Project is estimated at $2.2 million yearly. Another strategic goal for the performance and efficiency improvement of Koyna Hydropower plant is the improvement in the hydro unit efficiency of operation. The current turbine overhauls in the Koyna plant have been there since its construction and replacing the current turbine machinery is expected to improve the efficiency and the performance of the station [21].
The hydro unit overhaul so as to attain a higher efficiency is the same as an automobile engine overhaul to as to improve the economical consumption of fuel by the vehicle. The improvement of the efficiency results in more production of energy by the use of same quantity of water in the dam. The major overhauling of turbines include the strategies such as replacing and modifying wear plates and seal rings so as to minimize the leakage of high pressure water through the wicket gate systems which normally takes place during the shutdown of hydro units. Preventing the water leakage results in extra available water in the future to generate substantial electricity for the Koyna Plant [22].
The wholesale market value for minimizing the water leakage through wicket gates is approximate at $200K per unit yearly. If the generated electrical energy from the water saves were generated through burning oil at a traditional power plant, more than 10000 crude oil barrels would be burned to generate the quantity of electricity generated by the water saved. The figure below shows the primary hydro unit components which are majorly considered in the turbine efficiency and performance improvement:
The hydro turbine unit is a unit that uses the flow of water and force the magnetic generator to spin resulting into the generation of electrical energy. This system of thermodynamic may be assumed to be an open system, nevertheless, there are some factors and losses which must be accounted for in the determination of the total and complete output efficiency of the Koyna hydropower plant. There is need of every unit getting overhaul after every 10 years or 15 years. Depending on the results of the inspection and tear and wear circumstances. During the process of overhauling a unit, numerous machine components and factors are replaced, tested, and inspected [10]. The figure below shows the comparison between the post overhaul data and pre-overhaul data against the amount of power generated:
Research shows that the efficiency of any power station including the Koyna Hydropower station can be improved by having tighter tolerances and tither clearances in the turbine pit wear, turbine seal rings, and also through the modification of the wicket gates design so as to reduce the profile of wicket gate camber. These factors once implemented will not only improve the overall efficiency of the plant, but also in the long run benefit the people of Satara district who heavily depend on the dam for the source of electrical energy. Improved efficiency and performance means that more electrical energy will be generated by utilizing the same water flow and water intake [23]. The figure below shows the new set of wear plates that should implemented to replace the current wear plates using in the hydro unit of Koyna power plant:
The Thermodynamics Laws can be applied when analyzing the design modifications and tighter clearances which will assist in improving the efficiency and capacity of the Koyna hydro-turbine unit.
The components of hydro-units for this research include wicket gates, wear plates, and seal rings. An appropriate seal on the seal rings should permit excess water flow through, hence converting additional water and wasting less energy. The leakage of water past worn wear plates puts an additional load on a turbine runner when functioning in condense mode. Furthermore, the leakage of water past worn plates reduces the efficiency of the Francis turbine, particularly when functioning wicket gates are closed and at partial loads [3].
The seal rings of the turbine runner have both rotating and stationery components. The stationary components are attached to the turbine itself and the rotating components are attached to the turbine runner itself. The major function of the seal rings is to minimize the leakage of water around the shroud of the turbine runner and between the turbines cover plate and crown plate of the runner. The sealing water acts as a medium for cooling so as to prevent seizing and heating of the runner bands in case the revolving and stationary metal components come in contact. The current seal rings are made of stainless steel and their designs use tow metals of different features which is desirable in case of accidental contact between stationary and rotating rings [25].
The proposed seal rings are currently being produced and manufactured from Nitronic 60 material which is an all-purpose metal. This alloy has a good temperature properties of about 1800F with an oxidation resistance. The addition of Manganese and Silicon to the Nitronic 60 alloy results in a matrix which inhibit fretting, galling, and wear in the annealed condition. The propose seal rings made from Nitronic 60 material will ensure proper tight and seal tolerances and also conserve water and reduce energy wastage.
In the figure above, the turbine runner is being machined and turned to attain the final tolerances and clearances for the seal rings. The lower seal rings are composed of rotating seal rings which rotate with the turbine runner, and the stationary seal ring which remains stationary. The same applies to the upper seal rings.
The wear plate is a component of the turbine which is situate in the lower and upper section of the wicket gate. The present design of the wear plate used in the Koyna turbine unit is made of chrome-vanadium steel, however, the proposed design of the wear plates are made from the Nitronic 60 material. When analyzing and studying the wear plates, it is clear that the water flows at a high pressure of 250 pse which results in water erosion that wears out and damages the wear plates. Additionally, once the wicket gates are closed, the leakage of water that passes through the wear plates that have worn out results in wastage of energy in water. The leaked water past worn wear plates reduces the efficiency of the turbine runner, specifically when opening the partial loads [19].
Extreme corrosion of the wear plates affects tremendously the efficiency of the turbine unit as it is more exposed to the leakage of water which may lead to cavitation. Cavitation is the fluid vaporization as a result of loss of pressure which cause destruction of surrounding walls, noise, produces vibration, collapse, and forms vapor pockets [26]. There is need of refurbishment of the current wear plates of Koyna Hydropower plant using Nitronic 60 wear plates as shown in the figure below:
The wicket gate regulates the water flow from the penstock which is the input pipe, and then to the turbine runner into the scroll case. These types of gates are also known as guide vanes or paddles. The modification of the current wicket gates used in Koyna hydro-turbine unit to have a tighter clearances and slimmer profile will automatically minimize the leakage of water between these wicket gates. This can be attained by evaluating the wicket gates as an airfoil, by considering the angle of attack, camber, length, and chord length of the airfoil. The tighter clearances minimize the leakage of water, and store additional water in the reservoir for the future use whenever the water is not needed. The figure below shows the instances when the wicket gates are pinched shut under ordinary conditions of operation when every gate is subjected to different forces [27]. These forces results in bending about the vertical and horizontal axes.
A shearing spin is situated between the gate shifting rings and each gate stem which is strong enough to sustain the optimum forces of operation that the system can experience, however, this shearing spin will yield or break and protect the remaining mechanisms from injury in the event that one of the gates get locked. The current design of the wicket gates is such that in the event that a single gate becomes disconnected from the mechanism of gate-shifting, no section of the gate can come in connection with the turbine runner. The connections and mechanisms that regulate the wicket gates are installed on the shift ring situated in the turbine pit. The modifications of the wicket gates can be done by making them squeeze tighter so as to prevent leakage [28].
The current old case-steel wicket gates that are being used in the Koyna turbine unit have thinner profile and are made from material of stainless steel. By making these wicket gates tighter, there will be reduced water leakage and conservation of energy. It has been proved that the newly optimized wicket gates profile has the ability of improving the peak efficiency between 1% and 1.25%, resulting in an increased capacity of 5%. The proposed optimized design of wicket gates have a thin trailing edge, with an asymmetrical shape, and sleeker profile as shown in the figure below:
Where d1 which is the black outline is the proposed design with slimmer asymmetrical profile, and d0 which is the black outline is the current wicket gates profiles that are presently used in Koyna turbine unit. The 2% average efficiency of the system is achieved when the attack angle in increased by 2o, and the edge gap trailing by 0.02inches. This proposed wicket gates permits additional water flow to pass through the gates hence increasing the maximum flow rate to the turbine to 3600cfs from the current 3400cfs resulting to an increased capacity of 7MW [20].
As the level of water keeps on dropping at the Koyna Dam, the future analysis and research can be allocated in an need design of turbine runner for operations ranges of low head. This calls for the need of alternation or modification of the electrical and mechanical components to improve and monitor efficiency and the capacity. By making the wicket gates tighter, there will be reduced water leakage and conservation of energy. It has been proved that the newly optimized wicket gates profile has the ability of improving the peak efficiency between 1% and 1.25%, resulting in an increased capacity of 5%. The sealing water acts as a medium for cooling so as to prevent seizing and heating of the runner bands in case the revolving and stationary metal components come in contact [20].
The current seal rings are made of stainless steel and their designs use tow metals of different features which is desirable in case of accidental contact between stationary and rotating rings. The approach that can be utilized in the improvement in the flow capacity to the turbines, and the output power capacity of the plant is to replace the current old cast steel wicket gates that are presently being used in the Koyna hydropower plant with the new stainless steel wicket gates to permit additional water to flow through the turbines. These proposed stainless steel wicket gates possess a more streamlined flow profile than the present old cast steel wicket gates, and are designed with a huge optimum opening [22].
The modification and replacement of the three major components of hydro unit namely wicket gates, wear plates, and seal rings can improve the efficiency of Koyna Hydropower plant by approximately 2% and the capacity of the plant can also be increased by 3 percent to 5 percent. In order to attain such efficiency and performance, there is need of changing the disunions of seal rings and wear plates so as to have a tighter clearances, and the design profile of wicket by increasing the attack angle by 2o, and also the edge gap trailing of the wicket gate should be increased by 0.02inches. It is expected that the capacity and efficiency of the power plant will be increased by 8000MW yearly per unit [19].
By preventing the leakage of water in the power hydro unit, additional water becomes available to generate more electricity or electrical energy. By the installation of the new machined and modified turbine components namely wicket gates, wear plates, and seal rings in the Koyna Hydro turbine unit, there will be a reduction in the water leakage throughout the turbine unit.
Conclusion:
To ensure that the Koyna Hydropower project performs its stipulated functions effectively, there is need of identification of the limitation and potentials of the power plants and then proposing on the ways through which the performance of the project can be improved to benefit the locals in Satara district. Thermodynamics plays a significant role when designing and analyzing systems of thermal design. During the analysis of the energy balance, the major consideration made is the process where the environment and system come to equilibrium. The energy balance for the entire system can be observed in equation below which includes the internal, potential, and kinetic energies of the system.
The modification and replacement of the three major components of hydro unit namely wicket gates, wear plates, and seal rings can improve the efficiency of Koyna Hydropower plant by approximately 2% and the capacity of the plant can also be increased by 3 percent to 5 percent. In order to attain such efficiency and performance, there is need of changing the dimensions of seal rings and wear plates so as to have a tighter clearances, and the design profile of wicket by increasing the attack angle by 2o, and also the edge gap trailing of the wicket gate should be increased by 0.02inches. It is expected that the capacity and efficiency of the power plant will be increased by 8000MW yearly per unit. By preventing the leakage of water in the power hydro unit, additional water becomes available to generate more electricity or electrical energy. By the installation of the new machined and modified turbine components namely wicket gates, wear plates, and seal rings in the Koyna Hydro turbine unit, there will be a reduction in the water leakage throughout the turbine unit.
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