Load Measurement At 2400MW Tehri Hydro Power Complex...

Load Measurement at THDC – Koteshwar - Uttaranchal

Load Measurement

At

2400MW Tehri Hydro Power Complex Koteswar

Uttaranchal

Using SCAD 500 Strain Measurement System


ABOUT THDC

Koteshwar H.E. Project is an integral part of the 2400 MW Tehri Hydro Power

Complex.

Koteshwar Project comprises a 97.5 m. high concrete Dam and Surface Power

House, housing 4 units of 100 MW each and is located around 22 Km.

downstream of Tehri Dam. Koteshwar Project is a run-off-river scheme with

minimum diurnal storage. The Koteshwar Project will regulate water releases

from Tehri Reservoir for irrigation purposes. The reservoir created by

Koteshwar Dam shall also function as balancing reservoir for Tehri Pumped

Storage Plan


Generators at THDC

The Generators for THDC are supplied by Bharat Heavy Electricals Limited – Hyderbad.

TYPE OF GENERATOR

RATED PARAMETERS:

Rated Capacity (KVA) :- 111111

Rated Capacity (K W) :- 100000

Maximum Continuous Output (KVA) :- 123000

Maximum Continuous Output (KW) :-110000

ELECTRICAL DATA:

Resistance of stator winding per phase

at 75°C:- 0.0047 Ohms

Resistance of rotor winding at 75°C:- 0.19 Ohms

Capacitance per phase to ground of stator winding:-

0.75mF

MECHANICAL DATA:

Flywheel Moment of the Rotor :- 14600 TM2

Rated Speed :- 142.86 RPM

Maximum Runaway Speed :- 265 RPM

Weight of Wound Stator (without Foundation Plates):- 194000 Kgs

Weight of Rotor:- 338 300 Kgs

Height of Stator Frame :- 3130 mm

Outer dimension of Stator - Across Flat :- 10650 mm

Height of Generator Shaft :- 6960 mm

Overall Diameter of the Rotor :- 8560 mm

Diameter of Generator Barrel :- 12400 mm

Stator Core Inside Diameter :- 8600 mm

No. of Slots :- 360

Weight (with lifting device);- 350 Tons


Generators at THDC

The Generators weigh 350 Tons.

On each Generator there are 8 ring load Cells as shown

in the left.

Each Load cell is Configured as a Full Bridge.

Between The Rotor and the Load Cell a Thrust Pad is

inserted so that the load from the Rotor is applied on the

Load Cell.

The load of 350 Tons has to be equally distributed across

the 8 Load Cells, so that the Rotor is perfectly balanced.

So Each Load cell must record a load of 43.75 Tons

Ring Load Cell

Ring Load Cell

Rotor

THRUST PAD


Generators at THDC

Thrust Pad inserted between the Rotor and the Load Cell. The Load cell

is configured for a Full Bridge and the cables routed from the Load cell

is seen in the picture.


SCAD 500

Strain Measurement System

SCAD 500 is a 6 Channel Strain Measurement System designed for Static and Dynamic Strain Measurements.

SCAD 500 accepts 4 strain gage inputs (any combination of 120 Ohms, 350 Ohms or 1000 Ohms quarter, half or full bridge

configurations) and 2 amplified transducer inputs.


6 Channel System – Four Strain Gage Inputs and Two Amplified Transducers Inputs.

Accepts Quarter Bridge, Half Bridge and Full Bridge Strain Gage Configurations.

System has built in circuitry for 120 Ohms, 350 Ohms and 1000 Ohms, Quarter and Half Bridge

Strain Gage Configurations.

Simultaneous Display of all 6 Channels in Microstrain or user defined Engineering Units.

On Line Graphical Display of any One Channel.

Peak Hold – Max / Min for all Channels.

Selectable Display of Channels.

Auto Zero.

Gage Factor Setting from 0 .1 to 99 ( 3 Decimal Digits)

Excitation Voltage:- Selectable from 0 to 10 VDC in steps of 10 mV.

Full Scale Range:- 10,000 me ; 25,000 me ; 50,000 me and 1,00,000 me

+/- 10VDC - Analog Output for Strain Gage input Channels .

RS 232 Interface.

Dynamic Response:- 150 kHz Per Channel

FEATURES

SCAD 500

Strain Measurement System


SPECIFICATIONS

EXCITATION VOLTAGE Selectable from 0 to 10 VDC in steps of 10 mV.

INPUT CHANNELS - 4 Strain Gage Input Channels.

- 2 Amplified Transducer Inputs.

Input Range : +/- 10 VDC.

Power Supply for the sensor : +/- 15VDC.

BRIDGE

CONFIGURATIONS

Quarter Bridge, Half Bridge or Full Bridge for 120 Ohms, 350

Ohms and 1000 Ohms Strain Gages.

The system incorporates internal bridge completion circuitry for

120 Ohms, 350 Ohms and 1000 Ohms Strain Gages.

DISPLAY 128x64 Pixel Graphics LCD

Simultaneous Display of all 6 channels in Microstrains or user

Defined engineering units and Current Date and Time.

ENGINEERING UNITS Each Channel can be set for user defined engineering units via

the Mx+B scaling format.

DISPLAY UPDATE RATE 1 sample per second per channel

GAGE FACTOR SETTINGS 0.1-99 ; Resolution – 0.001

BRIDGE FACTOR

SETTING

1(Quarter Bridge), 2 (Half Bridge) or 4 (Full Bridge) or user

defined.

BRIDGE BALANCE Independent Zeroing for each channel or Simultaneous Zeroing

of all the channels.

Bridge Balance Setting are stored in a built in NVRAM.

FULL SCALE STRAIN

OUTPUT

Selectable: – 10,000 me , 25,000 me , 50,000 me and 1,00,000

me.

RESOLUTION OF THE

DISPLAY UNIT

1 me for a Range of 10,000 me.

FULL SCALE ANALOG

OUTPUT

+/- 10 VDC

DYNAMIC RESPONSE DC to 50 kHz (Flat). Roll off from 50 to 150 kHz . Each

Channel has a Low Pass Filter with cut off frequency of 40 Hz.

Filter can be enabled or disabled.

CALIBRATION Shunt calibration across the 1000 Ohms passive arm to simulate

5000 me.

INPUT POWER +/- 15VDC & +5VDC . 110 – 230 VAC , 50 /60 Hz Adapter

supplied with the system.

DIMENSIONS 224 x 212 x 92 mm ( L x W x H)

WEIGHT 1.6 Kgs (Excluding AC Adapter)


Measurements and Test Results

SCAD 500 System Installed

At the Generator.

Mr.S.Manjunath of

Pyrodynamics

Carrying out Measurements

Using SCAD 500.



TEST 1.

STATIC MEASUREMENTS:-

In this Test, the Thrust Pad is

installed on the Load Cell.

The Rotor is lifted up using a

crane.

The SCAD 500 is zeroed in this

position.

In this test only 3 Load cells have

been used for measurements.

The Rotor is then slowly assembled

on the Thrust Pads.

As per the Design the load of 368

Tons must be equally distributed

across the Thrust Pads. So each

Load cell must measure 46 Tons.

The Load cell has been calibrated

in microstrains.

The Load cells connected were

PAD 8, PAD 6 and PAD 4.

Calibration Factors:- PAD8=0.0401,

PAD6=0.048; PAD4=0.043,

SCAD 500 READINGS

PAD 8:- 1190 me

Pad 6:- 1034 me

Pad 4:- 1062 me.

Using the Calibration Factors

the Equivalent Loads:-

PAD 8:- 47 Tons

Pad 6:- 49 Tons

Pad 4:- 45 Tons.

SCAD 500 Interfaced to Notebook PC and

Data Recorded in SCAD VIEW Software.


Once the Load Measurements

have been carried out, and if the

load distribution is not uniform

then balancing has to be carried

out.

The balancing can be carried out

using the mechanism circled in

Blue Color.

The Bolt is rotated to balance

the Rotor,


LOAD VS TIME

44

44.5

45

45.5

46

46.5

47

47.5

48

48.5

49

49.5

6:17:17

PM

6:20:10

PM

6:23:02

PM

6:25:55

PM

6:28:48

PM

6:31:41

PM

TIME OF THE TEST RUN

LO

AD

(T

on

s)

PAD 8

PAD 6

PAD 4


TEST 2.

DYNAMIC MEASUREMENTS:-

In this Test, the Rotor is rotated

manually using a crane.

The Data is logged to the PC via

the RS 232 interface.

The Load Vs Time Plot is as

shown.

The measurements have been carried out successfully using SCAD 500 System

under very noisy environment.

The SCAD 500 has proved that it is capable of carrying out measurements under

tough environmental conditions.


Central Glass and Ceramic Research Institute – Kolkatta.

Indira Gandhi Centre For Atomic Research – Kalpakkam.

Gas Turbine Research Establishment – Bengaluru.

Indian Institute of Science – Bangalore – Department of Aerospace Engineering.

Indian Institute of Science Bangalore – Department of Civil Engineering.

Indian Institute of Technology – Kharagpur - Department of Mechanical Engineering.

Indian Institute of Technology – Kharagpur – Tribology Laboratory.

Indian Institute of Technology – Kanpur – Department of Mechanical Engineering.

Indian Institute of Technology – Chennai – Department of Applied Mechanics.

Indian Institute of technology – New Delhi - Department of Applied Mechanics.

National Metallurgical Laboratory – Jamshedpur.

Bhabha Atomic Research Centre – Mumbai.

Bharat Heavy Electricals Limited – Hyderabad.

Hindustan Aeronautics Limited – Bangalore.

Defence Research and Development Laboratory – Hyderabad.

Tata Steel – Jamshedpur.

BMS College of Engineering – Bangalore.

College of Engineering – Pune.

Jadhapur University – Kolkatta.

Central Road Research Institute – New Delhi.

DOW Chemical International Private Limited – Pune.

Vikram Sarabhai Space Centre – Thiruvananthapuram.

Tagore College of Engineering – Chennai.

Peekel Instruments B.V. – Netherlands.

isi-sys – Kassel – Germany.

North Coast Technical Sales Inc - U.S.A.

List of End users of SCAD 500

System


For More Detailed Information or Demonstration Please contact us at

PYRODYNAMICS Plot No 272

KIADB Industrial Area Phase 2 Harohalli ; Taluka Kanakpura

Dist. Ramanagaram Bengaluru Rural - 562 112 Karnataka State – India

Tel:- +91 9686478833

Email:- [email protected]

Web:- www.pyrodynamics-india.com

Facebook:- Pyrodynamics

Load Measurement At 2400MW Tehri Hydro Power Complex...

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