ELECTRICAL COMPONENTS OF MHP

Electrical Component Design

 Standard Electrical Components of MHPs
 Generator
 Control Equipment
 Protection Equipment
 Earthing System
 Transformers
 Primary Distribution System
 Secondary Distribution System
 Power Limiting Device
 Metering Equipment
Generators
 Types
 Synchronous Generator(SG)
 Asynchronous Generator(Induction Motor as
Generators or IMAG)
 Asynchronous Generator(Induction
Synchronous Generator(SG) Motor as Generators or IMAG)
Principle of Synchronous Generator
Exploded View-Synchronous
Generator
Schematic diagram of an Induction
Generator
Principle of an Asynchronous
Generator
Exploded View of an Squirrel Cage
Induction Machine
Comparison Between SG and IMAG
Synchronous
Generator(SG)
 Generally competitive in high
power range >100kVA
 Not readily available in
developing countries
 Complicated & liable to
breakdown; High
maintenance cost
 Complicated
 Needs to be ordered
Asynchronous
Generator(IMAG)
 Generally competitive in
small power range <30kVA
 Readily available in small
power range
 Rugged & simple; Reliable
and low maintenance cost
 Simple
 Possible with normal design
(4P or more)
Comparison Between SG and IMAG
contd…
Synchronous
Generator(SG)
 Self exciting
 Can supply reactive power
 Higher full load efficiency; good
part load efficiency
 High Rotor Inertia
 Good Voltage regulation
 Generally good technical support
available
 Good over load and motor start
capacity
 Can be made to sustain SC and
clear fault
 Fairly simple Selection,
calculation
Asynchronous
Generator(IMAG)
 External source needed for excitation
 External source needed for supplying
reactive power
 Lower full load efficiency; poor part
load efficiency
 Low Rotor Inertia
 Poor Voltage regulation
 Technical support generally does not
exist
 May de-excite under such condition
 De-excites under SC and might need
re-magnetization
 Needs calculation and re­adjustment
Types based on relative position of
Armature and Field Winding
 Rotating Armature Type(Brushed Type)
 Generally not preferred in MHPs due to high
maintenance cost(Slipring and Brush)
 Rotating Field Type(Brushless Type)
 Exciter Armature is mounted in the same shaft as that of
the main generator and AC voltage generated in the
rotating exciter armature is converted to DC voltage
though the use of 6 Nos of rotating diodes to feed to the
main generator rotating field winding
Synchronous Generators(bit more)
 Generally Cylindrical Rotor Type and Salient Pole
Type
 Cylindrical Rotor Types(4/2Pole machine) are high
RPM(mostly 1500/3000RPM for a 50Hz Generation and
1800/3600RPM for 60Hz Generation) and invariably
used with Steam Turbine/Gas Turbine
 Salient Pole machines are generally low RPM type and
generally manufactured in RPM range starting from
142.8 RPM and upto 1000RPM for a 50Hz system.
Practical Approach
 As standard Diesel Engines (as prime mover for DG
sets) manufactured in Indian Subcontinent have RPM
as 1500, off the shelf Salient Pole Generators are also
designed for an RPM of 1500 to suit direct coupling.
 In MHPs of Nepal,1500RPM Synchronous Generator
becomes natural choice.
 Few renowned manufacturers of Synchronous
Generators(in Mini/Micro Hydro range) of India origin
are KEL, Kirloskar Electric
company,Cummins,Crompton,Greaves,Jyoti etc.
Practical Approach
 KEL make Generators have Compounding
Transformer based Excitation System(to maintain
voltage within +-5%) and no need of electronic AVR
for size upto 125kVA,Starting Current Capability upto
2-3 times rated current.
Compounding Transformer based
Excitation System
Synchronous Generator Sizing
 Various Factors to Consider
 Temperature factor(A)
 Altitude factor(B)
 ELC Correction Factor(C)
 Power Factor(D)
Generator kVA=Installed Capacity in kW/(A*B*C*D)
 Generator rating Factors
Maximum ambient
20 25 30 35 40 45 50 55
temperature (oC)

A Temperature factor 1.10 1.08 1.06 1.03 1.00 0.96 0.92 0.88

Altitudes (m) 1000 1250 1500 1750 2000 2250 2500 2750

B1 Altitude factor 1.00 0.98 0.96 0.945 0.93 0.915 0.90 0.88

Altitudes (m) 3000 3250 3500 3750 4000 4250 4500

B2 Altitude factor 0.86 0.845 0.83 0.815 0.8 0.785 0.77

C ELC correction factor 0.83

D Power factor When load is only light bulbs 1.0
When load includes tube lights and other inductive
0.8
loads
Synchronous Generator Sizing
contd…
Generator size as calculated above is multiplied by 1.3 to
allow for the following conditions
 The output of the turbine could be higher than expected due
to better design(efficient design)
 If large motors (> 10% of generator size) are supplied by the
generator, the generator should be able to handle the starting
current.
 The generator is always generating rated power when using an
ELC
Practical Calculation
 Suppose we need to find Correct Generator Size for a 15kW
installed capacity scheme.
 Assume ambient temp of 40 deg Celcius,A=1
 Altitude above mean sea level as 1250m,B=0.98
 ELC correction Factor,C=0.83
 Load as a mix of predominantly Incandescent lighting(PF:1)
plus some inductive load like FT(PF:0.5) so as to give an
average power factor,
D = 0.8
Generator Size in KVA considering safety factor of 1.3
=1.3*15/(1*0.98*0.83*0.8)=29.966=30kVA
Hence we see that for all practical purposes the Generator Size
in kVA to be chosen is 2 times the installed capacity in kW
IMAG
 IMAG is Squirrel Cage Induction Motor run as
Induction Generator
 Induction motor when rotated above its rated
synchronous speed by some prime mover(hydraulic
turbine in case of MHP)and fed required excitation
though capacitors or through import of reactive power
from Grid, Generates Electrical Power. Slip in such
case is negative.
 Very Rugged Construction due to general ruggedness
of squirrel cage rotor. Highly common to use in
Pico/Peltric Sets.
Practical Approach
 Though IMAG is cheaper in range up to 30kVA size, SG
is preferred over IMAG in sizes above 10kW due to
practical considerations
 IMAG is however used almost invariably in
Pico/Peltric (Pletric: Pelton+Electric Generator) sets
upto 5kW
MHP in operation: Synchronous
Generator in Focus
MHP in operation: Double Jet Pelton
Turbine in Focus
Control Equipment
 Voltage Control Equipment
 Compounding Transformer for voltage regulation in the
range of +-5% for generators upto 125kVA
 Additionally fitted electronic AVR for sizes >125kVA
• Frequency Control Equipment
 Electronic Load Controller(ELC) upto installed capacity
100kW
 Hydromechanical/Electronic/Digital Governor for installed
capacity>100kW
Electronic Load Controller(ELC)
 An equipment which allows constant power
generation( no flow control) and maintains constant
system frequency by dumping additional generated
power to electric immersion heaters used as ballasts.
 ELCs are considered to be cheaper alternatives of
costly flow control governors in case of MHPs.
 Since ELC’s use Thyristors as switching device, a lot
many harmonics are generated requiring derating of
generators(ELC correction Factor: C)
ELC Panel Board
Inside View of an ELC Panel Board
ELC Continued
 Sizing of ELC and associated Ballast for installed
capacity upto 50kW
 Size of ELC=Installed Capacity in kW
 Size of Ballast=1.2*Installed Capacity in kW(to take care
of possible additional power generated due to better
system efficiency)
 Sizing of ELC and associated Ballast for installed
capacity > 50kW and upto 100kW
 Size of ELC=0.6*Installed Capacity in kW
 Size of Main Ballast=1.2*0.6*Installed Capacity in kW
 Size of Extension=0.4*Installed Capacity in kW
Protection Equipment
 Plant protection Equipment
 Outdoor Protection Equipment
Plant protection Equipment

 Overcurrent Protection
 Thermal Adjustable Type Moulded Case Circuit Breaker
 for Protecting generator from normal overload/short circuit in
the distribution line(Rating:25% oversized)
 HRC fast fuse
 for Protecting ELC power components(Thyristors etc) from
short circuit/earth fault occurring in ballast circuit
Plant protection Equipment
contd…

 Overvoltage/Undervoltage Protection(set at 110% and 85%)

 Under voltage Protection optional for plants <30kW
 Over Frequency/Under Frequency Protection
(set at 51.5Hz and 48.5Hz)
 Under frequency Protection optional for plants <30kW

 Varistor (to protect ELC board components from transient

over voltages)
Outdoor Protection Equipment
 Lightening Arrestors to protect lines from Lightning
 0.5kV Metal Oxide(Gapless)Arrestors for 400Volt Line
 9kV,5kA Metal Oxide(Gapless) Arrestors for 11kV Line
• Drop Out(DO) Fuse to Protect Transformers from Over
Current
Earthing System
 All non current carrying metal parts to be earthed to
protect equipment/human being from safety hazard
 An earth Continuity Conductor(ECC) to run though
the perimeter of the powerhouse
 Generator body, Turbine Enclosure, Belt Guard, ELC
Panel board, Ballast Tank, Metallic Door, Window
Frame etc (if used) all to be connected to ECC
Earthing System Continued
 Generator(Star Connected) Neutral to be earthed
separate from the earthing of non current carrying
metal parts
 Lightning Arrestors fitted at first pole should have
separate earthing from that of neutral GND.
 600mm*600mm*3.15 mm copper plate is used for
earthing purposes(weighs around 10kg)
 Earth Resistance value <5 Ohm is desirable but in no
case should exceed 10 Ohm.
 Typical Values for Soil Resistivity
Moderate climate, Desert climate
Type of soil
high rainfall (>500mm/year) (<250 mm/year)

Range of
Typical value Range of measured
measured values
(Ωm) values (Ωm)
(Ωm)

Clay 10 5-20 10-1000

Porous limestone 50 30-100 50-300

Sandstone 100 30-300 >1000

Quartz, marble, carbonaceous 300 100-1000 >1000

limestone

Granite 1000

Slate, petrification, gneiss, 2000

rock of volcanic origin
Transformers
 Few very simple practical formulas as below
 VHV / VLV = THV / TLV , where the terms have their usual
meanings.(Note that the voltages in the formula are to
be phase voltages and not line to line voltages and the
formula equally applies for both single phase and three
phase transformers)
 IHV =kVA/(√3*kV HV) and ILV =kVA/(√3*kV LV) for a 3
Phase Transformer and
 IHV =kVA/kV HV and ILV =kVA/kV LV for a 1 Phase
Transformer
Transformers contd….
 Type based on purposes
 Step Up Transformer(Used outside MHP P/H to step up
voltage level form generation voltage ie 400V to primary
distribution voltage ie 11000V)
 Step Down Transformer(Used at loadcentres to reduce
primary distribution voltage of 11000V to utilization
voltage of 400V)
Oil Immersed Transformer
Plan and Legend of a Transformer
TYPICAL RATINGS AND FEATURE FOR 100kVA STEP UP TRANSFORMER
TABLE 1

Type Three-phase, 11/0.4 kV

Rated capacity 100kVA
Rated voltage - Primary 400V
- Secondary 11000 V
Highest system voltage
- Primary 440 V
- Secondary 12kV
Rated Frequency 50 Hz
Connection
- Primary Gnd. Wye
- Secondary Delta
Cooling System ONAN
Vector group YNd 11
Rated impedance voltage 3.5 - 4.5%
BIL for windings and
bushings for secondary side 75 kV
Withstand voltage, 50 Hz, 60 Sec.
- Primary 28 kV
- Secondary 3 kV
No load tap changer ± 2.5% to ± 5% on HV side

Mounting Platform
Insulation levels (IEC) 76 LI 75 AC 3/AC 28
Insulation temperature class (IEC 76) A
Maximum allowable noise level at
3 metre hemispherical radius <44 dB
Applicable standard IEC
TYPICAL RATINGS AND FEATURE FOR 50kVA STEP DOWN TRANSFORMER
TABLE 2

Type Three-phase, 11/0.4 kV

Rated capacity 50kVA
Rated voltage - Primary 11 kV
- Secondary 400/230 V
Highest system voltage
- Primary 12 kV
- Secondary 440 V
Rated Frequency 50 Hz
Connection
- Primary Delta
- Secondary Gnd. Wye
Cooling System ONAN
Vector group Dyn 11
Rated impedance voltage 3.5 - 4.5%
BIL for windings and
bushings for primary side 75 kV
Withstand voltage, 50 Hz, 60 Sec.
- Primary 3 kV
- Secondary 28 kV
No load tap changer ± 2.5% to ± 5% on HV side

Mounting Platform
Insulation levels (IEC) 76 LI 75 AC 28/AC 3
Insulation temperature class (IEC 76) A
Maximum allowable noise level at
3 metre hemispherical radius <44 dB
Applicable standard IEC
Sizing of Transformers
 Size of Step Up Transformer is based on following factors
 Installed plant capacity
 Average Power Factor of Load
 Calculating size for 30kW Installed Plant size with average
power factor of load as 0.8
 kVA Rating of Transformer required=Installed Plant
Size/Power factor=30/0.8=37.5
 Now since 37.5kVA not being an standard transformer rating,
we should chose nearest higher rating ie 50kVA
 Necessary provisions may have to be incorporated for the
possibility of future load growth(in case it is planned to
replace turbine generator set at a later date with more
efficient turbine and suitable size generator)
Transmission and Distribution(T& D)
 Types
 Suspended Overhead on Poles(Overhead Line)
 Buried Cables(Underground Cable)
 OH Line(Features)
 Less Expensive
 Frequent Maintenance Required
 Less cost per maintenance
 Does not look aesthetically good in dense locality
 Not preferred in areas which experience heavy snowfall
T& D contd…
 UG Cable
 Costly Installation(if done per standard 6 times costly compared to
OH)
 Less Maintenance
 Higher cost per maintenance
 Highly desirable in densely located areas
 Obvious choice for areas which experience heavy snowfall
 Design Criteria of OH distribution line(as MHPs can not afford
the luxury of UG cable)
 Maximum allowable voltage drop at the farthest end shall not
exceed 10%
 Maximum TL line to line voltage in case of isolated MHPs is 11kV
 ACSR(Aluminium Conductor Steel Reinforced) conductors are the
norms of the day(as against hard drawn copper which were used in
earlier days)
Transmission and Distribution(T& D) contd…

Typical 3 Phase 4 Wire LT distribution

Primary Distribution Line Hardware and
Fittings
Voltage Drop Calculation
 L-L Voltage Drop in case of 3-Phase balanced
distribution
=√3 * I* (R*Cos φ +X*Sin φ)Volt
Where I is the load current in ampere, R is the
Resistance/Phase in ohm, X is the reactance/Phase in
ohm ,and φ is the power factor angle.
Voltage Drop in case of 1-Phase 2 wire system
= 2 * I* (R*Cos φ +X*Sin φ)Volt
Where symbols have their usual meaning
Sizes and designations of ACSR conductors used in micro-
hydropower schemes
Inductive reactance at Approximate weight
50 Hz and 50 cm (kg/km)
Current rating in still air
Name Resistance (Ω/km) spacing (Ω/km)
(amp)

0.355 80
Squirrel (20 SQ.MM AL) 76 1.374

0.349 106
Gopher (25 SQ.MM AL)
85 1.098

0.345 128
Weasel(30 SQ.MM AL)
95 0.9116

0.335 214
Rabbit(50 SQ.MM AL)
135 0.5449

0.328 339
Otter(80 SQ.MM AL)
185 0.3434

0.315 394
Dog(100 SQ.MM AL)
205 0.2745
Minimum vertical clearance for overhead
conductors

Place Low tension High tension (1-11 kV)

Off road 4.5 m 5m

Beside motorable road 5m 5.5 m

Across from motorable road 5.5 m 6m

A horizontal clearance of at least 1.2 m shall be observed in all cases.

•The minimum sag for conductors up to 11 kV can be
calculated by the following empirical formula:

2
 L 
d = 
 172 .8 
where, d = sag in m
L= length of span in m
Sag for spans of overhead cables
The value of sag should be included when determining the ground clearance of a
transmission line.

Span (m) 20 30 40 50 60 80
Minimum sag (mm) 13 30 54 84 121 210
Poles used in MHPs
 Due to cost consideration , LT(Low Tension) poles are
entirely made out of hard wood.
 Seasoned Pole would be better option.
 Other possibilities could be PSC(Pre Stressed
Concrete) pole or steel tubular pole(where there is no
cost constraint) or steel telescopic poles
 Steel Tubular(either swaged type or folding type) poles
are the norms for 11kV Distribution Line and also for
the double pole structure which supports
transformers.
Pole specification for hardwood poles

Minimum length (m) 6.0 7.0 8.0 8.5 9.0

Maximum span (m) 35 35 35 35 35

Buried length (m) 1.0 1.2 1.5 1.7 2.0

Minimum top diameter (mm) 125 140 150 175 175

Minimum ground clearance (m) 4.0 4.6 5.5 5.8 6.1

Insulators and Hardware
 Shackle Insulators of suitable voltage ratings (suitable
creepage path)---Up to 1000V OH Line
 Shackle Insulators --- Supported(Clamped)by D-Iron
set which is a clamp made out of galvanized steel
 Pin Insulators of suitable creepage path are used for
straight runs of 11kV Line
 Disc Insulators along with suitable tension Set are
used for deadening a line.
 Suitable Stay sets are provided at first pole, at line
end, at all poles set at an angle and at every fifth pole
even if the poles are in a straight line
Shackle Insulator specifications

S. N Size Dimensions Weight Corresponding

conductor
1 Small 55 mm x 55 200 gm Squirrel, service wire
mm
2 Mediu 75 mm x 90 600 gm Gopher, weasel and
m mm rabbit
3 Large 100 mm x 110 1300 Dog
mm gm
Spacing between Conductors
 Conductor spacing
 300mm upto 400V system
 400mm upto 1000V System
 600mm in case of 11kV line
 Horizontal or Triangular alignment(ACSR conductor)
 Spacing between conductors=√(d+V/150)
Where Spacing in m, V is the L-L voltage in kV and d is
the sag in metres. In general,70% should be added as
safety factor on the value calculated above.
Service Wire
 Should be double insulated
 Additional voltage drop in service wire not to exceed
2%
 Service wire shall be of the same material as that of
line conductor to avoid electrolytic corrosion.
 Minimum size of 4-6 sq.mm. to be used depending on
the span
Power Limiting Device
 MCB of suitable rating is generally used
 0.5A(Rated Current),5kA(Breaking Current) MCBs are
used for prescribed power of 100W
 The purpose is to disconnect the line against sustained
overload(control) and also to provide protection
against short circuit in the household wiring.
Metering
 Types available
 Electromechanical Type(Cheap but less accurate)
 Static Type(Costlier than EM type but far more accurate)
 Digital Type(Multifunctional Meter):Far more costlier
than Static Type but has tremendous advantages like far
superior accuracy, Possibility of data logging, data
communication, Multifunction Capability, Possibility of
field adjustment