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CONTENT INSIDE
Akshay Urja
Hydro & Renewable Operations
01 From the Chief’s Desk 01
02 Business & Performance 02
03 Centenary Year Celebrations 09
04 Safety – A Core value 13
05 Employee Speak 17
06 Tata Power – Community Care
Initiatives 22
April 2015
Volume 2 Issue 1
One must forever strive for excellence, or even
perfection, in any task however small and never be
On 9th of February, 2015, we were witness to an event of a lifetime. It was a day of celebration, not
just for the Hydro, but for the entire Tata Power family.
A century ago, our founder Mr. Jamsetji Tata envisioned the necessity to harness the power of the
abundant water reserves in the Western Ghats in order to provide the city of Mumbai with a clean,
and abundant source of electricity. It was a truly revolutionary project in those times.
9th Feb - CENTENARY DAY CELEBRATIONS
Through this vision was born the Tata Hydro Electric
Company, the fore-runner to the present day Tata
Power Company. Sadly, the founding father didn’t live to
see the project come to light. But many others strived
hard to ensure that the vision was manifested into
reality. This centenary year was a celebration of that
spirit –
a) Founding’s father’s vision to create abundant and sustainable energy supply
b) The incumbents who ensured that the vision is fulfilled
Hydro, and specifically Khopoli, is where the 100 year old journey had started, and thus, it was an
apt place to pay tribute to our founding father. Hydro, also has a unique distinction of having
many employees among us who have been responsible for running this plant for 4 generations.
The occasion was magnanimous, a once in a lifetime event for all of us. And the Hydro team, in
partnership with the Central corporate team, ensured that the event lived up to the momentous
occasion.
EVENTS OF THE DAY
The attendees list included members of the senior management team of Tata Power, Members of
Group Executive Council, directors from Tata Sons, retired directors of Tata Power, retired
employees of Tata Power along with their wives, current employees of Tata Power Hydros, and
the employees of Tata Power group spread across the geography, who had joined us through 42
satellite links.
Akshay Urja
Akshay Urja
Bhira PSU 200 MVA STATOR
REPLACEMENT
INTRODUCTION Tata Power’s Bhira Hydro Power Station is a surface power station with an installed capacity of 300 MW, including one generating unit of 150 MW, named Bhira Pump Storage Unit (BPSU). The onsite construction of new & higher capacity stator for BPSU has been going on since Dec 2014 by Voith Hydro Pvt Ltd, which will replace the existing stator of BPSU. It is decided to replace the existing stator to upgrade the capacity and to avoid forced outages due to frequent occurrence of faults in existing stator. Project information
Other activities were Generator Cryogenic cleaning and Runner overhauls that were conducted in record time. Tests like Polarization &Depolarization Current Analysis, Capacitance & Tan Delta, Non-linear Harmonic of Insulation Test, Partial Discharge Analysis, DC Winding Resistance, ELCID Test on Stator core, Wedge Tightness Test were carried out and found the unit in healthy condition.
Akshay Urja
Old Governor Panel New Governor Panel
Unit-7 & Unit-8 Overhaul was done back to back in the month March ’15 successfully. The Sulzer
make DTL -595 Governor of Unit 7 and Unit 8 were installed 15 years ago, and was giving frequent
trouble resulting in loss of generation and increased forced outages. Technical support was not
available. This DTL-595 governor was replaced with smarter Siemens make AK-1703 ACP governor.
In this governor manual operation is also possible from the HMI provided on governor panel. Start
and Stop sequence is provided on HMI for fast trouble shooting of problem. The governor related
alarms are provided on HMI for better understanding during tripping and start/stop sequence. In
new Governor we have taken assurance from the OEM for spares for next 15 years, both for
Support and Services.
Khopoli Overhaul
Akshay Urja
Bhivpuri – Technical Focus Areas
• New 4 MVA make Transformer was commissioned at Bhivpuri in March 15.
• Old transformer was prone to frequent oil leakages and test results verified it’s deteriorated
condition. It had failed earlier in 2008 and was repaired in-house.
• This has resulted in improved reliability of TRPH Generation and enhanced workplace safety.
• This was major capex job of Rs. 40 Lakhs
New 4 MVA Transformer
New bay for 110 KV Khopoli - Bhivpuri Line 2 has been commissioned and taken in service. This
will improve the power evacuation capacity, reliability and stability of Bhivpuri Power House.
110 KV RADSS Bus fault relay was replaced with new ABB make REB 670 numerical relay, which
was required for remote operation of the Station.
All 110 KV equipment side GODs have been replaced for facilitating remote operation. Also
22KV isolators at Headworks have been replaced.
New 415 V ACDB at Khandi was commissioned in Jan 2015. This has improved the power supply
On 9TH FEBRUARY, 2015 was a significant day for Tata Power, especially Khopoli
Hydro Power Station. It was on this day, a hundred years ago, and at this very
location that the company first began its’ commercial operation.
A century ago, our founder Jamsetji Tata envisioned the necessity to harness the power of the abundant
water reserves in the Western Ghats in order to provide the city of Mumbai with a clean and abundant
source of electricity. Through this vision was born the Tata Hydro Electric Company, the fore-runner to
the present day Tata Power Company. The company commissioned its’ first hydro-electric power
generating station at Khopoli in on 9th February, 1915.
The occasion was magnanimous, a once in a lifetime event for all of us. And the Hydro team, in
partnership with the Central corporate team, ensured that the event lived up to the momentous
occasion.
9th Feb - CENTENARY YEAR CELEBRATIONS
Events of the Day
Mr. Vivek Talwar : Chief Culture Officer, compered the occasion
in his inimitable style. He shared anecdotes about mahaseer fishes,
and through it established the concept of Invisible Goodness. An AV
film on Invisible Goodness was projected.
The attendees list included Directors from Tata Sons, Members of Group Executive Council, retired Directors of Tata Power, members of the Senior Management team of Tata Power, retired employees of
Tata Power along with their wives, Committee Members of Tata Hydro Electric Employees’ Union,
current employees of Tata Power from Hydros. Live telecast of the even was relayed through 42 satellite
links for employees of Tata Power group spread across the geography to witness the historic event.
Though most of the machinery of yesteryears are not in use anymore, some about 100 years old, they have been duly preserved and were on display in all their glory. Khopoli employees took special pride in displaying the mechanical contraptions.
Speeches :
Our MD : Mr. Anil Sardana spoke about continuing to live the Values living up to the founding father’s values. He spoke fondly of how the business values of a century back are still relevant today. He mentioned the need of the organisation to document our past successes and stories, so that it can be passed on to the generations to come.
Tata Power, in 1915, had generated 12 MW of energy from
Hydro. As a tribute to Jamsetji Tata, the MD, on behalf of the
organisation, committed to commissioning at least 120 MW of
hydro-electric power generation in the Centenary Year.
Safety Day celebrated at Bhivpuri. All employees came together & participated whole heartedly
To ensure safe environment at site, 5 Star Safety Management System (SMS) that closely embeds various parameters such as Safety organization, Mgmt. Control System, Fire Control System, Accidents, Incidents & Near-miss reporting and Workplace implementation, is being followed at workplace. Monthly safety trainings carried out at all sites to train and improve the capability of individuals working at wind farms Wind turbines require one to work at an elevated height. Therefore, as mandated by the process, using of ‘Double Lanyard Safety Harness’ along with ‘Fall Arrester’ has become a standard practice.
Mock Drills
Rigorous mock exercises are carried out on monthly basis to successfully tackle any future emergency
situations. Some of the exercises carried out are Rescue, Firefighting, Snake Bite, Scorpion bite, Road
accident, WTG Panel flash over, Electrical Shock etc. (as per the site requirements)
Various mock drills / exercises are routinely carried out considering following scenarios: Ground Fire,
Natural Calamity, Road accidents, Snake Bite, Electrocution and Chemical splash in various wind farms.
BCP drill was successfully conducted at various sites
a. What motivated you to come up with your brainchild, micro hydro turbine?
Well right from my academic years, it’s been my passion to work on machines. When I was posted in Bhivpuri Mechanical Maintenance, I was working on a cross flow turbine which could harness the hydro power available in tailrace water discharge. When I just completed the primary mathematical analysis of turbine, 2012’s Knowledge fair arrived and out of enthusiasm we participated in the competition. We were out of the competition in the very level of evaluation. However, when our MD Mr. Anil Sardana visited our stall he encouraged me to think beyond the ordinary and posed a challenge to make a turbine which actually can be used in our tailrace like water streams for power generation. That was the moment that propelled all of us to work on this extraordinary project. Not only did we win the 1st prize in the organizational level Knowledge Fair, but also in actual field wherein we commissioned our first prototype that is continuously generating 3.5 KW power at our Khopoli tailrace. We have now moved ahead and have created a 15 KW turbine setup, which is ready to be installed in tailrace very soon. b. What was the key technological aspect/challenge that you had to work on during creation of micro turbine? Considering the nature of industry that we are in, our scope for doing actual R&D gets limited, since it requires a completely different set of knowledge & resources. It took almost 8 months of deeply focused studies to finally come out with a conceptually agreed design. In the absence of sophisticate software, for every design problem we had to do long mathematical modeling instead. Also, in the absence of adequate testing facility (jobs of such nature ideally require a lot of field trials), we had to make a turbine which could use at low head ranges without much loss of efficiency. At the same time, we wanted the cost to be lower than the other products available in market. Our engineering skills & perseverance were put to test, requiring us to do a lot of brainstorming and innovations to finally overcome these challenges.
c. How is this different from any other micro-hydro turbine, technically as well as commercially?
When we started working on this project, we went through most of the micro turbine setups available in the market. We found that most of them below head range of 3 meters, are financially not viable. Also there was a technological constraint which restricts use of same type of turbine in different types of water flow conditions. We took up a conscious decision to work on this void. The turbine we designed can work on any range of water head from 0.5 m to 3 m. We kept its design so simple that it can be commissioned & operated by even an average person with little technical knowledge. But the bigger challenge was the cost aspect. The total cost of the 15 KW turbine that we developed in-house, is approx. 6 lakh rupees, which means that if it runs for 14 hours a day, the cost of turbine can be recovered in just about 2 years. This is the major advantage compared with the other micro turbine setups currently available in market.
e. How much duration was required to work on this? What was the support that you received at the organizational level?
In such type of projects (which involves R&D), basic designing & the mathematical analysis involved takes majority of the time, which was true for our project too. The design-to-actual trials took almost 13-14 months. This includes focused group studies for 3 months. The one aspect that is very critical for success of such projects is management’s trust in the team and flexibility of time lines. We really are very grateful to Hydro leadership for giving us both of these in abundance. Everyone in senior position were very supportive to the project, especially Mr. Mahesh Paranjpe (Chief – Hydro & Renewable Operations), whose constant technical guidance and interest helped us a lot in achieving success. f. While working on innovative/out of the box projects, what are the key areas one needs to focus on?
Basic scenario analysis, which tells you what is currently available in market and what is not. This helped us to identify the void in the market. Currently, the market does not have an easy to install & financially viable turbine setup for water head range below 3 meters. This enabled us to focus on this specific head range. Another key aspect is the mathematical analysis. You need a lot of mathematical analysis for such kind of design projects. Thus time spent on books & research material plays a very important role.
g. What usage do you envision for this project? For the organization and the community as a whole?
This turbine can work at any head range from 0.5 m to 3 m without any significant drop in efficiency. The setup we designed for it makes it very user friendly in terms of installation in tailraces of our hydro stations. Moreover there are many locations in & around our power houses where seasonal water streams flows, where this setup can be used. Since we have kept the design very simple & cost very low, people from rural areas where such small water stream flow, can use it for their day to day electrical power usage. We are also working on the horizontal variant of this setup which can increase the scope of this turbine to a very far end. If our efforts result in even a very finite saving of costly electricity by replacing it with power from natural unharnessed water stream, it will be the greatest reward for us.