Post on 30-Nov-2020
Load Measurement at THDC – Koteshwar - Uttaranchal
Load Measurement
At
2400MW Tehri Hydro Power Complex Koteswar
Uttaranchal
Using SCAD 500 Strain Measurement System
Load Measurement at THDC – Koteshwar - Uttaranchal
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
Load Measurement at THDC – Koteshwar - Uttaranchal
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
Load Measurement at THDC – Koteshwar - Uttaranchal
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
Load Measurement at THDC – Koteshwar - Uttaranchal
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.
Load Measurement at THDC – Koteshwar - Uttaranchal
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.
Load Measurement at THDC – Koteshwar - Uttaranchal
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
Load Measurement at THDC – Koteshwar - Uttaranchal
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)
Load Measurement at THDC – Koteshwar - Uttaranchal
Measurements and Test Results
SCAD 500 System Installed
At the Generator.
Mr.S.Manjunath of
Pyrodynamics
Carrying out Measurements
Using SCAD 500.
Load Measurement at THDC – Koteshwar - Uttaranchal
Measurements and Test Results
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.
Load Measurement at THDC – Koteshwar - Uttaranchal
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 Measurement at THDC – Koteshwar - Uttaranchal
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
Measurements and Test Results
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.
Load Measurement at THDC – Koteshwar - Uttaranchal
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
Load Measurement at THDC – Koteshwar - Uttaranchal
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:- pyrodynamics@gmail.com
Web:- www.pyrodynamics-india.com
Facebook:- Pyrodynamics