BAHIRDAR UNIVERSTY

BAHIRDAR INSTITUTE OF TECHNOLOGY (BiT)

FACALTY OF ELECTRICAL AND COMPUTER ENGINNERING

DEPARTMENT OF ELECTRICAL ENGINNERING

STREAM ELECTRICAL POWER ENGINNERING

Industrial Internship Final Report

Bahir Dar, Ethiopia

June/2018
 DECLARATION

We are 4th year Electrical Engineering students and we have undertaken our internship experience
in Tana Beles hydroelectric power plant [hosting company] for a period of March 8/ 2018 to July
8/2018 under the guidance of mentor Mr. Edemialem [Academic advisor] and, Mr. Ambachew,
Mr.wodaje , Ms. Adey and Mr. W/Mariam, Mr.liulseged [company advisors ].We clarify that our
work is original and compiled according to the internship report writing guide line given by the
department.

Group Name Id No Signatures

Bekalu Achenef …………………………BDU0701437UR …………………….

Serkalem Basha ……. ………….………. BDU0702267UR …………………….

Tiruneh Yeneneh…………………...........BDU0702404UR …………………….

Wudineh Tegegne……………….…….…BD0702462UR …………………….

Yitayal Gizachew…………….…………. BDU0702518UR …………………….

Name of advisor Signature Date

Mr. Edemialem G. …..…… …………

Examiner Signature Date

1………………. …………….. ………..

2…………………. …………….. ..………

3………………. ……………… .………

Date: June/ 2018

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 ACKNOWLEDGEMENT

First and foremost, we would like to express our sincere appreciation to Bahir Dar University
which prepares this internship program. Next we would like to express our deepest gratitude to
EEP that allowed joining and working our internship program in the TBMPP. Thanks a lot to all
workers of TBMPP for giving a professional training, experience and good practical skill.

We want to give grateful thanks to our advisor Mr. Edemialem G. who gave us moral support and
guided us in different matters regarding to the internship program. Unfortunately, it is not possible
to list all of them in this limited space. Thank you to all. Thank you for everything.

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 EXECUTIVE SUMMARY

Internship program has a key role for students to have an experience on practical skills by inter-
relating previous theoretical knowledge’s and helps to apply hands on work duty in a certain
occupational field. With this concept we have been working in tana beles multipurpose project
from March 8/2018 up to July 8/2018 G.c. During this period, we have been working in the three
sections (maintenance, operation and inspections in the project) so as to have deep knowledge in
process of hydropower generation.

This report consists of five chapters including brief history of the company, its vision, mission and
objectives, its generation process and products, main customers, organizational structure, overall
internship experiences in different electro mechanical system components, electric power
generation and distribution and installation system, and their control system in PLC, overall
achievements and project done on effective thermal control methods, overall internship benefits
we gained. After all we have given conclusion on our stayed and also we tried to recommend both
our host company and Institute.During the internship period in addition to academic achievements
we have gained important benefits and experiences in terms of social interaction, co-ordination,
communication skills to professionals, responsibility of work career, and leadership skills that are
essential for our lives.

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Contents
DECLARATION ................................................................................................................................................ i

ACKNOWLEDGEMENT ................................................................................................................................... ii

EXECUTIVE SUMMARY ................................................................................................................................. iii

LIST OF ACRO NYMS AND SYMBOLS ............................................................................................................ xi

CHAPTER ONE ............................................................................................................................................... 1

INTRODUCTION ............................................................................................................................................. 1

1.1Background of the Company ................................................................................................................... 1

1.2 Vision, Mission and Objective of EEP .................................................................................................. 1

1.2.1 Vision............................................................................................................................................ 1

1.2.2 Mission ......................................................................................................................................... 1

1.3 Objective of the company ................................................................................................................... 1

1.4 Location ............................................................................................................................................... 4

1.5 Host company main products and services ........................................................................................ 4

1.6 Production Process of the Company................................................................................................... 5

1.7 The main customers or the end users of its products or services ...................................................... 5

1.8 Organizational structure of the company ........................................................................................... 6

1.9 Work flow............................................................................................................................................ 6

CHAPTER TWO .............................................................................................................................................. 8

OVERALL INTERNSHIP EXPIREANCE .............................................................................................................. 8

2.1 Objectives of the internship ................................................................................................................ 8

2.1.1 General objective ......................................................................................................................... 8

2.1.2 Specific objectives ........................................................................................................................ 8

2.2 How we did get the company ............................................................................................................. 8

2.3 How a hydropower plant works.......................................................................................................... 8

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2.4 Work section of the company ........................................................................................................... 10

2.4.1 Task one (Operation) ................................................................................................................. 10

2.4.2 Task two (Inspections) ............................................................................................................... 10

2.4.3 Task three (Maintenances) ........................................................................................................ 12

2.5 process of tasks ................................................................................................................................. 12

2.5.1 Procedures that we followed to do our task ............................................................................. 12

2.5.2 Goods that we have gained during performing our tasks ......................................................... 13

2.5.3 Challenges that we faced during we performed our tasks ........................................................ 13

2.5.4 The measurement that we have took to overcome these challenges ...................................... 13

2.6 Overall system components and operation...................................................................................... 13

2.7 Intake ................................................................................................................................................ 14

2.7.1 Inlet structure ............................................................................................................................ 14

2.7.2 Intake structure.......................................................................................................................... 15

2.7.3 approach channel....................................................................................................................... 15

2.7.4 Inlet stop logs ............................................................................................................................. 16

2.7.5 Trash rack ................................................................................................................................... 16

2.7.6 Rack cleaning machine ............................................................................................................... 16

2.7.7 Intake gate (wheel gates)........................................................................................................... 16

2.7.9 The low pressure headrace tunnel ............................................................................................ 17

2.7.10 Surge Tank................................................................................................................................ 17

2.7.11 Penstocks ................................................................................................................................. 17

2.7.12 High pressure headrace tunnel ................................................................................................ 18

2.8 Power house ..................................................................................................................................... 18

2.8.1Machine hall (erection) floor ...................................................................................................... 18

2.8.2 Generator floor .......................................................................................................................... 20

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 2.8.3 Turbine floor .............................................................................................................................. 26

2.8.4 MIV (spiral case) floor ................................................................................................................ 29

2.9 Switchyard......................................................................................................................................... 31

2.9.1 Disconnect switches /Isolators .................................................................................................. 32

2.9.2 Circuit breaker............................................................................................................................ 32

2.9.3 Surge/lighting arresters ............................................................................................................. 33

2.9.4 Bus bars ...................................................................................................................................... 33

2.9.5 Bus couplers ................................................................................................................................... 34

2.9.6 Bus bar supporting insulators .................................................................................................... 34

2.9.7 Current transformers (CT) .......................................................................................................... 34

2.9.8 Voltage transformers (VT).......................................................................................................... 34

2.9.9 Earthing Switch .......................................................................................................................... 35

2.9.10 Pantograph............................................................................................................................... 35

2.9.11 Control system ......................................................................................................................... 35

2.9 Outlet ................................................................................................................................................ 35

PROJECT AND ITS CONTRIBUTION TO THE COMPANY ............................................................................... 36

3.1. Introduction ......................................................................................................................................... 36

3.2. Problem statement . ..................................................................................................................... 36

3.3. Objective .......................................................................................................................................... 37

3.3.1. General objective ...................................................................................................................... 37

3.3.2 Specific objectives ...................................................................................................................... 37

3.4. Significant of the project .................................................................................................................. 37

3.5. Scope of the project ......................................................................................................................... 37

3.6. Limitation and Delimitation of the project. ..................................................................................... 38

3.6.1 Limitation of the project ............................................................................................................ 38

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 3.6.2 Delimitation ............................................................................................................................... 38

3.7. Literature review.............................................................................................................................. 38

3.7.1 Causes of overheating electrical equipment’s. .......................................................................... 39

3.7.2 Causes of overheating enclosure electrical equipment’s. ......................................................... 39

3.7.3 Effects of Overheating ............................................................................................................... 41

3.8. Materials and methodology ............................................................................................................. 42

3.8.1 Materials .................................................................................................................................... 42

3.8.2 Methodology .............................................................................................................................. 43

3.10 Cooling fan .................................................................................................................................. 46

3.10.2 Industrial enclosure Filter Fan Design Options ........................................................................ 46

3.11 How to Control automatically the Fan by Using Thermistor. ......................................................... 49

CIRCUIT DIAGRAM .............................................................................................................................. 49

PRINCIPLE OF OPERATION .................................................................................................................. 51

CHAPTER FOUR ........................................................................................................................................... 54

OVERALL BENEFITS FROM THE INTERNSHIP ............................................................................................... 54

4.1 Practical skills .................................................................................................................................... 54

4.2 Theoretical knowledge...................................................................................................................... 54

4.3 Interpersonal communication skills .................................................................................................. 54

4.4 Improving team playing skills............................................................................................................ 55

4.5 Improving leadership skills................................................................................................................ 56

4.6 Understanding about Work ethics and related issues ...................................................................... 56

4.7 Entrepreneurship Skills ..................................................................................................................... 57

CHAPTER FIVE ............................................................................................................................................. 58

CONCLUSION AND RECOMENDATION ........................................................................................................ 58

5.1 Conclusions ........................................................................................................................................... 58

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 5.2 Recommendation.............................................................................................................................. 58

5.2.1 Recommendation for TBMPP..................................................................................................... 58

5.2.2 Recommendation for my university .......................................................................................... 59

References .................................................................................................................................................. 60

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List of figures

Figure1. 1: Location Map of the TBHPP ........................................................................................................ 5

Figure1. 2:Production process of TBHPP ...................................................................................................... 5

Figure1. 3: Organizational structure of TBHPP ............................................................................................. 6

Figure2. 1:Hdropower plant layout ............................................................................................................... 9

Figure2. 2:Overview of the TBHPP power plant ........................................................................................ 14

Figure2. 3: General intake structure ............................................................................................................ 15

Figure2. 4: Structure of approach channel .................................................................................................. 15

Figure2. 5: General layout of Powerhouse cavity and associated structures .............................................. 18

Figure2. 6:MIV of TBMPP ............................................................................................................................ 29

Figure2. 7:Switchyard TBHEPP ................................................................................................................. 32

Figure2. 8: Single line diagram switchyard ................................................................................................ 34

Figure3. 1: Electrical Enclosure in BHPP ................................................................................................... 40

Figure3. 2:Electrical Enclosure in BHPP .................................................................................................... 40

Figure3. 3 Electronics life ........................................................................................................................... 42

Figure3. 4: Result of a temperature controlled Fan when the temperature is above 25°C .......................... 49

Figure3. 5: NTC Thermistor ....................................................................................................................... 50

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 List of Table

Table1. 1: Hydro power plants in service ..................................................................................................... 2

Table1. 2: Hydro power plants under construction ....................................................................................... 3

Table2. 1: Hydro power plants under construction ..................................................................................... 21

Table2. 2: Characteristics power transformer ............................................................................................. 24

Table3. 1: Temperature rating of equipment’s............................................................................................ 44

Table3. 2:Specifications of the circuit components .................................................................................... 51

Table3. 3:project budget analysis................................................................................................................ 53

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LIST OF ACRO NYMS AND SYMBOLS
A Ampere
AC Alternative-current
BHPP Beles Hydropower Project
CB Circuit-Breaker
CEO Chief Executive Officer
CT Current-Transformer
EELPA Ethiopian Electric Light Power Authority
EEP Ethiopian-Electric-Power
EEPCO Ethiopian-Electric-Power-Corporation
EEU Ethiopian-Electric-Utility
HVAC Heating Ventilation and Air Conditioning
HV High-Voltage
ICS Inter-Connected-System
LED Light Emitting Diode
LV Low-Voltage
MIV Main Inlet Valve
MVA Mega-Volt-Ampere
OFWF Oil Forced Water Forced
PD Power Dissipation
PLC Programmable Logic Control
SCADA Supervisory Control and Data Acquisition
SF6 Sulfur Hexafluoride
TBHPP Tana Beles Hydropower Project
TBMPP Tana Beles Multipurpose Project
T Temperature
UIL University Industrial Linkage
UEAP Universal Electrical Access Program
VT Voltage-Transformer

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 CHAPTER ONE

INTRODUCTION

1.1Background of the Company

Electric Power was introduced to Ethiopian in the 19th Century, during the regime of emperor
Menilik. The first diesel generator was introduced to the palace in 1898 GC. The first Hydro Power
Plant was constructed on Akaki River in the year 1912 GC in order to supply power to small
factories in Addis Ababa. The name of the company was changing in different times since its
establishment. Ethiopian electric light and power authority (EELPA) which was established in year
1956 E.C. Its name was changed to the Ethiopian Electric Power Corporation (EEPCO) since in
1997 E.C. And also EEPCO is changed into EEU in 2006 E.C, even if now a day for doing well
Ethiopian electric utility is branched in to two departments those are EEP (which works on
transmission and substations) and EEU (the purpose of the utility is distributing and selling
electrical energy to the costumers) under the Ministry of Water and Energy. The purpose of the
corporation is to engage in the business of producing, transmitting, distributing and selling
electrical energy.

1.2 Vision, Mission and Objective of EEP

1.2.1 Vision

To be a center of excellence in providing quality electric service at everyone’s door and being
competitive in energy export. Vision is not only to be a center of excellence in providing quality
electric service at every one’s door, but also being competitive export industry and earning a
valuable foreign currency for the country.

1.2.2 Mission

EEP provide adequate and quality electricity on generation, transmission, distribution and sales
services through continuous improvement of utility management practices and responsive to the
socio-economic development and environmental protection needs of the public.

1.3 Objective of the company

In order to provide quality service delivery, EEP has formulated clear objectives, which enables it
to satisfy the customer’s need and play its role on the power market.

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Then it has several objectives;

 Provide generation, transmission, sales of bulk electric power, and grid based
UEAP (universal electrical Access program) through continuous improvement
of the socioeconomic development and environmental protection need of the
country.
 To increase the generation capacity to insure adequate and reliable power supply
by implementing the generation program.
 To enhance the financial capacity of the company by executing all scheduled
projects with in specified budget and time.

Currently there are 12 hydro power plants in ICS with total installed capacity of around 3780 MW
and, 2 diesels standby and one geothermal power plant of 7.30 MW installed capacity. But,
Ethiopia has the potential of producing more than 45,000 MW of electrical energy from hydro
power, more than 10,000 MW from wind, more than 5,000 MW from geothermal power plant.

Table1. 1: Hydro power plants in service

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Table1. 2: Hydro power plants under construction

Hydroelectric station Type Capacity(MW) Status River

Reservoir 6400 Under constriction Blue Nile
Grand Ethiopian River
renaissance
Gilgel gibe IV Reservoir 1472 Proposed Omo River
Gilgel gibe IV Reservoir 660 Proposed Omo River
Halele worabesa Reservoir 440 ? Omo River
Chamoga yeda Reservoir 278 ?
Genale dawa III 254 Under constriction
Genale dawa V 250 Proposed

Total 8,950

Among these Tana beles HEPP is our hosting company. Tana Beles is a multipurpose project
which utilizing Lake Tana reservoir for electric power generation and irrigation. Lake Tana,
besides its famous name for its larger extent, navigation service, fish resource site, climate
regulation for Bahr Dar town and aesthetic value, it is served for hydroelectric power generation
and irrigation projects.

The project utilized 160 m³/s of water and generates 460 MW power and about half of the water
is utilized for downstream irrigation. The Cherechera regulation wear (dam) constructed at the
outlet of Blue Nile from Lake Tana is the prelude for this project. The Tana Beles project is an
underground structure which consists of an intake structure on the SW of the lake shore near the
Kunzla town, and 11.5 km long and 7.2 m diameter headrace tunnel, and 274 m vertical penstock
shaft, about 7km long tail race tunnel, underground powerhouse complex (powerhouse cavern,
transformer cavern, galleries, draft tubes, manifolds, irrigation by pass) and the downstream
diversion wear. The Government of Ethiopia signed a contract with SALINI Construction
Company to build the plant on July 8, 2005 and construction began soon after. Because of the
project's remote location, transportation and manning of personnel and equipment was difficult,
often taking 4–5 months for supplies to arrive. On June 2, 2007, a tunnel boring machine (TBM),
operated by salni, began boring the 7.2 km tailrace tunnel and completed it on May 31, 2008
SALINI Construction Company awarded a sub contract to construct the actual power station to
VA Tech Hydro. On May 11, 2010, the first 115 MW generators at the power plant began operation

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and on May 14, 2010, the plant was inaugurated. The project's cost was around seven billion birr.
The power plant was fully operational in February 2012.

1.4 Location

The Tana Beles hydro power project site is located in West Gojam, near Kunzla town (small town
where the intake structure is sited). The Tana Beles multipurpose project covers about 20km
distance from the intake to the outlet. The powerhouse is located at 2/3 of the total length of the
project (12.5km downstream of the intake and 7.5km up stream of the outlet) and is an underground
about 300m below the surface. The cavity is sited along the Beles valley about 11.5km SW of
Lake Tana and at a distance of 20km from Kunzla.
To access the project, from Addis Ababa the rout deflects left at Durbete (Woreda town) 64 km
short of Bahir Dar town and needs a drive of about 70 km on all-weather road.

1.5 Host company main products and services

 The main product of the generation is electrical energy.

 The main services of the generation are to provide adequate and quality electricity
generation.
 For job opportunity to the local people and the nations of Ethiopia
 Effective utilization of the country’s water resource
 Improved infrastructures around the project area
 To save money and time by decrease use of wood and coal fire. Some people used wood
and coal for preparing their food and also for lighting at night. This seriously cause
environmental pollution and deforestation, this also causes health and wealthy impacts
which later may cause economic and social problem.
 To reduce environmental flood and pollution. In general electricity has a great roll to
performing our daily activity easily

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 Figure1. 1: Location Map of the TBHPP

1.6 Production Process of the Company

The Production process of the company starts at the dam where water is drained to passes through
the tunnel and fall over the turbine. The turbine rotates and generates AC power by using generator
(alternator). The generated electricity is then getting in to step up transformer for being transmitted
over the transmission line to reduce the loss.

Figure1. 2:Production process of TBHPP

1.7 The main customers or the end users of its products or services

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  Bahir-Dar substation and through that, it is included to Ethiopian electric grid systems.
 The whole society of the country’s people, institutes, commercials, machines, industries
and urban areas.
 Some African countries are also beneficial, like Sudan, Djibouti &Kenya. The owner of
TBMPP generation station is EEP.

1.8 Organizational structure of the company

The work flow in Tana Beles hydropower plant has the following branches. From these branches
in the intern period of TBHPP we were worked in the maintenance and operation team section.

Figure1. 3: Organizational structure of TBHPP

1.9 Work flow

In four-month internship program we participated in the maintenance and operation teams in Tana
Beles multipurpose project. These teams are the two basic main powers for the production of
electricity in Tana Beles power plant. Maintenance is the process by which any equipment or

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machinery can be maintained in proper and efficient condition. The electrical equipment or
apparatus like any other electric machines requires carefully planned program of checking or
inspecting, if it is to give satisfactory and trouble-free service for a long time.
The periodic inspection and maintenance details may vary with the type of machine and its
working condition but planning and inspection of different items at regular intervals will meet
most of the requirements of the time.
The performance of any equipment or machine or apparatus must be particularly observed
immediately after commissioning it in respect of its operating voltage, current, starting device, any
unusual vibrations and noise.
TBMPP project has two main work groups. These are the maintenance and operation groups.
Work flow in maintenance:
a) Discus the day work according to the plan except sudden
emergency appears.
b) Then perform their task within group.
c) Report their data to maintenance leader.
Work flow in operation:

a) Within their shift recording over all plant conditions hourly from
SCADA system and by taking reading from the field.
b) Report to the maintenance team to take action in the equipment’s that
need maintenances.
c) Report the data and problems to the operation leader.
The maintenance and operation leaders collect the data from both team and give to the plant
manager. The plant manager makes decisions and report problems that are not solved by TBMPP
workers.

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 CHAPTER TWO

OVERALL INTERNSHIP EXPIREANCE

2.1 Objectives of the internship

The four-month internship program comprises of general and specific objectives, both added to
produce skilled man power in engineering aspects.

2.1.1 General objective

The aim of the internship program enables engineering students under the institute to relate their
theoretical knowledge to the practical world.

2.1.2 Specific objectives

The interns, during the internship, are aimed to play a great role in improving their practical,
theoretical, interpersonal communications, team playing, entrepreneurship and leader ship skills,
understanding about work ethics related issues, responsibility etc. Adaptation of the work
environment and determination of future field to study is also the part and parcel of the specific
objectives.

2.2 How we did get the company

From the time we took internship request papers we have been trying to reach good factories or
companies including Ethiopian electric power corporation. Since our deep interest was to work in
Ethiopian electric power, we have gone far to make it happened. However, every single way was
blocked since EEP did not accept individual internship request applications but from the UIL
(University industrial linkage) office. Thus we come across to discuss with UIL. Then the office
wrote a letter to EEP to accept the 5 students he listed on the letter. Based on our interest we choose
to work in generation station near to Bahir Dar. But, there was some problems that are challenge
us to get application letter in order to join the generation stations. After one-week bulky day the
EEP write the letter to Tana Beles power generation stations to accept us.

Finally, we directly gone to the Beles generation station; the company CEO Mr. Misganaw accepts
our internship program by checking the sender letter then gives us gust house.

2.3 How a hydropower plant works

A typical hydropower plant is a system with three parts:

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1. Power plant where the electricity is produced;
2. Dam that can be opened or closed to control water flow; and
3. Reservoir (artificial lake) where water can be stored.

To generate electricity, a dam opens its gates to allow water from the reservoir above to flow down
through large tubes called penstocks. At the bottom of the penstocks, the fast-moving water spins
the blades of turbines. The turbines are connected to generators to produce electricity. The
electricity is then transported via huge transmission.

Figure2. 1:Hdropower plant layout

1. Water in a reservoir behind a hydropower dam flows through an intake screen, which filters out
large debris, but allows fish to pass through.
2. The water travels through a large pipe, called a penstock.
3. The force of the water spins a turbine at a low speed, allowing fish to pass through unharmed.
4. Inside the generator, the shaft spins coil of copper wire inside a ring of magnets. This creates an
electric field, producing electricity.
5. Electricity is sent to a switchyard, where a transformer increases the voltage, allowing it to travel
through the electric grid.

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6. Water flows out of the penstock into the downstream river.
2.4 Work section of the company
When we had been in TBMPP, our work task was making maintenance, take measurements in
control room with operators, and taking inspections of equipment’s in power house and
switchyard. In our internship duration different maintenance and inspection has taken. We have
tried to actively participate in all of them. To know the various problems occurring in the power
plant, maintenance and inspection are important plans. The advantage is its low cost extensive
information, and low risk to failure. Each maintenance strategy depends on the information to be
obtained about the condition of the device. Knowing information about condition of power
generating unit equipment is the most important aspect and absolute necessity for any maintenance
activity. There are different tasks of operation, maintenance and inspection activity which was
performed during our four-month internship periods.

2.4.1 Task one (Operation)

Operation is one of our tasks that we have participated in our four-month intern program which
target is made a preventive maintenance before damage is happen on equipment. Mostly it has
done in the control room by operators. They can control over all generation station on the manual
control mode and auto control unit control mode in the control room. If an accident happens in the
generation station the alarm signal comes on the control room. Then they made measurement and
reset the alarm. If the alarm is off that is good unless and otherwise they announcing to the
maintenance group to make a fast response.

2.4.2 Task two (Inspections)

Inspection is a main part of preventive maintenance to determine the future condition by observes
and takes present measurable data of the components. Some of them that we have participated are
observe and take measurable data of sensors, oil level of different hydraulic devices, voltage of
each DC supply batteries, temperature and pressure indicator devices, run the emergency diesel
generator, and observation of the device’s safety at every Friday. This action helps us to take
precautions for equipment before damage, and to maintain the failed devices at the beginning in
the system as soon as possible that saves our time and effort of the final maintenance.

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2.4.2.1 Inspection in switchyard

On every Friday we took inspection in switchyard like observing on power lines and equipment if
there is nest, check cracking of bushings, observing gas amount of SF6 CB, check safe operation
of contactors& relays etc.

2.4.2.2 Inspection in power house

On every Friday we took inspection in power house like observing& recording the measurable
data of different sensors, oil level of different transformers& generators, check the voltage of each
battery supply temperature and oil pressure indicator of each equipment’s, and observation of all
the device’s safety etc.

2.4.2.3 Inspection of emergency diesel generator

A standby diesel generator is used to generate 400v voltage and by using power transformer it
converts to 15 kV to give power for the power station when black out occurs or the station cannot
obtain power from grid system. It has a rating of;

1. Output power is 640 kW

2. Rated power is 800 kVA

3. Rated voltage is 400 V

4. Rated speed is 1500 rpm

In order to test the normal operation of diesel generator we do the following procedures:

 First check starting battery voltage using multi-meter

 Check the water level that used for cooler system
 Check the fuel amount
 Check the oil level by observing with a sticker
 Place the selector switch at local position
 Press the start push button of the diesel and run for 15 minutes
 Finally press stop push button and place the selector switch to auto position

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2.4.3 Task three (Maintenances)

There are different parts of maintenance activity which was performed during our four-month
internship periods. It is our favorite team we try to actively participate in all of them. The task of
maintenance is identification of equipment’s fault, repair or replacement if there is breakdown,
and improving plant availability all over the time that has done mostly by maintenance team. If
the alarm that comes on control switch board is permanent fault, then the operators announcing to
the maintenance group to maintain that fault fast as soon as possible by checking its manual control
circuit of fault device or machine in order to bring it back to its functional state or good working
order.

. Some of them that we participated are listed below:

 Maintaining the bearing of the air injection compressor

 Maintaining the non-return valve of drainage water pump
 Maintaining filter kit of the HVAC.
 Maintaining and replacing different temperature sensor
 Cleaning and replacing carbon brush with new one
 Maintaining and replacing different enclosure electrical equipment, but power
supply, converters was a big deal because they malfunction many times due to poor
thermal control methods. That is the main reason we choose to do something in our
project.

2.5 process of tasks

2.5.1 Procedures that we followed to do our task

We arrived on time at the station and made a marvelous relation with the Engineers, technicians
and the operators and then we interview them about each device working principle, type, its uses
and coordination with other devices, draw backs and limitations. We also study the overall
operation system of the station. We read any related document in the station for the specific
devices. Then;

 Identify the problem that has faced on equipment

 Identify the area of fault happened equipment
 Collect data to solve the problem faced using full information from the manual

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  After this we faced to maintain the equipment by repair it or replace by equipment if it is
completely failed.
 Show our day to day activities to our advisor to get basic comments to correct our selves.
 Take the comment & correct us when told by the advisor.
 Give proposed solution to the given problem
 Finally set all the necessary data & comment that we collected in a written document

2.5.2 Goods that we have gained during performing our tasks

We have been gained creativity and the ability to solve a problem following the rules like, Risk
management, Self-confidence, Innovative skills, developing Educational background with
practical skill and develop confidences for proposing solution able ideas for big companies.

2.5.3 Challenges that we faced during we performed our tasks

Honestly there was a lot of problems we faced during we performed our task. But once we were
read a very nice speech from our university article board which is “great things never come from
comfort zone” we think that is right we gained many more things but the zone was not comfort.
Some of the problems are listed below;

1. The weather condition inside the power house was hot.

2. Inside the power house the sound is very noisy.
3. The program to train students was not well organized. Most of the time we worked by ourselves
to get knowledge.
4. There is also shortage of water and there are not enough houses.

2.5.4 The measurement that we have took to overcome these challenges

First of all we tried to know the causes of the problems. In addition to surrounding weather
condition, for problems one, we found that it is due to the air injection compressor, because it
pushes a very hot air to the inside of the power house and we found that is design problems. For
problems two it is also the complete failure of the air injection compressor of the three units,
because if it works the sound out of the turbine may be decreased. For problems three and four it
is management problems we strictly recommend the company manager to solve the problems. For
other problems it is design problems, so we tried to find a solution for it.

2.6 Overall system components and operation

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In The TBMPP water from Lake Tana is taken via the intake structures. These structures are the
main gates for the water to enter the whole system. Hence we have tried to explain the flow of
water form this intake structures to the outlet where the water is finally combined with the
Johanna River after finishing its journey through the tunnel and goes to give yet another use for
irrigation in the surrounding area. Tana Beles hydropower plant has four main work stations in
order to produce the electricity from the natural water reservoir which is Lake Tana.
The four working stations are: -
1. Intake
2. Power house
3. Switchyard
4. Outlet

Figure2. 2:Overview of the TBHPP power plant

2.7 Intake
2.7.1 Inlet structure

The inlet structure is provided with five sluices to let the water approach to the power intake, with
fifteen stop logs elements.

This structure is one of the components of the water conveyance system in which the design flow
160m3/s is passes through. It is equipped with stop log gates to five respective bays. The upper
parts of the inlet gate are bridge structure used as road way to pass vehicles.

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2.7.2 Intake structure

This is the main structure of TBMPP, it has spillway, trash rack, gates (bulkhead, roller gate and
air vent), geometrical adaptation transition, dismantling chamber, transition/connector to low
pressure tunnel. The water when pass through the intake structure has a velocity 0.48m/s.

Figure2. 3: General intake structure

2.7.3 approach channel

The approach channel draws the water from the Lake Tana and conveys it to the headrace tunnel.
It is subdivided in two sections, upstream and downstream of the channel inlet structure.

Figure2. 4: Structure of approach channel

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2.7.4 Inlet stop logs

The inlet structure contains 15 (fifteen) stop logs elements. The stop logs are used to isolate the
lake from power intake and to do inspection and maintenance activities on its downstream side.
The inlet consignment crane will be used for the erection, operation and maintenance of the inlet
stop logs. During the plant working, these sluices are open and the stop logs are stored on the top
of the inlet structure by means of proper supports.

2.7.5 Trash rack

It is horizontal beam which is used to support the panels and is free from vibration during all
Operating condition and is sufficiently sturdy to limit as much as possible any deformation. It also
used to block and collecting large dusts like grasses during the flow of water to the head race
tunnel. Due to their location, trash rack maintenance operations are possible only when the plant
is not working, because the inlet shall be closed (by means of stop logs) and the intake zone
completely emptied.

2.7.6 Rack cleaning machine

The machine is used to clean the trash rack screen panels by removing floating debris, that is
coming with water and to facilitate the passage of water to the tunnel.

2.7.7 Intake gate (wheel gates)

The main purposes of these gates are to allow maintenance and inspection of the power tunnel.
The gates will normally be in open position. The control panel foresees the terminal boards for
remote control signals and therefore the gate operation could be also possible from the control
room. Each gate is operated by a hydraulic system able to raise the gate leaf even under unbalanced
pressure conditions. Closure is guaranteed the leaf weight, the cylinder acting as a brake.

2.7.8 Bulkhead Gate

The function of the bulk gate is to isolate the Power intake from downstream tunnel & to allow
inspection and maintenance of the intake wheel gates and head race Tunnel.
The bulkhead gate operates only in balanced conditions and with the downstream wheel gate in
closed position. The gate structure is endowed of an internal by pass system in order to balance
the pressure levels upstream and downstream.

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2.7.9 The low pressure headrace tunnel

Low pressure headrace tunnel is used to carry water from the intake to the penstock. It has
characteristics of low Pressure tunnel is shown below
 Length………………………………………………….11.823 km
 Excavated Diameter…………………………………….8.1 m
 Finished diameter………………………………………7.2 m
 Invert slop………………………………………………3.00 m/km

2.7.10 Surge Tank

A surge tank is a small reservoir or tank (open at the top) in which water level rises or falls to
reduce the pressure swings in the conduit

A surge tank is located near the beginning of the conduit. When the turbine is running at a steady
load, there are no surges in the flow of water through the conduit i.e., the quantity of water flowing
in the conduit is just sufficient to meet the turbine requirements. However, when the load on the
turbine decreases, the governor closes the gates of turbine, reducing water supply to the turbine.
The excess water at the lower end of the conduit rushes back to the surge tank and increases its
water level. Thus the conduits prevented from bursting. On the other hand, when load on the
turbine increases, additional water is drawn from the surge tank to meet the increased load
requirement. Hence, a surge tank overcomes the abnormal pressure in the conduit when load on
the turbine falls and acts as a reservoir during increase of load on the turbine.
It is 91.2 m high and 18m internal diameter.

2.7.11 Penstocks

Penstocks are open or closed conduits which carry water to the turbines. They are generally made
of reinforced concrete or steel. Concrete penstocks are suitable for low heads (< 30 m) as greater
pressure causes rapid deterioration of concrete. The steel penstocks can be designed for any head;
the thickness of the penstock increases with the head or working pressure.
TBMPP plant has steel penstock which has the following characteristics;
 7.2 to 6 m diameter and 286 m long

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2.7.12 High pressure headrace tunnel

It is high pressure area where the water is taken from the penstock and directed to the main inlet
valves (MIV). Here it had bifurcates and irrigation bypass. The bifurcate is a structure used to
divide the incoming water from the penstock to the main inlet valve of each unit. The irrigation
bypass is used to direct the water from the penstock to the tail race tunnel when the power house
is under maintenance, or when the main inlet valve is closed and no water will flow to the bifurcate.

2.8 Power house

Figure2. 5: General layout of Powerhouse cavity and associated structures

The power house of TBHPP is located fully underground which is excavated with Drill and Blast
Technology.
The overall dimension of the power house: -
 Length………….53 m
 Width ………….57.6 m
 Height ………...40.65 m
There are different floors in the powerhouse. These are;
1. Machine hall(erection) floor
2. Generator floor
3. Turbine floor
4. MIV (Spiral case) floor

2.8.1Machine hall (erection) floor

It is the top floor of the power house. The upper part of the generator compartment (including the
Slip ring of the generator) and air conditioning devices can be observed on this floor. The slip rings

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of the generator are used to supply dc excitation source for the field winding or rotor winding
through carbon brush. In this floor there is also generator circuit breaker, switch gear and crane

2.8.1.1 Generator circuit breaker

GCB are used for synchronization, disconnection and for fault-tripping of the generators. In
TBHPP SF6 type is used and equipped with operating mechanism, auxiliary switch and control
equipment.

2.8.1.2 Crane system

The overhead crane is widely used in power house to lift necessary equipment’s & things. It travels
longitudinally along the railroad with the crab moving transversally and hooks Hoisting up &
down, thus performing the operation.

2.8.1.3 Switchgear

Switchgear is the combination of electrical disconnects switches, fuses or circuit breakers used to
control, protect and isolate electrical equipment. Switchgear is used both to de-energize equipment
to allow work to be done and to clear faults downstream. This type of equipment is important
because it is directly linked to the reliability of the electricity supply. This is also automatic like
the control room. In our case this is the place where the feeder and the outgoing lines can be kept.

2.8.1.4 DC Battery room

TBHPP has two sets of DC systems. One is 110v DC system; it provides supplies for control
panel, alarms, indications & emergency lighting for the power plant. The other is 48v DC system;
it provides supplies for communication system. It is a lead acid battery with capacity of 640AH.

2.8.1.5 Control room

Control room is a room used as an operation’s center in which all the equipment’s of the unit can
be monitored and controlled throughout every 24hrs by operators. The operators controlled and
monitored the all power house unit equipment’s by using SCADA.
Supervision Control and Data Acquisition (SCADA) is a new generation of open distributed,
object-oriented, bus-style computer control system developed for hydropower station and large
scale industries. SCADA system comprises a number of hardware elements linked together via a
local area network. The SCADA system also can switch a pump or motor on or off and has the

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capability of putting motors on a "Hand" operating status, off, or Automatic. "Hand" refers to
operating the equipment locally, while Automatic has the equipment operate according to set
points the operator provides on a computer that can communicate with the equipment through
SCADA.
The functions provided by system is mainly supervising and controlling the operation of
hydropower stations. SCADA System is used to display all the events and archives with their
graphical representation and value of characteristics over the time axis whereby any number,
character, graphical representation of curve and objects are possible to visualize on one workplace
as independent process picture or as an object in a process picture.

 PLC; is a digitally operating electronic apparatus which uses a

programming memory for the internal storage of instructions for
implementing specific functions such as logic, sequencing, timing, counting
and arithmetic to control through digital or analog modules, various types
of machines or process. PLC is an industrial computer control system that
continuously monitors the state of input devices and makes decisions based
upon a custom program to control the state of output devices.

2.8.1.6 Pressurized air tube

It is a tube made of steel which used to pump air to the different place of the power house by
sacking the air outside the power house using large air injection compressor.

2.8.1.7 Telecommunication system

In TBMPP fiber optic multiplexer equipment is installed for telecommunication service between
TBHPP, Bahir Dar and load dispatch center, and also the internal communication between the
power plant, switch yard, housing compound, intake and outlet.

2.8.2 Generator floor

It is the floor found underneath of machine floor and mainly consists of Generator pit, unit
automation and protection panel, static excitation system, unit auxiliary board, vapor extraction
pump, and different types of transformer.

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2.8.2.1 Synchronous generators

Three phase synchronous generators are the primary source of all the electrical energy we
consume. A synchronous generator usually operates in parallel that forming a large power system
supplying electrical energy to the loads. Synchronous generators are not only used for generating
active power; they can also be used for both generation and consumption of reactive power.
When they are in over-excitation mode they deliver reactive power to the power system; while
they absorb reactive power from the grid when working in under excitation mode. Standard
generators should be installed in order to keep the cost of the power plant as low as possible, and
for the synchronization speed of generator, i.e. Its specific speed, flow and net head would be
directly proportional to rotational speed of the turbine the synchronous generator has different
parts such as: rotor, stator, guide bearings, head cover, shaft seal, rotor shaft, brackets etc.

The armature winding is placed on the stator (stationary part) designed to generate balanced three-
phase voltages and are arranged to develop the same number of magnetic poles as the field winding
that is on the rotor. The rotor is also equipped with one or more short-circuited winding know as
damper windings. The rotor is driven by the prime mover at constant speed and its field is excited
by direct current. The generator excitation system regulates generator voltage and controls the
reactive power flow.
The generator in hydroelectric power stations is driven by turbines and they have salient pole rotor
construction.

Table2. 1: Hydro power plants under construction

Rated output Power 133MVA

Rated voltage 15 kV

Rated frequency 50±2%HZ

Power factor 0.86

Synchronous speed 375rpm

Number of pole 16

Run away speed 590rpm

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Generator excitation system

All synchronous machines except certain machines like permanent magnet generators require a
DC supply to excite their field winding of rotor. As synchronous machine is a constant speedy
machine for a constant frequency supply, the output voltage of the machine depends on the
excitation current. This excitation current has fed to field winding through an electro graphite type,
open terminal brushes and slip ring. The slip rings are mounted above the rotor in a separate
enclosure. The slip ring and brushes are made of highly wear-resistant material. Excitation system
contain control and power elements to provide the required field current to the generator. The
control of excitation current for maintaining constant voltage at generator output terminals started
with control through a field rheostat, the supply being obtained from DC Exciter.
There are two types of Excitation System.
1. Dynamic exciter (rotating type)
2. Static Exciter (static type).

TBHPP use static excitation system in order to maintain the system stability in interconnected
system network. It is necessary to have fast acting excitation system for large synchronous
machines which means the field current must be adjusted extremely fast to the changing
operational conditions. Besides maintaining the field current and steady state stability the
excitation system is required to extend the stability limits. It is because of these reasons the static
excitation system is preferred to conventional excitation systems. the AC power is tapped off from
the generator terminal stepped down and rectified by fully controlled thyristor Bridges and then
fed to the generator field thereby controlling the generator voltage output under normal operation,
and use DC batteries for starting units.

Static excitation system consists of the following Equipment: -

 Full wave self-controlled bridge rectifier
 Excitation transformer
 Field circuit breaker
 Excitation startup& field discharge equipment
 Automatic voltage regulator and operational control circuit cubicle

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2.8.2.2 Oil-vapor extraction pump

It is a pump which found in outside the generator house in all four units and used to sack a mixture
of oil and air. But due to design problems it releases the oil-vapors mixture to the outside air.

2.8.2.3 Transformers

In TBMPP there are different types of transformers in different location so I generally write all
types of transformers in this section.

Transformer is a static device that transfers electrical energy from one electrical circuit to another
electrical circuit through the medium of magnetic field &without change in the frequency and
power. Generation of electrical power in low voltage level is very much cost effective.
Theoretically, this low voltage level power can be transmitted to the receiving end. This low
voltage power if transmitted results in greater line current which indeed causes more line losses.
But if the voltage level of a power is increased, the current of the power is reduced which causes
reduction in ohmic losses in the system, reduction in cross sectional area of the conductor i.e.
reduction in capital cost of the system and it also improves the voltage regulation of the system.
Because of these, low level power must be stepped up for efficient electrical power transmission.
This is done by step up transformer at the sending side of the power system network. As this high
voltage power may not be distributed to the consumers directly, this must be stepped down to the
desired level at the receiving end with the help of step down transformer. Electrical power
transformer thus plays a vital role in power transmission.

The most important tasks performed by the transformer are:

 Change in voltage & current levels in electrical power system
 Matching source & load impedance for maximum power transfer in electrical & control
circuit
 Electrical isolation (isolating one circuit from another)
 For measurement purpose (instrument transformers)

Power transformer

The transformers are located in a cavern downstream of the power house. The cavern is 51 m
long, 13.5 m wide and 10 m height. It accommodates four steps up transformer. A concrete fire
protected partition wall is provided to separate each transformer bay. These transformers are

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placed under the tunnel and it is used to step up the voltage from 15 kV to 400 kV by lowering the
current from 5119 A to 192 A for ease of transmitting power through transmission lines.

Table2. 2: Characteristics power transformer

Cooling system Oil forced water forced (OFWF)

Primary connection Delta

Secondary connection Star with neutral

Rated power 133MVA

Nominal voltage H.V 400 kV

Nominal voltage L.V 15KV

Nominal current H.V 5.1192 kA

Nominal current L.V 192A

Tap charger Offload

IEC Group YNd11

Excitation transformer

Excitation transformers are used to magnetize generators and synchronous motors. Excitation
transformers are a main component of any electrical system and its failure can cause the black out
of the system. It takes 15 kV from generator and converts to 740 V DC then used to produce rotor
field. It is therefore important to make the right selection of transformer. Primary is connected to
the generator terminals. Secondary is connected to the Thrusters / regulator. The transformer is
generally air−cooled which operate on over temperature and Connection is delta-star.

Auxiliary Transformer

The Unit Auxiliary Transformer is the Power Transformer that provides power to the auxiliary
equipment of a power generating station during its normal operation. This transformer is connected
directly to the generator out-put by a tap-off of the isolated phase bus duct and thus becomes
cheapest source of power to the generating station.

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It is generally a three-winding transformer i.e. one primary and two separate secondary windings.
Primary winding of UAT is equal to the main generator voltage rating. The secondary windings
can have same or different voltages. One of the winding (primary) receives 15 kV from generator
and the two secondary windings are; one is used to step down to 400 V and supply to auxiliary
device. The third winding passes 15 kV to switch gear and supply to station service.

Station Service Transformer

Station service transformer is transformers which step down from 15 kV to 400 V. It supplies 400
V to unit general MCC by stepping down 15 kV from switchgear. The general MCC supply to unit
MCC and for a service like; lighting, socket etc. It also supplies to generation station and housing
compound.

Ground Transformers

Ground transformer is used to provide a ground path to either an ungrounded ways or a delta-
connected system. Grounding transformers are typically used to provide a relatively low-
impedance path to ground, thereby maintaining the system neutral at or near ground potential. In
TBHPP the ground transformer is connected to the neutral point of star connected output of
synchronous generator.

2.8.2.4 Protection, control and monitoring electrical equipment

For each generating unit in TBHPP have a protection, control and monitoring equipment’s in
central controlling system. Centralized control system equipment is located in the control room
and is interconnected to the generator switchboards located near the units. Required control and
monitoring of all functions of the hydroelectric power plant are provided to the operators. Hard-
wired pushbutton switches provide for direct operator manual control of unit start-stop, breaker
close (initiating automatic synchronizing), breaker trip, voltage, loading, and gate limit raise-
lower. Analog or digital panel meters and indicating lights continuously indicate the status of all
main units, breakers, transformers, and lines.

In TBHPP the following device are used.

 Control boards
 Protection boards
 Automatic voltage and current regulator

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  Auxiliary devices
 PLC etc.

2.8.2.5 Relays

Relay is device that detects the fault and initiates the operation of the circuit breaker to isolate the
defective element from the rest of the system. It detects the abnormal conditions by constantly
measuring the electrical quantities (voltage, current, frequency and phase angle) which are
different under normal and fault condition.

2.8.3 Turbine floor

2.8.3.1 Turbine

The hydraulic turbine is a machine which uses the potential energy of water and converts into
mechanical energy. This mechanical energy is used in running an electric generator which is
directly coupled to the shaft of the hydraulic turbines. From this electric generator, we get electric
power. Francis turbine is the most common in low head and high water flow HEPP. It is a reaction
type of turbine from medium high to medium low heads and medium small to medium large
quantities of water.
In TBHEPP there are four vertical shafts Francis turbines.
 Turbine number and type Francis (vertical)…4 turbine
 Total installed capacity……………….460 MW
 Average annual energy………………2051GWh/year
Generally, Francis turbine uses more relative to others due to:
 We can more easily control
 It has low head and high flow
 The water inters the blades radially and comes out axially, parallel to turbine shaft
 The speed would have developed 1KW under 1m head
 Utilizes both potential and kinetic energy
A Francis turbine consists of the following main parts:
1. Spiral casing: The spiral casing around the runner of the turbine also known as the scroll case.
Throughout its length, it has numerous openings at regular intervals to allow the working fluid to
each blades of the runner. This maintains a constant flow rate despite the fact that numerous
openings have provided for the fluid to enter the blades.

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2.Stay ring: The primary functions of the guide or stay vanes is to convert the pressure energy of
the fluid into the momentum energy just before the fluid impinges on the blades. It also serves to
direct the flow at design angles to the runner blades.
3. Runner blades: Runner blades are the heart of any turbine. These are the centers where the
fluid strikes and the tangential force of the impact causes the shaft of the turbine to rotate, and
producing torque.
4. Wicket gates: wicket gates are around the outside of the turbine's rotating runner control the
rate of water flow through the turbine for different power production rates. Francis turbines are
almost mounted with the shaft vertical to isolate water from the generator, also to facilitate
installation and maintenance. These gates are controlled by servomotors and hydraulic governors.
5. Runner shaft: is the structure of the turbine which rotates due to the water pressure applied and
connected to the turbine shaft.
The operational mechanism of runner specially wicket gate is mainly controlled by hydraulic
governor and servomotor as described below.

 Hydraulic Governor

A governor is a combination of devices and mechanisms, which detect speed deviation and convert
it into a change in servomotor position. A speed-sensing element detects the deviation from the
set point; this deviation signal is converted and amplified to excite an actuator, hydraulic or
electric, that controls the water flow to the turbine. In an electro hydraulic governor, a sensor
located on the generator shaft continuously senses the turbine speed. The input is fed into a
summing junction, where it is compared to a speed reference. If the speed sensor signal differs
from the reference signal, it emits an error signal (positive or negative) that, once amplified, is sent
to the servomotor so this can act in the required sense. The basic function of the governor is to
control speed and /or load.
This system automatically monitors and maintains the speed of the hydraulic unit and also used to
synchronize the generator frequency to the system frequency (Hz) for connection to the power
grid. Due to this it is the main back bone of the generating unit.

The main important component of governor is: -

 Frequency control
 Load adjustment is done due to the speed control

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  Over speed device/emergency device

Servomotor

Generally, servomotors are hydraulic piston machines, which operate with the use of oil pressure.
So the turbine servomotor is used to operate the wicket gates by the oil pressure exerted and
controlled by the electronic governors.

The servomotors are installed in the upper stream wall of the turbine pit and it is double action.
When the pressure oil goes into the servomotor cylinder, it pushes the piston to move, which pass
the force to rotate the control ring via the connecting rod. The rotation of control ring manipulates
the distributer mechanism to open and close. The counteraction force to the servomotor will exert
to the concrete through the servomotor liner. One side of the servomotor is the inlet high pressure
oil and the other side is the low pressure oil which is connected to the oil receiving tank. The high
pressure oil inlet into the two servomotor are located on the opposite side so when one servomotor
is pushing the other is pulling. Thus it brings the turning torque which closes and opens the guide
vane.

2.8.3.2 Shaft seal

It is used to govern the flow of water after deriving the turbine blades into the draft tube. There is
also a shaft seal filter which is used to filtering the water entering into the seal.

2.8.3.3 Air injection compressor

In this type of compressor air is compressed by oil. It is used to balance the system pressure inside
the turbine and the working pressure coming from the MIV when the unit is not in full load i.e.
when Power < 105 MW. It is used to protect formation of cavitation.

2.8.3.4 Mechanical breaker compressor

It used oil to control the rotational speed of the shaft. The rated speed of the shaft is 375rpm, so
when the rotational speed is 20% it holds the shaft.

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2.8.4 MIV (spiral case) floor

2.8.4.1 Main inlet valve

Main inlet valve is used for controlling the flow of water to the turbine by fully close or full open
state. In TBMPP spherical valve was designed and used based on the advantage of the head and
their cost. It is operated by hydraulic servo motors and controlled by their own governor.
The main inlet valves contain tube which is called by pass. By pass is steel tube used to balance
the water pressure in the penstock side with the turbine side when the system is start from
maintenances or other blackouts happen.

The main uses of the main inlet valves are;

 To do maintenance on a unit or isolate the unit from the water pressure in the
penstock.
 To prevent guide vanes and runner from damaging by high pressure of water in
the penstock.

Bypass

Figure2. 6:MIV of TBMPP

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  MIV GOVERNOR: used to regulate the piston of the MIV

2.8.4.2 Draft Tube

As the name indicates draft tube is a pipe of gradually increasing area which connects the outlet
of the runner to the tail race. In general, it is used to change the velocity energy of the water leaving
the runner in to pressure energy at its outlet. In addition to this the cross section area constructed
in such a way to prevent efficiencies loss and water column separation. The inlet part of the draft
tube has a significant role in supporting the runner. The size of draft tube increase from inlet to
outlet part, the reason behind this is that by increasing the area we can dissipate the speed of water
in order to prevent scouring or other related defects.

 Draft tube gate

The main purpose of the draft tubes gate (slide gates) is to control the flow of discharge water
through the draft tube. The gates will normally be in open position and will be closed to allow
inspection and maintenance of turbines. Remote control is provided and therefore the gates
operations are possible also from the control room. The gates must be operated only and with
balanced water pressure conditions. The filling of turbine draft tube can be carried out using the
by-pass system.
2.8.4.3 Tail race tunnel

The high pressure tunnel where all the water collected from the draft tube is finally directed to the
outlet.

2.8.4.4 Cooling system

In the generation station many components and machines are hot during their normal operation;
this causes damage of the components. In order to prevent these problems cooling systems is
required.

There are two type of cooling water system these are: -

1. Clean (demineralized) water; which is closed circuit that recycles all the time for cooling all
the necessary components listed below efficiently.
2.Raw water; which is open circuit that is tapped directly from spiral case of MIV, and it passes
the primary filter and strainer that purposely cools the clean water that comes after doing work at

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common heat exchangers by means of heat conduction, and enters to draft tube after cooling the
clean water.

The cooling water system consists, for each unit, of independent closed circuit filled with
demineralized water. The closed circuit is cooled by heat exchanger supplied with raw water with
the inlet and outlet located in the tailrace downstream the draft tube gate.

The primary water contains different dust, so they need different filters. These are:
1) Self-cleaners: - are used to catch small fish before entering the primary filter.
2) Primary filters: - are used to filter out the primary water that comes from draft tube after
hitting the turbine. This water directly going to the heat exchanger and flash filter.
3) Flash filter: -these filters purify the primary water that go to the shaft seal.

The cooling system for TBMPP supplies cool water to the following equipment’s:
1) Turbine shaft seal
2) Unit Step up transformer oil/water heat exchangers
3) Turbine governor oil/water heat exchanger
4) Generator thrust bearing oil/water heat exchangers
5) Generator air/water heat exchangers
6) Generator guide bearing oil/water heat exchangers
7) Turbine guide bearing oil/water heat exchangers

2.8.4.5 Firefighting water supply equipment

It is used to protect fire in the power house during emergency cases that contain pressurized Water
with air. The water is first stored in the fire tank by using a pump which is coupled from the draft
tube of the unit one. Then by using gravity the water flows from the fire tank to the power house
in the steel tube.
2.8.4.6 Drainage pump
All water leaking into the power house from the surrounding rock and fore bay together with all
discharges from the generating plant is led into the drainage pump by passing through the drainage
water tube. In TBMPP there are five drainage pumps, which are used based on working time.

2.9 Switchyard

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The Switchyard is a place where different HV switches and equipment used for the switching,
protection and monitoring of the electrical parameters are found. It is the protective part of the
whole power system. It is also, most essential part for transmission, distribution, and generation.
TBMPP 400kv switchyard is located directly to the north side of the powerhouse.

Figure2. 7:Switchyard TBHEPP

2.9.1 Disconnect switches /Isolators

Disconnect switches are used in addition to circuit breakers. These are provided on each sides of
circuit breaker to provide isolation and enable maintenance. Disconnect switches are not able to
interrupt fault currents. It may either be an off-load or on-load disconnect or/isolator. TBHPP
isolators are an off-load type. “Off-load” means the device is designed to open the circuit without
any current flowing.

The current rating of an off-load isolator will refer only to the value of current allowed to
continuously pass through the device. The making and breaking current rating will be zero.
The operation of off-load isolators type is: -While opening the circuit, the circuit breaker opens
first and isolator next and while closing the circuit the isolator closed first and then circuit breaker.

2.9.2 Circuit breaker

A circuit breaker (CB) is a device used to complete, maintain, and interrupts currents flowing in
circuit under normal or faulted condition. Designed to open an electric circuit under over current
or fault conditions. This isolates the faulty line or equipment from the live portion of the substation
by opening automatically through protective relays; control cables etc. in definite time.

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Types of circuit breakers
1. Air blast circuit breaker
2. SF6 circuit breaker
3. Vacuum circuit breaker
4. Minimum oil circuit breaker
From the above types of circuit breaker TBMPP switchyard used SF6 circuit breaker.SF6 circuit
breakers operate to switch electric circuits and equipment in or out of the system. These circuit
breakers are filled with compressed sulfur-hexafluoride gas which is acts to open and close the
switch contacts. The gas also interrupts the current flow when the contacts are open. SF6 has
excellent insulating property. SF6 has high electronegativity. That means it has high affinity of
absorbing free electron. Whenever a free electron collides with the SF6 gas molecule, it is absorbed
by that gas molecule and forms a negative ion.

2.9.3 Surge/lighting arresters

Surge arresters are protective device for lighting surge voltages due to lighting strikes or equipment
fault or other events to prevent damage to equipment and disruption of service. They are installed
on many different pieces of equipment such as power transformers, circuit breakers, bus structures,
and steel superstructures in substations/switchyard. The typical lighting /surge arrester has a high
voltage terminal and ground terminal. It protects the equipment by divert the lighting to ground.

2.9.4 Bus bars

Bus bars are nothing but the solid or tubular aluminum conductors supported on post insulators.
Bus bar in the generating station/switchyard and substation form important link between the
incoming and outgoing circulates. It carries electric supply with maximum load.

Types of bus bars arrangements

1. Single bus bar arrangement
2. Double main and transfer bus bar arrangement
3. Duplicate bus bar system

Form these bus bar arrangements TBMPP switchyard used double main and transfer bus bar
arrangement. This arrangement incorporates all advantages of the double bus as well as transfer
bus scheme.

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This scheme needs a bus coupler for the on load transfer of circuits from one main bus to the other
and a transfer coupler for taking out circuit breaker of various circuits for maintenance.

Figure2. 8: Single line diagram switchyard

2.9.5 Bus couplers

Bus couplers are used when double bus bars of many power transformers are connected together.
It becomes useful when one of the power transformers fails or faults occurs in either of the bus
bars by energizing the other and maintains the faulted bus bar at time.

2.9.6 Bus bar supporting insulators

This serves to isolate the bus bar switches and other support structures and to prevent leakage
current from flowing through the structures or to ground. These insulators are similar in functions
to other insulator used in transition poles and towers.

2.9.7 Current transformers (CT)

Current Transformers (CT’s) are instrument transformers that are used to supply a reduced value
of current to meters, protective relays, and other instruments. CT’s provide isolation from the high
current primary, permit grounding of the secondary for safety, and step-down the magnitude of the
measured current to a value that can be safely handled by the instruments.

2.9.8 Voltage transformers (VT)

The VT is used to step down the voltage of a circuit to a low value that can be effectively and
safely used for operation and protection of instruments. The main functions CVT’S are for

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measurement, protection and coupling device in PLCC (power line carriers’ communication).
These are connected in parallel to the system. Generally, it steps down the incoming 400KV to
100V in the switchyard.

2.9.9 Earthing Switch

Earthing Switch is necessary to earth the conducting parts before maintenance and also to provide
deliberate short-current while testing.

2.9.10 Pantograph

Pantograph is conductor which is used to connect the output of power transformer with in bus bar.
In TBMPP there is single pantograph for single line output.

2.9.11 Control system

The control system is equipped with Four Levels of control System.

1. from Field Panels
2. from Mimic Panel
3. from SCADA
1. Field level: - is the HV equipment's closest command level (outdoor control panels), it is
intended only for maintenance purposes and it works without any interlock.
2. Mimic panel level: - in this case the commands come from the mimic panel installed in the
switchyard control room, from where a global view of the switchyard is given.
3. SCADA level: - is the remote command level, commands are initiated from the SCADA
system/Operator Stations, Engineering Station or Tool box.

2.9 Outlet

The outlet of TBMPP is consisting of river diversion, outlet structure, and pedestrian crossing and
regulation weirs (two of them with pedestrian crossing).

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 CHAPTER THREE

PROJECT AND ITS CONTRIBUTION TO THE COMPANY

3. Project Title; Effective thermal control methods of enclosure electrical equipment’s.

3.1. Introduction

Electronic components such as integrated circuits, transistors, diodes, resistors and capacitors,
among others are designed and built to withstand particular amounts or levels of heat. Take note
that when used in an electronic system such as an actual consumer electronic device, most of these
electronic components generate heat. Examples are the diodes used in display technologies and
integrated circuits in a central processing unit of a computer or mobile device. However, different
internal and external situations can result in overheating that can potentially damage an electronic
component. This project paper explores and discusses the effects of heat or more appropriately, of
overheating of electronic components found in enclosure and controls panels in our hosting
company TBMPP.

In this project we are looking for the appropriate thermal control method for TBMPP especially
for enclosure electrical equipment and control panels. All of us were responsible in the design of
the thermal control methods and to make automatically control mechanism for the selected thermal
control solution.

3.2. Problem statement .

In TBMPP there are different enclosure electrical equipment and control panels but due to some
design problems the control panel have not thermal control systems, due to this many electrical
equipment especially converters, which convert AC to DC are malfunction and they are tend to a
complete failure. This is a basic problem which tends to stop devices which used a DC sources
then it will take the unit out. As we heard from the maintenance room members they told us they
changed converters due to a complete failure but now there is no extra converters, therefore the
problem is very critical which needs firm solution. We carry out this project to find the current
situation in the mega projects of the world and try to find the best thermal control methods for my
host company TBMPP.

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3.3. Objective

3.3.1. General objective

 To design effective thermal management system

3.3.2 Specific objectives

 Extending the service life of the internal components.

 Understand the consequences of over-heated electronics
 Identify the sources of damaging heat

3.4. Significant of the project

 Guaranteeing continuity of service

 Avoiding down-time and malfunctions caused by overheating of electrical and electronic
devices.
 Reducing costs associated with the manufacturing processes and maintenance cycles and
costs for the installation
 It increases our capacity/ability of solving problems
 It also increases creativity
 System performance is also increased

3.5. Scope of the project

The scope of the project is mainly concentrated on thermal control methods and its engineering
analysis for only control panels. In this project we only focused to explore the available thermal
control methods used in the mega projects of different parts of the world and we try to find the
best out of it for our host company. We are not interested to manufacture the cooling unit. Instead
we will explore how to choose best thermal control methods and its Engineering analysis and
installation methods deeply. Since all tasks in TBMPP are automatically controlled we are also
interested to control the cooling unit by using automatic temperature control method which called
as thermistor.

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3.6. Limitation and Delimitation of the project.

3.6.1 Limitation of the project

 Thermal conditions analysis is based on the surrounding conditions since surrounding

conditions are different from place to place our project may be usable for only the host
company. For others company they may follow our procedures to control thermal
conditions of enclosure electrical equipment.
 To do the installation of the system, first we should take the unit out because it may occur
a fault during the installation. Since all station is in ICS it takes a long time to get the
allowance from EEP to take the unit out hence we can’t move any longer to carry out the
installation.
 Administration problem to bring the selected materials in time and delay of the allowance
to make the units out deliberately for the installation.

3.6.2 Delimitation

 We only focused on an enclosure which contains converters, and synchronizing control

panel which has different electrical equipment’s, since they are the major problem which
mainly malfunctioned and totally failed. But our project strictly recommends to do further
exploration and find a solution for different enclosure electrical equipment found in
TBMPP, because there are many different controls panels that need thermal control
methods.

3.7. Literature review

Causes of overheating enclosure electrical equipment, the effects of poor thermal management
systems, thermal optimization solution, a guide for choosing thermal optimization solution and
how to control the cooling units automatically from various precursors were addressed.

Before we proceed to causes of overheating of enclosure electrical equipment we should look the
general causes of overheating of electrical equipment because most of the equipment’s are found
in the enclosure.

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3.7.1 Causes of overheating electrical equipment’s.

Overheating may be a result of direct and indirect, as well as internal and external influences. This
means that there are different causes or factors at play why an electronic component becomes
subjected to excessive levels of heat.
The study of B. Liao, A. A. Maznev, K. A. Nelson, and G. Chen (2016) mentioned the inevitable
fact that consumer electronic devices such as portable laptops and smart phones are becoming
more prone to overheating. This is because the physical dimensions of these devices are becoming
smaller. This cluttered engineering device increases overheating susceptibility due to reduced
thermal flow. This scattering prevents the phonons from carrying away heat. Design and
engineering problem can be a direct and internal cause of overheating

Environmental factors can also lead to overheating. A reference material (Berk, 2009) lists down
and discusses some of these factors. Fluctuating weather conditions or induced differences in
ambient temperature can wear and tear electronic components. This is because temperature cycling
can induce cracks over time as materials within a component expands and shrinks

3.7.2 Causes of overheating enclosure electrical equipment’s.

Typical devices housed in an enclosure in an Automation Control System are the following.

 Variable frequency drive (vfd)

 Servo drive
 Programmable logic controller (plc)
 Starter kit
 Power supply
 Inverter
 Relays
 Terminal blocks
 Indicator lights
 Transformer.

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 Figure3. 1: Electrical Enclosure in BHPP

Figure3. 2:Electrical Enclosure in BHPP

There are basically two sources that can cause the enclosure’s internal temperature to rise above
the ratings of the control equipment.

3.7.2.1 Internal Sources

The same items that can be damaged by heat may also be the source of the heat. These include
items such as:

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1. Power supplies 2. Servos
3. AC Drives/inverters 4. Soft starters
5. Transformers 6.PLC systems
7. Communication products 8. HMI systems
9. Battery back-up systems 10. Due to Internal heat balance not calculated

3.7.2.2 External Sources

Other sources of heat that can cause the internal temperature of your enclosure to rise above a
desired level involve the external environment. These include items such as:
1. Industrial ovens 4. Blast furnaces
2. Solar heat gain 5. Uncontrolled external climatic conditions
3. Foundry equipment 6. Pollution and difficult or harsh environmental conditions.

3.7.3 Effects of Overheating

Damage to an electronic component is the potential and direct effect of overheating. This is
especially true if the component is unable to withstand the excessive levels of heat. Note that most,
if not all, of failures in electrical and electronic components, are commonly associated with
overheating and subsequent burning. This is why systems failure analysis of electronic components
typically involves examining for evidences or indications of overheating and burning (Berk, 2009).
The susceptibility of an electronic assembly or electronic device to fail increases exponentially
with temperature (Cengel & Ghajar, 2015). In addition, there is a relationship between the
performance, including the lifespan or lifecycle of an electronic component and its particular range
of operating temperature (Mehoke, 2005). Temperature can essentially dictate the efficient
performance of electronic components, as well as how long, will last.

Overheating also triggers damaging and cyclic interaction between particles.

Every 10 C / 18 F over room temperature cuts electronics life by half.

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 Figure3. 3 Electronics life

Mechanical properties

Mechanical properties of materials change with increasing temperature.

1. Elasticity and strength are reduced
2. Ductility increases temporarily
3. Atomic Mobility increases

3.8. Materials and methodology

3.8.1 Materials

3.8.1.1 Hardware components

1. Cooling fan
2. Thermometer
3. Driller
4. Thermistor
5. Diode
6. Resistor
7. Fan Dc Motor
8. Capacitor
9. Voltage Regulator
10. BJT

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3.8.1.2 Software components

 The software requirement is ProClima v5.0 software which is designed by Schneider

Electric, as a leading international specialist in energy-efficiency management to simply
enter the collected thermal data in the software; ProClima v5.0 will then suggest the
solutions that best suit the features of our installation.
 We also used protues 8 software to get the simulation of the control unit.

3.8.2 Methodology

The methodology we followed from various precursors was addressed.

3.8.2.1 Analysis of thermal conditions

It is essential to calculate a complete, reliable heat balance before considering any management
solutions. A heat balance consists of measuring and analyzing thermal conditions inside and
outside the enclosure. Based on these measurements, the ProClima v5.0 software will help us
to identify the solutions that best suit our control enclosure and the environment in which it is
installed.

 Thermal analysis inside the enclosure

First of all, it is essential to identify the most delicate devices or functions: the ones that should be
given protection priority. Delicate devices can be the cause of shut-down or malfunctions.

We should understand first to know Critical temperature for each device.

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Table3. 1: Temperature rating of equipment’s

Equipment Recommended Maximum temperature

operating with a risk of malfunction
temperature in °c
Variable speed drives 30 38
Programmable logic controller 32 35-40

Contactors 45 50
Circuit breaker 45 50
Fuses 50 50
Power supply 30 35
Printed circuit board(PCBs) 30 35
Electric battery(accumulators) 20-25 30
Telecommunication equipment 40-50 55
PFC capacitor 50 55

The thermal management solution must be sized according to the critical temperature of the most
delicate element of the enclosure. This temperature should never be exceeded.
Therefore, the mean working temperature recommended for the inside of the enclosure is
35°C.This is the reference temperature for the control equipment integrated in the thermal solution.

 Measuring the air temperature

The measurement of air temperature inside the enclosure must be taken over a complete period
(e.g.: one production cycle, 24hours, 1week etc.).
This data will be used:
> To complete the overall thermal analysis
> To avoid exceeding the critical temperature of each device
The temperature measurement inside the enclosure should be taken in three separate areas (T1, T2
and T3), because we should take the mean temperature of the panel.

T1 (at the top of the panel) is: 34.5 °c

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T2 (at the middle of the panel) is: 35 °c
T3 (at the bottom of the panel) is: 34 °c
Based on this the Mean temp of the enclosure is = (T1 + T2 + T3) / 3, 34.5+35+34/3=34.5 °c.

3.8.2.2Analysis of weather conditions

 Measuring the air temperature

To ensure reliable calculations, the external temperature measurement should be taken over a
complete period.
Max. Mean temperature is: 35 °c
Min. mean temperature is: 29 °c

 Measuring the humidity level (%)

This consists of determining whether the environment is:

 Dry: Humidity level < 60%
 Humid: Humidity level between 60% and 90%
 Very humid: Humidity level > 90%

Based on this the environment in my host company TBMPP is dry in which the humidity level is
less than 60%

3.8.2.3 Analysis of pollution and difficult or harsh environmental conditions

It is essential to measure and analyze air quality in the installation area of the control enclosure. A
prior inspection of the installation site is generally enough to identify the constraints to which the
electrical and electronic devices will be exposed.
Difficult or harsh environments are;
 Sites with presence of oils, solvents and aggressive substances Saline, corrosive or sugary
environments
 Dusty atmospheres: cemeteries, flour mills, ceramic and wood processing plants, rubber
factories, etc.
 Nuclear, chemical, petrochemical sites, etc.
 Bottling plants (high humidity levels)
 Metalworking sites
 Textile plants (fibers tend to block the air intakes)

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Based on this the installation area of the control enclosure of our company TBMPP is clean and it
is not harsh environment, therefore the issue is not serious in this case.

3.10 Cooling fan

Fans provide air for ventilation and industrial process requirements. Fans generate a pressure to
move air (or gases) against a resistance caused by ducts, dampers, or other components in a fan
system. The fan rotor receives energy from a rotating shaft and transmits it to the air.

3.10.2 Industrial enclosure Filter Fan Design Options

Forced air systems by using fan can provide much greater heat transfer rates than those available
with natural convection and radiation; therefore, internal electronic packages have lower hot spot
temperatures with forced air systems. The amount of cooling air flowing through an enclosure
determines the temperature rise inside the enclosure due to the heat input. The more air that flows
through the enclosure the lower the temperature rise

How to we use proclima v5.0 software to select the right fan and its installation.

1. Enter the project and customer details (optional)

2. Enter the internal and external temperature data
3. Enter the electrical specifications of the installation (voltage, power, etc.)
4. Determine the power dissipated by the equipment. If this value is not known, ProClima v5.0 can
calculated it:

A. According to the number and type of electric and electronic devices installed in the enclosure.

B. According to a temperature reading.

5. Select the enclosure and the installation type.

6. Select the thermal management system.

7. View and print the study summary.

RESULT FROM PROCLIMA V5.0 SOFTWARE.

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Page | 47
Page | 48
3.11 How to Control automatically the Fan by Using Thermistor.

Brief discussion:

The circuit exploits the property of sensor to operate the DC Fan. A sensor is a type of transducer.
In a broader sense, a transducer is sometimes defined as any device that converts energy from one
form to another. Besides that, the component that made up the temperature sensor is known as
thermistor. Thermistor is a kind of temperature dependent resistor and its resistance varies
depending on the temperature in its vicinity. There are two types of Thermistors- Negative
Temperature Coefficient Thermistor (NTC) and Positive Temperature Coefficient Thermistor
(PTC). NTC Thermistor decreases its resistance when the temperature increases while PTC
Thermistor increases its resistance when the temperature increases. Thermistors are bead like
resistors available from 100 ohms to 10K or more values. In this circuit, a 1K (25°C) NTC
Thermistor is used. A small DC fan increases or decreases its speed as per the temperature change.
When the temperature decreases below a certain level, Fan automatically turns off.

CIRCUIT DIAGRAM

Figure3. 4: Result of a temperature controlled Fan when the temperature is above 25°C

A) Thermistor:

A thermistor is an electronic component that exhibits a large change in resistance with a change in
its body temperature. The word “Thermistor” is actually a contraction of the words “Thermal
Resistor”.

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The thermistors, which are to be described herein are ceramic semiconductors and have either
large positive temperature coefficient of resistance (PTC) devices or large negative temperature
coefficients of resistance (NTC). Both types of thermistors (PTC and NTC) have definite features
and advantages which make them ideal for certain sensor applications.
In this circuit, NTC type Thermistor of 1K at 25°C is used.

1) NTC Thermistor

Figure3. 5: NTC Thermistor

The NTC thermistors are composed of metal oxides. The most commonly used oxides are those
of manganese, nickel, cobalt, iron, copper and titanium. The fabrication of commercial NTC
thermistors uses basic ceramics technology and continues today much as it has for decades. In the
basic process, a mixture of two or more metal oxide powders is combined with suitable binders,
are formed to a desired geometry, dried and sintered at an elevated temperature. By varying the
types of oxides used, their relative proportions, the desired atmosphere and the desired
temperature, a wide range of resistivity and temperature coefficient characteristics can be obtained.

2) Thermistor Basic Operation

Assuming, as a first-order approximation, that the relationship between resistance and temperature
is linear, then: 𝛥𝑅 = 𝜥𝜟𝑻
Where: ΔR, change in resistance
ΔT, change in temperature
Κ, first-order temperature coefficient of resistance
Thermistors can be classified into two types, depending on the classification of, If 𝜥 is positive,
the resistance increases with increasing temperature, and the device is called a positive temperature
coefficient (PTC) thermistor. If Κ is negative, the resistance decreases with increasing temperature,

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and the device is called a negative temperature coefficient (NTC) thermistor. Resistors that are not
thermistors are designed to have a 𝜥 as close to 0 as possible, so that their resistance remains
nearly constant over a wide temperature range. Instead of the temperature coefficient k, sometimes
the temperature coefficient of resistance αT (alpha sub T) is used. It is defined as:
1 𝑑𝑅
αT =𝑅(𝑇) 𝑑𝑇

Table3. 2:Specifications of the circuit components

No Name of components Specifications No. of components

used

1 Resisters 1 kΩ 3
2 Variable resisters (1-5) kΩ 1
3 Diodes 1N4001 5
4 LEDs 1.8-2.2V DC 2

5 NPN Transistors BC2PC 1

6 Motor Permanent magnet 1
DC, 12V ,0.06A
7 Thermistor 10 K @25 °C 1
8 Capacitor 1000μF 2
9 Transformer 230/12V, 600mA 1
10 Voltage regulator 12v dc supply 1
regulator

PRINCIPLE OF OPERATION

The circuit is an open loop system. In this circuit initially 230V AC is stepped down to 12V AC.
Then this AC is converted into DC by a rectifier circuit consisting of 4 diodes D1, D2, D3 and D4.
Two non-electrolytic capacitors C1 and C2 are connected parallel to give more sensitivity to the
circuit as they have the ability to smoothen the voltage across them. As the capacitor charges, the
rate of change of voltage slows, and charge slows, as the charging current falls thus showing an

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exponential curve. An LED L1, through a resistance R1 is there across the capacitors to detect the
flow of current.
Now it is seen that, the thermistor’s’ and a variable resistor R2 (Potentiometer used here) is divided
by R3 resistance of 1K. Initially R2 resistance and that of the Thermistor is almost same and there
is no potential difference, so there is no voltage difference thus no current flows though the circuit.
And hence the motor does not rotate. When the thermistor senses the temperature, as it is NTC
(Negative Temperature Coefficient), its resistance decreases with the increase of temperature. As
a result, the current and voltage also increase creating a voltage difference across thermistor and
the potentiometer R2. Due to this potential difference, a current starts flowing through R3. a
voltage regulator is used to regulate the voltage to maintain a constant value of voltage across the
circuit. A transistor is used as a switch. Diode D5 is used as a Suppression diode or Fly-back diode,
to suppress the sudden voltage spike across the inductive load, i.e. the motor, when the voltage is
suddenly increased or decreased, due to rapid temperature change sensed by thermistor. The
hardware implementation of this circuit justifies this circuit operation.

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Budget

Budgeting is simply balancing your expenses with your income. If they don't balance and you
spend more than you make, you will have a problem. Many people don't realize that they spend
more than they earn and slowly sink deeper into debt every year.
Here our project breaks down is shown as follows in table:
Table3. 3:project budget analysis

No Name of components No.of components Cost of each

used component in us
dollar($)
1 Resisters 3 3.50
2 Variable resisters 1 1.00
3 Diodes 5 0.25
4 LEDs 2 8.42
5 NPN Transistors 2 0.20
6 Voltage regulator 1 2.00
7 Thermistor 1 0.01
8 Capacitor 2 0.10
9 Transformer 1 100.00
10 NSYCVF850M230PF 1 54.96
Total 19 169.47

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 CHAPTER FOUR

OVERALL BENEFITS FROM THE INTERNSHIP

4.1 Practical skills

The main aim of internship is providing and developing practical skills with a practical real world
experience in the public or non-governmental sectors. Thus surplus practical skills are gained from
this program. Among those the following points are mentioned in terms of improving my practical
skills.
 Different Electro mechanical equipment’s maintenance skill
 Different Hydraulic components design and maintenance skill
 Air injection compressor maintenance skill
 Installation of a new device skill.

4.2 Theoretical knowledge

The internship programs have many benefits in upgrading our theoretical knowledge. It was
necessary by any means to change or interpret the theoretical knowledge to practical one. We get
invaluable and interesting theoretical knowledge through;
 Principles of how to generate transmit and distribute hydroelectric power
 Principles of energy conversion
 Working principles of turbine, generator and transformer
 Mechanism of controlling and protecting electro -mechanical equipment’s
 Cooling systems of machines

4.3 Interpersonal communication skills

During the inter program we were trying to develop our interpersonal communication skill with
the process by which we exchange information, feelings and face-to-face communication. We had
improved our communication skills in a good manner which we could talk to any person at the
station with confidence and easily as possible in our experience. We had observed that
communication between different sections of the project is vital to attain high efficient on work.

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As a result, the following benefits are gained in terms of improving my communication skills:
 Formal communication skill is improved.
 Effective decision making and problem solved skill is maintained.
 Relationships from communities are maintained.
 Good information which is essential for us is gathered.
 Personal needs are expressed and needs of others are understood.
 Ideas are spoken freely in public and other meetings.
 Social life is improved through the community.

4.4 Improving team playing skills

Team playing skills means the activity of working well together as team to solve or share ideas
and challenges. Teamwork is important because, it can speed up process and make things run more
efficiently and allows goals to be reacted in an efficient and timely method. A good team will
generate and further bond of trust and confidence both in themselves and one another. This
was positively affecting our self -steam, self-confidence in our life. We have developed the
following values after improving team plying skills;
 Commitment
We have improved the ability to take commitment towards something weather it is good or not.
This helps to improve our encouragement and initiation to accomplish any task with in the given
period of time. And also we have a commitment to work any tasks with team.
 Communication
After improving team plying skill, we have shared and discussed our idea freely with others. Hence
it is crucial to be able to communicate openly and honestly.
 Decision-making
The teamwork skill of effective responsible decision-making is arising the decision making
process.
 Tolerance of diversity
We have tolerated any idea and behavior which arises from various persons.
 Respecting others
We have respected anyone since he is just a man alone.

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4.5 Improving leadership skills
Leadership means the position being a person who lead/guide a group of people in an organization.
Therefore, during the internship period in TBMPP we have developed our leadership skills. To
achieve leadership skills, require a high level of commitment to learn from each experience. We
have observed that a good learner is well principal individual who is focus one common goal and
eliminate excess fear and other doubt from his employer and work for a common goal. During this
time, we have been able to observe that one should have great skills to be a leader ship, these are:
 Great listener.
 Take owner ship and responsibility.
 Communicate effectively.
 Commitment, integrity and passionate.
 Good management skill.
 Encourage others through positively.
Thus we have maintained the following values after improving leadership skills.

1. Taking responsibility

We have taken any responsibility which are essential to our work. Hence leadership requires
taking a responsibility of tasks, agreements and protocols.
2. Loyalty
We were loyal to serve our companies and country since we will have employed through those
elements.
3. Self-confidence
Good leadership by itself requires very confidence educated person. Thus we have good self-
confidence to achieve our goal and manage others.
4. Confidential/keeping secret/
We have kept companies secret when we will employ.
5. Unbiased decision maker

4.6 Understanding about Work ethics and related issues

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Work ethics are standards, principles or values that are generally based on conscientious. Mostly
work ethics are thought to a benefit of a person morally, thereby improving their character. Work
ethics is the core idea when you are in some staff, sounder standing of work ethics is crucial, the
internship program helps to us:

 To respect the entrance and working time in TBMPP being punctuality.

 To respect others in the work place.
 To prevent any kind of corruptions.
 To respect any kinds of job.
 To prevent us from addicted drugs in the workplace.

Additionally, we have gained a good work ethics, such as:

 Reliability
 Dedication
 Productivity
 Cooperation
4.7 Entrepreneurship Skills
In this internship program we learned small business startup skills where we should be empowered
with knowledge and skills to become effective entrepreneur. The state of being an entrepreneurship
can be realized when one engages in profitable risks and creates something of value. It is defined
by their habit of innovating and redefines market trends and limits. Generally, entrepreneurs who
are able to create worthwhile good and services give a greater impact to society; have faithful and
often tested with good results. Generally, entrepreneurship can be realized when we engage in
profitable system and create something value from theoretical to practical learning. This means a
person who is able to develop a new business area and affect the global economic condition.

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 CHAPTER FIVE
CONCLUSION AND RECOMENDATION
5.1 Conclusions
Generally, this internship program is a fruitful time for us because we have got different
experiences such as practical knowledge about the working principle of electromechanical and
hydraulic machines, their control& protection system from damage, the method of maintenance,
operation, inspection and the whole production process of electrical energy in the company. We
also know about the working environment of the company, solving challenges that are faced to the
company during working times and measurements taken to overcome these challenges, developing
good inter personal communication skills, entrepreneurship skills, necessary of work ethics and
also management system. Based on the major findings presented above it is easy to understand
that internship has a great significant role in upgrading student’s theoretical background
knowledge and improving Practical skill.
5.2 Recommendation
The internship program had many benefits for the students, the hosting company and for our
university career. So, we want to give recommendations for the company and to our university for
advanced involvement of internship program for students.

5.2.1 Recommendation for TBMPP

We would like to give the following recommendations for the company based on our observations
while we were conducted in our internship period.
 The company had administration problem while accepting internship students. It accepts
less number of students. Since doing this it is should give better service in practice and
safety requirements for students.
 The company should be ready for internship students by preparing project tasks and
workshop classes to give better experiences.
 The company had administration problem in providing clean water to its workers. In my
view it is a major problem which causes many problems to the workers. We recommend
solving this problem as soon as possible.
 The local people around TBMPP have not electricity power but they saw when it is
generated and transmitted to other places safely.

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  We think it is a big shame for the company in not provides the electricity to the local
people. Since they were the main labour work when the project constructed, we strictly
recommend EEP to give the electricity to them.

5.2.2 Recommendation for my university

 The university industry linkage should work in better coordination with the industries by
creating project proposals in how the students shall be treated in industries to achieve
experiences.
 The university should give necessary courses related to hydropower plant in detail.
 UIL should have better communication networks to the industries to see the progress of
students in effectively using their time for their objectives.

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References
[1]: Berk, J. (2009). Systems Failure Analysis. Ohio: ASM International
[2]: Ghana Shyam Soren, Ram Ashish Gupta, “Temperature Controlled DC Fan using
Microcontroller”, National Institute of Technology Rourkela
[3]: D. Zorbas. (1989) ‘’Electric Machines-Principles, Applications, and Control Schematics’’,
West, 2nd edition
[4]: Lampert, D.J., Lee, U., Cai, H. & Elgowainy, A. (n.d) Analysis of Water Consumption
Associated with Hydroelectric Power Generation in the United States. Energy Systems
Division, Argonne National Laboratory. https://greet.es.anl.gov/files/water-hydro
[5]: Ministry of Water and Energy, (2015) Integrated Water Resources Management Plan for Tana
Sub-Basin
[6]: Manuals of TBMPP.

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