IS 12800 (Part 2) : 1989

(Reaffirmed 2000)
Edition 1.1
(1993-07)

Indian Standard
GUIDELINES FOR SELECTION OF TURBINES,
PRELIMINARY DIMENSIONING AND
LAYOUT OF SURFACE HYDROELECTRIC
POWER HOUSES
PART 2 PUMPED STORAGE POWER HOUSE

(Incorporating Amendment No. 1)

UDC 621.224.7 : 627.8.091.3 : 621.311.21

© BIS 2003

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN , 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

Price Group 7
Hydroelectric Power House Structures Sectional Committee, RVD 15

FOREWORD

This Indian Standard (Part 2) was adopted by the Bureau of Indian Standards on 22 August 1989,
after the draft finalized by the Hydroelectric Power House Structures Sectional Committee had
been approved by the River Valley Division Council.
Pumped storage is a system wherein economical electrical energy, usually available at night or on
weekend days, is used to pump water from a lower to a higher elevation. In that process, electrical
energy from the system is converted to potential energy in the form of stored water. As and when
needed, water is released from storage through hydraulic turbines to generate high value
electrical energy during periods of maximum demand, usually during day time.
In fact all the reaction turbines may be used for reversible pumping and generating mode,
however, in most of the cases Francis type units find application. The reversible Francis type
pump turbine is essentially a centrifugal pump, which with certain modifications, performs as a
turbine when operating in the opposite direction. The conventional Francis turbine runner with its
large number and too short length of blades is not well adopted due to cavitation consideration
when operating in the reverse direction as a pump.
In the reversible turbines head variation should be limited and kept between 110 percent to 80
percent of rated head for smooth operation.
This edition 1.1 incorporates Amendment No. 1 (July 1993). Side bar indicates modification of the
text as the result of incorporation of the amendment.
For the purpose of deciding whether a particular requirement of this standard is complied with,
the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded
off in accordance with IS 2 : 1960 ‘Rules for rounding off numerical values ( revised )’. The number
of significant places retained in the rounded off value should be the same as that of the specified
value in this standard.
 IS 12800 (Part 2) : 1989

Indian Standard
GUIDELINES FOR SELECTION OF TURBINES,
PRELIMINARY DIMENSIONING AND
LAYOUT OF SURFACE HYDROELECTRIC
POWER HOUSES
PART 2 PUMPED STORAGE POWER HOUSE

1 SCOPE 3.4 Pump Input ( Pp )

1.1 This standard (Part 2) lays down guidelines It is the input at reversible pump turbine shaft
for selection of reversible pump turbine, during pumping.
preliminary dimensioning and layout of 3.5 Pump Specific Speed ( nsp )
pumped storage power houses for Francis
reversible turbine. However, it does not deal The speed at which a pump turbine when
with multistage pumping. operating in pumping mode would operate, if
runner was reduced to a size which would
2 REFERENCES deliver one m3/sec discharge under one metre
2.1 The following Indian Standards are head.
necessary adjuncts to this standard: 3.6 Rated Dynamic Head for Pumping
( Hp )
IS No. Title
The head at which the reversible pump turbine
IS 4410 Glossary of terms relating to deliver the rated discharge at the rated speed
(Part 10) : 1987 river valley projects: Part 10 and full gate opening.
Hydro-electric power station
3.7 Suction Head ( Hs )
including water conductor
system ( first revision ) Difference in elevation between minimum tail
water level and centre line of reversible pump
IS 7418 : 1974 Criteria for design of spiral turbine.
casing (concrete and steel)
3.8 Turbine Output ( Pt )
IS 4461 : 1976 Code of practice for joints in
surface hydro-electric power Output at reversible pump turbine shaft during
station ( first revision ) turbining.
4 MAIN PARAMETERS OF PUMP
3 TERMINOLOGY TURBINE
3.0 For the purpose of this standard the 4.1 Speed
definitions given in IS 4410 (Part 10) : 1987 and
IS 7418 : 1974 and following shall apply. As the rated generating capacity is the most
significant requirement, the speed of rotation is
3.1 Dynamic Head for Pumping selected on the basis of rated output during
Effective head against which reversible pump turbining. The statistical relationship between
turbine has to discharge which is gross head head and turbine specific speed is given in
plus all the losses in water conductor system. Fig. 1. Corresponding to rated head, the
turbine specific speed is obtained and speed of
3.2 Maximum Net Head
rotation is calculated by the following equation:
Maximum effective head available for power
generation which is gross head minus all the n P t × 1.358
nst = ------------------------------------
-
losses in water conductor system including 5⁄4
Ht
penstock.
where
3.3 Minimum Net Head nst = specific speed of pump turbine when
Minimum effective head permitted for power operating in turbining mode,
generation and is defined as minimum gross n = rated speed in revolutions/minute,
head minus all the losses in water conductor Pt = turbine output in kW, and
system including penstock. Ht = rated head acting in metres.

1
IS 12800 (Part 2) : 1989

FIG. 1 SPECIFIC SPEED AS TURBINE VS FIG. 2 SPECIFIC SPEED AS PUMP vs DESIGN

DESIGN HEAD HEAD
4.2 Pump Input ( Pp ) and Specific Speed calculated by the following formula:
At rated head, pump input in kW is obtained λ∆H p
from the following equation: Pp max = Pp  1 + -----------------
Hp
Pp = 9.8 Qp Hp/Ep
where
where
Pp = pump input,
Ep = pumping efficiency. ∆Hp = maximum dynamic head – design
Pump specific speed is determined from Fig. 2 dynamic head,
and rated pump discharge may be obtained λ = relative capacity variation, and
from the following formula: Hp = dynamic pumping head. At least 5
percent margin, and is taken for
nsp = n Qp
----------------- pump input.
Hp ⁄ 4 3
NOTE — At least 5 percent margin is taken for the
pump input.
where 4.3 Pump Turbine Setting
nsp = specific speed of pump turbine when To prevent excessive cavitation in pump
operating in pumping mode, turbines, submergence requirements are more
critical during pumping than for turbining. The
n = rotational speed in revolutions/minute, suction height with respect to minimum tail
Qp = discharge in m3/sec, and water level may be determined by the following
formula:
Hp = rated dynamic head in metres.
Hs = Hb – σ Hp – Hv
For preliminary calculations, pump efficiency
may be taken as a 0.9 and where
Hs = suction height below minimum tail
Pp = 11 Qp Hp water level in metres
4.2.1 To evaluate the capacity of motor Hb = barometric pressure =
generator, it is necessary to determine the elevation of power station in
maximum capacity in pumping mode. Figure 3 metres of water column
10.3 –
gives the relationship between relative capacity 900
variation and specific speed in pumping mode. HV = vapour pressure = 0.4 m from mean
From this curve, maximum pump capacity is sea water level at 30°C and

2
 IS 12800 (Part 2) : 1989

πD 1 n
Ku = ----------------------------
60 2g H p

where
g = gravitational constant, and
Hp = rated dynamic head.
The relationship between pump specific speed
and peripheral velocity coefficient is shown in
Fig. 6.
Peripheral coefficient ( Ku ) is determined from
this figure and the runner diameter ( D1 ) is
calculated from the above equation.
4.5 Spiral Casing
The dimensions of spiral casing as given in
Fig. 5 may be obtained from Fig. 7 and 8.
4.6 Draft Tube Dimensions
Major dimensions are the function of runner
FIG. 3 RELATIVE CAPACITY VARIATION vs inlet diameter and may be obtained by Fig. 9.
SPECIFIC SPEED AS PUMP
4.7 Clause deleted.
4.8 Clause deleted.

5 MAIN PARAMETERS OF MOTOR

GENERATOR

5.1 Number of Pair of Poles ( P )

Speed shall be determined as given in 4.1
determined by the following equation:
60f
P = ---------
n
where
P = number of pairs of poles,
f = frequency in cycles per second, and
n = rated speed of the machine in rev/min.

5.2 Air Gap Diameters ( Dg )

FIG. 4 CAVITATION COEFFICIENT (PUMP The maximum peripheral velocity ( Vr ) at
SIGMA) vs SPECIFIC SPEED AS PUMP rated speed may be obtained from Fig. 12. This
curve relates to sheet steel having yield stress
of 525 N/mm2. For better quality steels
σ = cavitation co-efficient, may be
peripheral velocity may be increased in the
obtained from Fig. 4.
ratio of yield strength. The value of air gap
NOTE — Usually 3 to 5 m margin is recommended in diameter ( Dg ) may be obtained from the
the above calculated value of suction height
following formula:
4.4 Runner 60 V
Dg = ------ -----r-
The size of runner is designated by inlet π n
diameter ( D1 ) of runner ( see Fig. 5 ) and main
dimensions of turbine shall be based on it. The where
runner diameter ( D1 ) is determined by the Vr = max peripheral rotor velocity, and
peripheral valocity coefficient ( Ku ):
n = rated speed of machine.
3
IS 12800 (Part 2) : 1989

FIG. 5 WATER PATH DIMENSIONS

FIG. 6 PERIPHERAL VELOCITY COEFFICIENT vs SPECIFIC SPEED AS PUMP

4
 IS 12800 (Part 2) : 1989

FIG. 7 RELATIONSHIP BETWEEN SPIRAL OUTLET VELOCITY DURING

PUMPING AND DESIGN HEAD

FIG. 8 SPIRAL CASE DIMENSIONS vs SPECIFIC SPEED AS PUMP

5
IS 12800 (Part 2) : 1989

FIG. 9 DRAFT TUBE DIMENSIONS vs SPECIFIC SPEED AS PUMP

5.3 Outer Core Diameter ( Do ) 5.5 Inner Diameter of Barrel ( Do )
Outer core diameter ( Do ) of the stator can be Inner diameter in case of circular shaped barrel
determined by the following relationship: (or inner across flat dimension in case of
polygonal shaped barrel) can be determined by
π
Do = Dg  1 + -------  adding 2.0 to 2.4 metres to stator frame
2P diameter:
where 5.6 Core Length of Stator ( Lc )
P = number of pair of poles.
Core length of stator can be determined as
5.4 Stator Frame Diameter ( Df ) below:
Stator frame diameter ( Df ) (across flat W
dimension in case of polygonal shape), can be ---------------------
Lc = K D g 2 n
o
found out by adding 1.2 metres to the outer core
diameter: where
Df = Do + 1.2 metres W = rated kVA, and
π
= Dg  1 + -------  + 1.2 m
Ko = output coefficient (obtained from
 2P  Fig. 13).

6
 IS 12800 (Part 2) : 1989

FIG. 10 RELATIONSHIP BETWEEN RUNNER WEIGHT AND DIAMETER D1

FIG. 11 RELATIONSHIP BETWEEN AXIAL HYDRAULIC THRUST COEFFICIENT AND

SPECIFIC SPEED AS TURBINE
7
IS 12800 (Part 2) : 1989

FIG. 12 RELATIONSHIP BETWEEN PERIPHERAL VELOCITY Vr AND PAIRS OF POLES

FIG. 13 RELATIONSHIP BETWEEN OUTPUT COEFFICIENT AND PAIRS OF POLES

8
 IS 12800 (Part 2) : 1989

5.7 Length of Stator Frame ( L ) Maximum total load is sum of maximum

Length of stator frame can be determined by hydraulic thrust and weight of rotating parts.
adding 1.5 to 2.0 m to the length of stator core. Generally 4 to 8 arms are taken.
Lf = Lc + 1.5 to 1.6 m 5.10 Axial Hydraulic Thrust
5.8 Height of Load Bearing Bracket The axial hydraulic thrust on the turbine
The height ( hj ) of the load bearing bracket can runner may be determined by following
be determined by the following formula: formula:

hj = Kb D f for suspended type generator, PH = KD12 Hmax in tonnes.

and
The value of K may be obtained from Fig. 11.
= Kb D g for umbrella type generator. 5.11 Weight of Generator Rotor — The
weight of generator rotor in relation to air gap
where
diameter and rotor weight in tonnes per metre
Kb = 0.65 for a load of 50 t/arm of the of core length may be obtained from Fig. 14.
bracket, This value shall be multiplied by the core
= 0.75 for a load of less than 100 t/arm length to get rotor weight.
and more than 50 t/arm of the bracket, 5.12 Axial load acting downward is the sum of
and hydraulic thrust, weight of turbine runner and
= 0.85 for a load of 100 t/arm. weight of rotor.

5.9 Number of Arms of Bracket 5.13 Weight of Turbine Runner

The number of arms of the bracket are decided The weight of Turbine Runner may be obtained
on the basis of total load on the thrust bearing. from Fig. 10.

FIG. 14 RELATIONSHIP BETWEEN ROTOR WEIGHT AND AIR GAP DIAMETER

9
IS 12800 (Part 2) : 1989

6 OVERALL DIMENSIONS OF POWER b) A gallery of 1.5 to 2.0 m width for

HOUSE approaching the draft tube manhole.
6.1 The overall dimensions of power station c) In case the main inlet valve is also
mainly depend upon the following: accommodated in the power station, a
a) Overall dimensions of the turbine, draft valve pit of appropriate size shall have to
tube and scroll case; be provided. The width of the valve pit
b) Overall dimensions of the generator; may be kept to accommodate the
c) Number of units in the power station; and following:
d) Size of the erection bay. i) Conventional butterfly valve,
NOTE — Provision for inlet valves, erection of rotor and ii) Butterfly valve with flow guides,
untanking of transformers should be in such a way that iii) Spherical valve, and
space required is minimum without impairing the
operational and maintenance requirements. iv) Pressure relief valve in the scroll case,
6.2 Length of the Power Station if any.
It depends upon the unit spacing, length of d) Provision of width for auxiliary
erection bay and length required for the crane equipments in the floors.
to handle the last unit.
6.4 Height of the Power Station
6.2.1 Unit Spacing
For determining the distance between the 6.4.1 The height of power station from the
centre line of the successive units, the overall bottom of the draft tube to the centre line of the
dimensions of the spiral casing, the draft tube spiral casing ( H1+H2 ) ( see Fig. 15 ) can be
and the hydrogenerator should be drawn with determined from Fig. 9. The thickness of the
respect to the vertical axis of the machine. A concrete below the lowest point of the draft
clearance of 1.5 to 2.0 m should be added on tube may be taken from 1 to 2.5 m depending
either side of the extremities of the above upon the type of foundation strata.
drawn figures to determine the unit, spacing.
6.4.2 The height from the centre line of the
The clearance should be such that a concrete
spiral casing up to the top of the generator = H4
thickness on either side of steel scroll case
(Fig. 15) can be determined as follows:
should be at least 1 to 1.5 m.
6.2.2 The length of the erection bay may be H4 = Lf + hj + K
taken as 0.7 to 1.5 times the unit spacing as per Lf and hj have been defined in 5.7 and 5.8
erection requirements. respectively.
6.2.3 The total length L of the power station The value of K may be taken as 5.5 to 7.0 m
can then be determined as follows: depending upon the size of the machine.
L = No×(unit spacing)+Ls+K
where 6.4.3 The height of the machine hall above the
top bracket of the generator depends upon the
No = number of units, hook level and the corresponding crane rail
Ls = length of the erection bay, and level, and the clearance required between the
K = space required for the crane to handle ceiling and the top of the crane. Further the
the last unit depending on the number height shall depend upon the height of service
and size of the crane which is usually bay floor from where the equipment has to be
3.0 to 5.0 m. handled.
6.3 Width of the Power Station Super
Structure 6.4.3.1 The hook level and the corresponding
crane level are determined by providing
The super structure of the power station is adequate clearance for the following cases:
required to cover only the machines and not the
entire length of the draft tube which is a) Handling/moving major items of
accommodated in the lower extended portion of equipment viz turbine runner assembly,
the substructure. For determining the width of rotor assembly and even entire generator
the power station super structure, the overall stator.
dimensions of the spiral casing and the hydro b) Unloading of heaviest equipment from the
generator may be drawn with respect to the trailors. For this purpose a height of 7.0 to
vertical axis of the machine. Super-structure 8.5 m between the erection bay floor and
columns should be clear of the down-stream the highest hook level may be sufficient.
extremities of the above drawn figure by about c) Hauling the main transformer with
1.5 to 2.0 m. On the upstream side provision bushing into the erection bay under the
should be made for the following: crane girder.
a) A clearance of about 1.5 to 2.0 m for d) Clearance required for untanking of
concrete upstream or scroll case. transformers.

10
 IS 12800 (Part 2) : 1989

FIG. 15 CROSS SECTION OF POWER HOUSE

6.4.3.2 A minimum clearance above the service 7.1.1 Main Machine Hall
gangway of the crane for the movement of The main machine hall accommodates the
working personnel may be 2 to 2.5 m and the hydroelectric generating unit. The different
clearance between the highest part of the unit blocks separated by expansion/contraction
gantry crane and ceiling of power house should joints and shall be in accordance with
be 0.3 m. With this consideration the height of IS 4461 : 1979. The level of centre line of the
the power house ceiling above the top level scroll case is given in 4.3. An elevation
hook may generally vary from 4 to 6.5 m difference of 4.0 to 5.0 m between the generator
depending upon the width of the machine hall floor and turbine floor may be adequate to
and capacity of the gantry crane. A typical accommodate equipments to be handled on the
example for calculating the overall dimensions turbine floor. The foundation levels of the
is given in Annex A. stator and lower bearing bracket should be so
7 GENERAL LAYOUT OF POWER STATION fixed that in the turbine pit, at least 2.2 to
2.5 m of head room is available above the speed
7.1 In general, a power station may be divided
ring top cover. The gantry columns may or may
into two areas as follows: not be equally spaced. These columns may also
a) The main machine hall housing the be preferably located on the central areas of the
generating units, and draft tube. The clear spacing between the
b) Erection bay. gantry columns may be kept 5.0 to 6.0 m.

11
IS 12800 (Part 2) : 1989

7.1.2 Erection Bay equipment, etc. Space also has to be provided

It may be located either as an extension of for cable running. The general facilities include
machine hall or in between depending upon the passenger lift, stair cases, reception room,
topography and number of machines. Though it toilets, workshop, etc.
is most convenient to keep the level of erection 7.3 Location of Main Transformers and
bay same as the generator floor level. In case Switchyard
erection bay level is lower than tail water-level
suitable arrangements be provided so that In order to provide the power transformers
there is no ingress of water inside the power nearest to the units to reduce the length of
house. leads, their location on draft tube deck, just on
7.2 Space for Auxiliary Equipment and the upstream side, on the roof or on one side of
General Services the power station towards switchyard should be
considered. Another consideration for locating
In addition to machine hall and service bay, the transformers is the desirability to bring
space has to be provided for auxiliary them to the erection bay for servicing for which
equipment and general services. The auxiliary a rail track is laid from the transformer
equipment includes control and relay panels, cubicles to the erection bay.
PICC equipment, TAC Switchgear, HT
Switchgear, D.C. battery chargers and 7.3.1 Power transformers are connected to
distribution boards, fire fighting equipment, air switchyard as well as control room. Switchyard
conditioning and ventilation equipment, cooling should, therefore, be located as near to the
water equipment, drainage and dewatering transformers and control rooms as possible.
equipment, LP and HP compressed unit Space between the dam and the power station,
auxiliary transformers (if dry type), power station roof or some nearby space be
illumination equipment, communication considered for this purpose.

ANNEX A
( Clause 6.4.3.2 )
TYPICAL EXAMPLE FOR CALCULATING THE OVERALL
DIMENSIONS OF POWER HOUSE
A-1 DATA Pump output —
Unit Capacity : 100 MW 9.8 × 112.9 × 105
Maximum Head (Turbine): 105 m Pp = ---------------------------------------------
.9
Rated Head : 100 m
Minimum Head : 75 m = 129 082.33 kW
Maximum Pumping Head : 110 m Capacity of motor generator —
Rated Pumping Head : 105 m
Pmax = 129 082.3  1 + 0.27 × --------------------------
Minimum Pumping Head : 80 m 110 – 105
Generator Capacity : 111 111 kVa 105
Power Factor : 09 = 130.741 MW
A-2 OVERALL DIMENSIONS 105
5 percent margin over Pmax = ---------- × 130.741 MW
From Fig. No. 1 and 2 specific speed may be 100
taken as:
Capacity of motor generator = 137.279 MW
nst = 190
nsp = 54 Pumping turbine setting —
Speed machine in turbine made = n = Hs = Hb – σHp – Hv
nst × Ht5/4/ P t × 1.358 σ from graph (Fig. 4) for nsp 54 = 0.26
5/4 Hb = Barometric pressure at power house
190 × 100 level taken 10 m
n = ------------------------------------------------
100 000 × 1.358 HV = Vapour pressure at power house level
= 163 rev/min (Nearest synchronous taken 0.4 m
speed 157.9, 166.7) taking 166.7 Hs = 10 – 0.26 × 105 – 0.4
rev/min
= 10 – 27.3 – 0.4 = 17.7 metres
Rated pump discharge —
n sp × H p3/4 Actual setting with margin = –17.7 – 4 = –22
Qp = ----------------------------- - Turbine centre line 22 metres below tail race.
n
Size of runner —
54 × 105 3/4
= ----------------------------- = 10.625 60 2g H
166.7 D1 = ---------------------------p-
Qp = 112.90 m3/sec Ku πn
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 IS 12800 (Part 2) : 1989

for nsp Ku = 1.07 from graph (Fig. 6) iii) Outer core diameter =
60 × 2 × 9.81 × 105 π
D1 = ------------------------------------------------------ × 1.07 m Do = Dg  1 + -------
3.14 × 166.7 2F
= 5.564 = 5.6 m
= 7.9  1 + ----------------------- = 8.589 4
3.141 59
Dimension of spiral case  2 × 18 
recommended velocity (refer Fig. 7)
= 8.6 m
at 105 metres = 10 m/sec.
iv) Stator frame diameter =
112.9 × 4
Inlet diameter D = ------------------------ Df = Do + 1.2 m
10 × n
= 8.6 + 1.2 = 9.8 m
= 3 791 mm
Assume = 3 800 mm v) Inner diameter of barrel =
A = 3 800 mm Db = Df+2.0 to 2.4 m
Dimensions of spiral case = 9.8+2.2 = 12.0 m
B = 1.1 × 5.6 = 6.16 m Core length of stator
C = 1.21 × 5.6 = 6.73 m ( Output in kVA )-
Lo = W
-----------------------------------------------------
D = 1.32 × 5.6 = 7.39 m KDg2 n
E = 1.05 × 5.6 = 5.88 m
111 111
Size of draft tube = = ----------------------------------------------------
H1 = 0.28 × 5.6 = 1.570 m 6.7 × ( 7.9 ) 2 × 166.7
H2 = 1.05 × 5.6 = 5.88 m = 1.594 m say 1.6 m
( H1+H2 ) = 2.25 × 5.6 = 12.825 m Length of stator frame = Lf = Lo + 1.5
L = 3.45 × 5.6 = 19.32 m = 1.6 + 1.5 = 3.10 m
W = 1.95 × 5.6 = 11.75 m Height of load bearing bracket =
Weight of the runner = 60 tonnes hj = K D f for suspended type generator
Axial hydraulic thrust PH = K.D2Hmax = K D g for umbrella type generator
= 0.13 × 5.62 × 105
= 0.75 7.9 = 2.108 m = 2.1 m
= 428 tonnes
Weight of generator rotor
Generator parameters
Weight/metre core length
= 220 T/metre
(from graph)
60 × 50
i) Pair of poles P = ------------------
- Weight of rotor = 220 × 1.6 = 352 tonnes
166.7
say 355 tonnes
= 18
axial load
60 V r
ii) Air gap diameter Dg = ------ × ------ = 352+428+60
π n
= 840 tonnes
60 69
= ----------------------- × ---------------
3.141 59 166.7 Using above data — overall dimension of Power
= 7.906 m say 7.9 m house can be computered.

13
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Review of Indian Standards

Amendments are issued to standards as the need arises on the basis of comments. Standards are also
reviewed periodically; a standard along with amendments is reaffirmed when such review indicates that no
changes are needed; if the review indicates that changes are needed, it is taken up for revision. Users of
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This Indian Standard has been developed from Doc : No. RVD 15 (4006)

Amendments Issued Since Publication

Amend No. Date of Issue
Amd. No. 1 July 1993

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