NEW BONG ESCAPE, HYDROELECTRIC POWER PLANT

LEHRI, DISTRICT MIRPUR, AJ&K

ISO 9001:2008 QUALITY MANAGEMENT SYSTEM

QUALITY PROCEDURE ISO Clause 7.5.1 : Control of Production and Service Provision

Title NBE Gates Operation

Document No : QP-75-06 Date : 2nd June 2014

OPERATION
Issue No. 1 Rev. 0 Page : 1 of 11

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AMENDMENT RECORDS

It is the responsibility of the holder of this document to ensure that this copy is kept up-to-date by the
inclusion of all amendments. Alterations to this document are not permitted without prior approval of PGM.

Rev. No. Revision Description / History Change by Date

PREPARED BY REVIEWED & ISSUED BY APPROVED BY

Senior Engineer (Planning & Performance) Head of Operations Plant General Manager

Dated : 2nd June 2014 Dated : 2nd June 2014 Dated : 2nd June 2014

© QMS NBE HPP. No copying without TNBRP AJK’s permission except as permitted by copyright law.
QUALITY PROCEDURE NBE Gates Operation

Document No : QP-75-06 Date : 02nd June 2014

OPERATION
Issue No. 1 Rev. 0 Page : 2 of 11
 1. OBJECTIVE
 The purpose of this document is to provide detailed information and guidance
on the operation of New Bong Escape Gates.
1.

2. SCOPE
 The scope of this procedure covers the operation of New Bong Gates from
Remote (NBEHPP Control Room via SCADA), Local Panel (LCU8) and
Manual Operation from Local Control Panel at respective gates.
 This procedure also covers the operational of NBE Gates during different
plant condition especially in the event of Unit(s) shutdown or tripping.

3. DEFINITION / ABBREVIATION
 HOD : Head of Department
 SSCE : Senior Shift Charge Engineer
 SCE : Shift Control Engineer
 NBE : New Bong Escape
 NBEHPP : New Bong Escape Hydroelectric Power Plant
 LCU : Local Control Unit

4. REFERENCES
 O&M Manual for NBE Water Level Regulation
 Standing Instruction for Early Warning System

5. RESPONSIBILITY
 Head (Operations)
 Senior Shift Charge Engineer
 Block Operator
 Junior Block Operator
6. GENERAL INFORMATION

6.1 The New Bong Escape Hydroelectric Power Plant (NBEHPP) relies on water
released from the Mangla reservoir, through the Mangla Powerhouse, into the Bong
Canal together with seasonal flows from the Jabbar Nullah. The water available to
the new plant is represented by the total flows less the irrigation requirement of the
UJC and is currently reflected by the flows through the New Bong Escape. The
proposed project will not change the existing water regime of the area. The surplus

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 water that is currently released through the New Bong Escape back to the Jhelum
River will be utilized for generation of electricity through the power house. There will
not be any impact on the irrigation water being released in the UJC, nor the Jhelum
River downstream of the New and Old Bong Escapes.

6.2 New Bong Escape gates consist of a gated regulator and a channel of 4,000 feet
(1,219 m) in length, was constructed as part of the Mangla Project, and is located on
the right bank of Bong Pond, 25,000 feet (7.62 km) downstream of Mangla Power
Station and about 1,400 feet (427 m) upstream of the Old Bong Escape. Nine radial
gates can be automatically controlled or manually operated to maintain a constant
water level in the Bong Pond. The Escape has a maximum capacity of 41,000
cusecs (1,165 cumecs). With the construction of NBEHPP these gates are modified
to be used as Emergency Spillway of NBEHPP and also to ensure the following
conditions defined in the PPA.

a) The Complex shall be operated in a manner to ensure that the water level
of New Bong pond shall be maintained at 254.45 m ± 0.061 m (834.8 feet
± 0.2 feet) under normal load acceptance or Unit shut down conditions.

b) Sudden load rejection of the Complex and the resulting surge shall be
accommodated through the turbines designed for such contingency,
sluicing of water through the power station and New Bong Escape duly
synchronized with the water flow and Complex operations or other
arrangement for quick water disposal.

6.3 The speed of NBE Gates has been modified to operate at speed 5 feet / minute.

7. CONTROL MODE OF NBE GATES

7.1 NBE Gates can be controlled via the following mode:

(i) Auto Control Mode

- Controlling of the gate is from the relay output of LCU8. The Bong
Pond water level is regulated by automatic controlling of NBE gates
based on the measurement value from water level sensor.
- In Auto Mode, the operation of gates can be performing from
NBEHPP Control Room when the selection in LCU8 Touch Panel is
set on “Remote Mode”. The operation from NBEHPP Control Room
is depending on the communication between LCU8 and LCU7 at
NBEHPP Control room.
- When the selection in LCU8 is set on “Local Mode”, the operation
can be made via soft switch on MMI. When operator click “Open”
command, the raising of gate will last for 20 seconds and the
operator can stop the gate rising by click “Stop” within 20 seconds.
When the operator click “Close” command, the lowering of gate will
last for 20 seconds, the operator can stop gate lowering by click

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 “Stop” within 20 seconds.

(ii) Manual Control Mode

The operator can control the opening and closing of the gate from the
push button installed on the Main Control Panel.

(iii) Local Control Mode

The operator can control the opening and closing of the gate from the
Local Control Panel adjacent to respective gate.

7.2 In case of power supply failure of NBE Gates, the operator shall operate the
gate(s) manually as per following steps:

a) Open the lid of clutch and see the position of dog clutch.
b) Unlock the hand wheel lever lock by pulling out the lock pin.
c) Move the Hand/Motor change lever to hand wheel swiftly and carefully
without stopping in the middle. This will disengage the motor and engage
two bevel gears. Hold the hand wheel to ensure that the weight of gate
does not cause it to overrun.
d) Turn the hand wheel clockwise to raise gate and counter-clock to lower the
gate.
e) To turn the gate to motor operation, turn the hand wheel and adjust the
dog clutch so that the teeth of the two jaws will engage.
f) Move the change lever to motor swiftly and carefully without stopping in
the middle. This will engage two jaws of the dog clutch.
g) Close the lid of dog clutch.
h) Ensure the locking of change lever.

Hand wheel Hand wheel lever

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 Worm Reducer Change lever lock Change Lever Motor 5.5
KW

Bevel Gear Dog Clutch

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 Dog clutch coupled with motor

Dog clutch disengaged from motor (Coupled with hand wheel)

8. WATER LEVEL REGULATION OPERATING REGIME

8.1 Two (2) mode of Operating Regime programming has been configured in order to
maintain the Bong Pond Level within the range of 254.45m ± 0.15m ie Joint Mode &
Distributed Mode.

8.2 Level Joint Mode will be activated when communication between LCU8 and LCU

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 7 is OK. In this mode, the measurement value of Bong Pond water level is coming
from the sensor installed at NBE Gauge House. With this value, LCU7 calculates and
and sets the flow discharge through the Unit(s) and NBE Gates.

8.3 In case of communication between LCU8 and LCU7 fails, Bong Pond water level
will be regulated with “Level Distributed Mode”. In this mode, to maintain the Bong
Pond water level, LCU7 calculates and sets the flow discharge through the turbines
according to the sensor installed at the Inlet of NBE Power House (connected to
LCU5 via hardwiring) and LCU8 calculates and sets the flow discharge through NBE
Gates according to the measurement value from the sensor installed at NBE Gauge
House.

8.4 Operational of the Units in Level Joint Mode from NBE HPP Control Room have
two (2) Operation Mode:

i) Level Mode
 In this mode, the Unit(s) receives flow set value from LCU7 to
maintain Bong Pond Level within the set range in which Unit(s)
power output will be control in accordance with Bong Pond Level.
 In this mode, the Unit(s) normally will run to their possible maximum
power output. The maximum power output set in this mode is
22.5MW per Unit. The maximum flow also has been set at 253m 3/s
per Unit.

ii) Power Mode

 In some situation which may result from the disturbance of grid
system, NPCC may require the power house to generate power
according to its power set point command.
 In this mode, if the Bong Pond Level deviates from the set level
range with threshold value, NBE Gates will be regulated alone to
maintain Bong Pond Water Level.

8.5 When Unit is just synchronized, the Unit will run at “Power Mode” by default.
Later operator can decide which mode to runs the unit either on “Level Mode” or
“Power Mode”.

9. OPERATION OF NBE GATES ON DIFFERENT PLANT CONDITION

a) Normal Plant Operations

During normal Plant operation the NBE gates would be closed and Mangla
discharge would be fully utilized by NBEHPP and UJC. Under normal
operation of NBEHPP the channel on downstream of NBE Gates would
always be only experiencing minor water leakage from the NBE Gates.

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 For the normal Complex Operations two scenarios are defined:

i. Spilling of Excess Water in addition to rated discharge capacity of the

Complex

ii. Normal shut down of Units

i. Spilling of Excess Water in addition to rated discharge capacity of the

Complex

In such conditions the:

a) SSCE/SCE would have to be very vigilant about the available

generation capacity and Hydrology variation and maintain the Bong
Pond level as per PPA requirements.
b) SSCE/SCE would get continuous updates on Mangla discharge on bi-
hourly basis.
c) Once realized that hydrology is beyond the plant existing capacity and
UJC requirements, SSCE/SCE would immediately inform NBE Gates
Control room.
d) Siren at NBE Gates shall be initiated for 5 minutes.
e) Initiate the Early Warning System in NBEHPP Control Room.

ii. Normal shut down of Unit(s) or Complex

In any event, Unit(s) or Complex has to be shut down normally due to

unavailability of hydrology out of Technical Limits or due to any other reasons
following measures to be taken:

a) SSCE/SCE shall inform the NPCC about shut down of the Unit(s) or
Complex
b) SSCE/SCE shall inform the NBE Gate control room.
c) Gates Control room shall initiate the siren for 5 minutes.
d) The shutting down of Units should be in stepwise (With time delay of
minimum 10 minutes interval for each Unit).
e) Initiate the early warning system in NBEHPP Control Room

b) Tripping or sudden shut down of Unit(s) or Complex

For the tripping or sudden shut down of the Unit(s) of Complex following two
scenarios are defined:

i. Tripping or shut down of one or two Units

ii. Tripping or shut down of the Complex

i. Tripping or shut down of one or two Units

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 During the operations of NBEHPP, any event of tripping or Plant prevailing
situation where one or two running units become suddenly unavailable this
would cause NBE gates to open to maintain Bong Pond water Level (with
remaining units synchronized, standby or unavailable). In this event following
procedure will be followed:

a) The NBE gates Control room personnel would immediately contact

SSCE/SCE and confirm gate opening or vice versa.
b) Block Operator to confirm to SSCE/SCE about sluicing of turbines.
c) NBE Gates control room shall operate the siren for 5 minutes.
d) SSCE/SCE shall initiate the early warning system in NBEHPP Control
Room.
e) SSCE/SCE would immediately inform Safety/ Security Personnel and
ask them to implement defined response procedure, which include the
patrolling of security personnel along the 7 km length of flood protection
dyke on Siren Car and with announcements on megaphone .
f) NBE gate operations personnel will confirm to SSCE/SCE that gate
opening is normal or abnormal.
g) Block operator will confirm to SSCE/SCE that sluicing of turbines is
normal or abnormal.

ii. Tripping of Whole NBEHPP Complex

During the operations of the Complex, faults on units or Grid may cause the
whole NBEHPP complex to trip (all four Units running), resulting in sudden
automatic opening of NBE gates in this condition following steps should be
taken:
a) The NBE gates Control room personnel would immediately contact
SSCE/SCE and confirm gate opening or vice versa.
b) Block Operator to confirm to SSCE/SCE about sluicing of turbines.
c) NBE Gates control room shall operate the siren for 5 minutes.
d) SSCE/SCE would immediately inform Safety/ Security Personnel and
ask them to implement defined response procedure, which include the
patrolling of security personnel along the 7 km length of flood protection
dyke on Siren Car and with announcements on megaphone.
e) NBE gate operations personnel will confirm to SSCE/SCE that gate
opening is normal or abnormal.
f) Block operator will confirm to SSCE/SCE that sluicing of turbines is
normal or abnormal..
c) Re-Synchronization of NBEHPP
In any event of whole plant tripping, the Energy Discharge from NBEHPP
would abruptly drop to nothing (considering the phenomenon of Sluicing). In
such events the Tail race Level of NBEHPP would considerably reduce and

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 with no or minimum flow the tail race could be used by for any of the below
purposes:
i. Short cut / crossing by the pedestrians or animals.
ii. Fishing.
iii. Boating.
iv. Recreation.
In view of above situation and after resetting of all the faults on tripped Units.
Before giving start pulse the SSCE/SCE have to consider following:

a) SSCE/ SCE would initiate beckon/ Siren along the Tail race side of
NBEHPP
b) SSCE/SCE would immediately inform Safety/ Security Personnel and
ask them to implement defined response procedure, which include the
patrolling of security personnel along the 7 km length of flood protection
dyke on Siren Car and with announcements on megaphone
c) Safety /Security would keep continuous liaison with SSCE/SCE and
update during the implementation and Phase wise clearance of the plan.
d) The SSCE/SCE on confirmation of ALL CLEAR would go for step wise
synchronization of Unit(s) or Complex.

10. APPENDICES
Appendix 1 : Water Level Regulation SCADA Page
Appendix 1
Water Level Regulation SCADA Page

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