75th Anniversary |
Navigating the waters: Q&A with Mukulesh Debnath
Dr. Mukulesh Debnath shares his extensive experience spanning over two decades, shedding light on the evolution of hydromechanical equipment and the dynamic landscape of hydro projects
Can you provide an overview of your experience with hydro projects and hydromechanical equipment? Since graduating, I’ve been deeply involved in hydro projects. My journey began as a designer specializing in Hydromechanical equipment, crafting various types of vertical and radial gates, and other related appliances essential for their operation. Over the past 20-25 years, the hydropower sector has witnessed numerous technological advancements. Each day brings forth new technologies and methodologies aimed at enhancing the flexibility and sustainability of hydropower. Recent developments in materials have further bolstered performance, durability, and reliability, leading to higher efficiencies and longer lifespans. While some of these advanced materials may presently come at a higher initial cost compared to traditional options, their benefits in terms of performance and maintenance make them increasingly competitive. On the other hand, the Indian Government has implemented notable initiatives to boost hydro power. This includes categorizing large Hydropower Projects (HPO) within the non-solar Renewable Purchase Obligation (RPO). Additionally, budgetary support has been allocated to cover the costs of enabling infrastructure such as roads and bridges, as well as funding for flood moderation aspects of hydropower projects on a case-by-case basis. Tariff rationalization measures have also been introduced, allowing developers more flexibility in determining tariffs by back-loading them over an extended project lifespan of up to 40 years. Moreover, the debt repayment period has been extended to 18 years, and an escalating tariff of 2% has been implemented.
What specific roles have you held in hydro projects, and what were your responsibilities in each role? My career journey commenced in 1995 when I embarked as a Trainee Design Engineer, entrusted with the task of designing hydro-mechanical equipment. It was an assignment that quickly captured my passion. Whenever time permitted, I eagerly visited the workshop to witness firsthand the transformation of my designs from mere drawings on A4 sheets to tangible objects. These encounters sparked countless questions, propelling me towards pursuing my master’s and Ph.D. degrees while still in service. The face I engoyed shouldering additional
54 | May 2024 |
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responsibilities earned me the position of Assistant General Manager at a relatively young age. Subsequently, I assumed the role of Project Manager, overseeing the construction of a 132MW hydroelectric project, laden with heightened responsibilities. Currently, I serve as the Vice President (Structural) at Texmaco Rail & Engineering Ltd, entrusted with the overarching responsibility of overseeing the Hydromechanical & Structural Engineering Division.
What are the key challenges you’ve encountered in working with hydromechanical equipment in hydro projects, and how have you addressed them? Hydropower, despite being the most mature renewable technology, faces several challenges in the modern age, with one of the major issues being the need to update ageing fleets to meet modern power system requirements. Geological surprises pose significant obstacles. Hydro Mechanical Equipment Work represents a multifaceted domain primarily focused on steelwork, involving intricate processes spanning Engineering, Procurement, Manufacturing, Transportation, and Erection/Commissioning of various components such as Gates, Penstocks, and Cranes/Hoists. These tasks sprawl across project sites, intricately connected with Civil and Electromechanical Works. Consequently, seamless coordination and integration with Civil and Electromechanical Works are imperative for the smooth advancement of projects. Hence, individuals equipped with expertise in Steelwork/ Equipment Design and associated downstream activities hold a significant advantage in effectively leading project teams and ensuring successful outcomes.
Can you discuss any innovative approaches or technologies you’ve implemented in hydro projects to enhance hydromechanical performance? Corrosion poses the strongest threat to the longevity and safety of any structure. To combat corrosion effectively, modern practices involve applying a 3-5 mm layer of stainless steel cladding over the designated thickness of the mild steel skin plate, enhancing its resistance to corrosion. Previously, such cladded plates were produced using the ‘explosive’ technique, but nowadays, the preferred method is hot rolled cladded steel manufacturing process.
Self-lubricating bearings have been implemented across various applicable domains to eliminate the need for conventional lubricants. Typically crafted from bronze or aluminum- bronze (metal-based) or Teflon (plastic-based), these bearings offer enhanced durability. Additionally, Teflon-clad Poly Chloroprene rubber seals are integrated to minimize operational frictional forces. Tailored seal designs have been innovated as per specific practical demands. For safety measures, the load cell concept has replaced mechanical arrangements. Moreover, guide rollers with damping systems have been introduced to ensure optimal functionality of radial gates. Energy chains are now employed for electricity transmission, accompanied by the integration of VVVF drives and hydraulic motors. Slip ring motors have become outdated. The adoption of PLC is a positive development. Optical fiber cables have been introduced for enhanced communication. Recently, cloud- based remote communication and signal data transfer have also been implemented. Ongoing research is exploring innovative coatings and surface treatments for hydraulic structures and waterways. Enhanced coatings applied to waterway penstocks are reducing surface friction, leading to increased electricity generation. Polyethylene reinforced with fiberglass is now a prevalent choice for such applications. The most innovative approaches often
emerge during the installation of various facilities, considering the unique nature of each installation site. In numerous projects, helicopters have been employed to enhance accessibility
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