Universal Power Company Limited

Kathmandu, Nepal

Tallo Khare Khola Hydropower Project (11 MW)

A REPORT ON SITE VISIT FOR OBSERVATION OF HYDROMECHANICAL &

ELETROMECHANICAL WORKS

Prepared By:
Bijaya Thani
Dordi Khola Jal Bidyut Company Limited
Tallo Khare Khola Hydropower Project (11MW)
Contents
ABBREVIATION .............................................................................................................................................. 6
1 GENERAL .................................................................................................................................................... 7
1.1 Project Background ....................................................................................................................... 7
1.2 Project Sumary .............................................................................................................................. 7
2 Fabrication of Penstock Pipe...................................................................................................................... 8
2.1 Hydro Mechanical Works Details ........................................................................................................ 8
2.1.1 Materials & Equipment required at hydro mechanical works ..................................................... 8
2.1.2 Manpower Available for the fabrication of penstock pipe .......................................................... 9
2.2 Cutting of the MS plate to required dimension .................................................................................. 9
2.3 Rolling of steel plate to required diameter....................................................................................... 10
2.3.1 Rolling Procedure ....................................................................................................................... 10
2.4 Welding of the pipe (Longitudinal and Circumference Welding) ..................................................... 11
2.5 Inspection of the welding joints........................................................................................................ 12
2.5.1 DPT (Dye Penetration Test) ........................................................................................................ 13
2.5.2 MPI (Magnetic Particle Inspection) ............................................................................................ 13
2.5.3 UT (Ultra Sound Testing) ............................................................................................................ 14
2.5.4 Radiography (X-ray Inspection) .................................................................................................. 14
2.6 Cleaning and Coating of Pipe ............................................................................................................ 14
3 Head Works (Installation of Hydro Mechanical Parts) ............................................................................. 15
3.1 Undersluice Gate............................................................................................................................... 15
3.1.1 Design Data ................................................................................................................................ 15
3.2 Undersluice Stoplog .......................................................................................................................... 16
3.3 Intake Gates ...................................................................................................................................... 16
3.3.1 Design Data ................................................................................................................................ 16
3.4 Intake Stoplog ................................................................................................................................... 17
3.5 Gravel Flushing Gate ......................................................................................................................... 17
3.5.1 Design Data ................................................................................................................................ 18
3.6 Gravel Flushing Stoplog..................................................................................................................... 18
3.7 Sand Flushing Gates .......................................................................................................................... 18
3.7.1 Design Data ................................................................................................................................ 18
3.8 Desander Outlet Gate ....................................................................................................................... 20
3.9 Coarse Trashrack ............................................................................................................................... 20
 3.9.1 Design Data ................................................................................................................................ 20
3.10 Fine Trashrack ................................................................................................................................. 21
3.11 Steel Lining in Undersluice .............................................................................................................. 21
3.12 Bellmouth ........................................................................................................................................ 22
3.13 Expansion Joint ............................................................................................................................... 22
3.14 Air Release Valve ............................................................................................................................. 23
4 Hydro Mechanical & Electro Mechanical Works At Power House........................................................... 24
4.1 EOT Crane.......................................................................................................................................... 24
4.1.1Reference Standard for Overhead Travelling Crane ................................................................... 24
4.2 Turbine and auxiliaries ...................................................................................................................... 25
4.2.1 Reference Standard for Turbine ................................................................................................ 25
4.3 Governor ........................................................................................................................................... 26
4.3.1 Reference Standard for Governor.............................................................................................. 26
4.4 Alternating Current Generator ......................................................................................................... 26
4.4.1 Reference Standard for the AC Generator................................................................................. 27
4.5 Common Oil Pressure System ........................................................................................................... 27
4.5.1 Description of Oil pressure system ............................................................................................ 28
4.5.2 Specification of Turbine Oil ........................................................................................................ 30
4.5.3 Working Scheme ........................................................................................................................ 30
4.6 Water Cooling System ....................................................................................................................... 31
4.6.1 Reference Standard for Cooling Water System ......................................................................... 31
4.6.2 Application ................................................................................................................................. 32
4.6.3 Description ................................................................................................................................. 32
4.6.4 Control System ........................................................................................................................... 33
4.7 Pressure Relief Valve (PRV) ............................................................................................................... 33
4.8 Bifurcation......................................................................................................................................... 33
4.9 Earth Mat .......................................................................................................................................... 34
4.10 Tail Race Gate ................................................................................................................................. 35
5 Factors Affecting Degradation of Penstock Quality and Measures to be Followed for Proper
Inspection and Repair ................................................................................................................................. 36
5.1 Degradation Mechanism Evaluation ................................................................................................. 36
5.1.1 General Corrosion ...................................................................................................................... 37
5.1.2 Localized Corrosion .................................................................................................................... 37
 5.2 A Case Study of Sundarijal Hydropower Plant Regarding Thickness Degradation ........................... 38
5.3 Inspection of Penstock and Pressure Conduits ................................................................................. 38
5.3.1 Inspection Procedures ............................................................................................................... 39
5.3.2 Frequency of Inspections ........................................................................................................... 39
5.3.3 Inspection Records ..................................................................................................................... 40
5.3.4 Pre-Inspection Work .................................................................................................................. 41
5.3.5 Initial (Visual) Assessment ......................................................................................................... 41
5.3.6 Detailed Assessment .................................................................................................................. 49
5.4 Penstock Evaluation .......................................................................................................................... 50
6 Guidelines for Operation and Maintenance of Hydropower Plant.......................................................... 51
6.1 Operation of Hydropower Plant Facilities/Equipment (Starting the System) ............................ 51
6.2 Black Start & System islands ............................................................................................................. 56
6.3 Guidelines for Maintenance of Hydropower Plants ......................................................................... 57
6.3.1 Maintenance of Civil Structures ................................................................................................. 57
6.3.2 Maintenance of Hydro-turbine & Auxiliaries ............................................................................. 62
6.3.3 Typical Problems in the Maintenance of Hydro-turbines .......................................................... 68
6.3.3 Maintenance of Generator & Auxiliaries ................................................................................... 71
6.3.4 Routine Maintenance of Power Transformers .......................................................................... 80
6.3.5 Routine Maintenance of Hydro-Mechanical Equipment ........................................................... 85
6.3.6 General Problems in Electrical Circuit and Checks..................................................................... 89
6.4 REQUIREMENTS FOR EFFECTIVE OPERATION AND MAINTENANCE ................................................. 89
6.4.1 Manpower Planning and Arrangement ..................................................................................... 89
6.4.2 Training Program for Operation & Maintenance........................................................................... 90
6.4.3 Planning and Arrangement of Spare Parts, Consumables, Tools and Testing Equipment ........ 91
6.5 Logging and Reporting ...................................................................................................................... 91
6.5.1 Logging ....................................................................................................................................... 91
6.5.2 Reporting........................................................................................................................................ 92
6.6 Equipment Labelling ......................................................................................................................... 93
6.7 A Typical Format for Spare Parts List / Monthly Report of Power Plant Operation and Maintenance
/ Typical Formats for Reporting .............................................................................................................. 94
7 Power House Generator Room Ventilation ....................................................................................... 107
7.1 Calculation of Heat Radiated by the Generator.............................................................................. 107
7.2 Calculation of Air Flow Required for Ventilation ............................................................................ 107
 7.3 Routing Factor ................................................................................................................................. 108
7.4 Ventilation Fans .............................................................................................................................. 108
7.5 Layout of Fans ........................................................................................................................... 108
8 References ............................................................................................................................................. 110
ABBREVIATION
A.C. Alternative Current
AA All Aluminum
ABCB Air Break Circuit Breaker
ACE Area Control Error
ACSR Aluminum Conductor Steel Reinforced
AE/JE Assistant Engineer / Junior Engineer
AGC Automatic Generation Control
AVR Automatic Voltage Regulator
BDV Breakdown Voltage
CBM Condition Based Maintenance
CGLS Central Grease Lubrication System
D.C. Direct Current
D.G. Diesel Generator
DoED Department of Electricity Development
DP Degree of Polymerization
GoN Government of Nepal
G.B Guide Bearing
EPI Engine Performance Indicator
EMM Emergency Management Manager
EIA Environmental Impact Assessment
DT Draft Tube
GV Governor
HP High Pressure
HRC High Rupturing Capacity
NEA Nepal Electricity authority
NPS Nepal Power System
O&M Operation and Maintenance
O/L Over load
OLTC On-Load Tap Changer
OPU Oil Pressure Unit
OTI Oil Temperature Indicator
PCB Polychlorinated Biphenyls
PID Proportional Integral Derivative
PM Preventive Maintenance
PT Power Transformer
SCADA Supervisory Control and Data Acquisition
UPS Uninterrupted Power Supply
WTI Winding Temperature Indicator
SWL Standard Reservoir Water Level
T.B Thrust Bearing
T-G Turbine-Generator
TSD Temperature Sensitive device
UGB Upper Guide Bearing
1 GENERAL

1.1 Project Background:

Universal Power Company Limited, a subsidiary of CEDB Hydro Fund Limited, is
developing TalloKhareKhola Hydropower Project (11 MW). TKKHP is located
atGaurishankhar Rural Municipal ward no 5,6 and 8 of Dolakha district in central
development region of Nepal. Geographically, the project area is located
between latitudes of 270 45’ 00”N to 270 45’ 43” N and longitudes of 860 11’
35” E to 860 13' 52''E. The Headworks is located at ward 6&8 and pipeline runs
through ward no 5 along the roadway whereas the powerhouse lies at the left
bank of KhareKhola just upstream of the KhareKhola confluence with Tamakoshi
River. The power will be evacuated through 5.3 km 132 kV transmission line to
the proposed Singati substation of NEA

1.2 Project Sumary

Installed Capacity 11 MW
Gross Head 140.5 m
Design Discharge 10.1 𝑚3 /sec at Q 40
Dry Season Energy 11,527,201 KWh
Wet Season Energy 51,204,551 KWh
Total Energy 62,731,751 KWh

1. The Employer/Owner: Universal Power Company Limited (UPCL)

2. The Engineer/Consultant: Professional Network for Engineering
Services Pvt. Ltd.
3. The Contractor (Headworks - Civil): Atlas Hydro Consortium (Joint
Venture)
4. The Contractor (Headworks - HM-): Cream Hydel Pvt. Ltd.
5. The Contractor (Waterway -Civil): Masding Devi /Rapti Hydro (J/V)
6. The Contractor (Waterway - HM): North Hydro and Engineering Pvt. Ltd.
7. The Contractor (Electromechanical): Flovel Energy Pvt. Ltd.
8. The Contractor (Blasting Material Supplier): Integrated Hydro
Management
9. The Contractor (Blasting, Civil): Lafa Construction
2 Fabrication of Penstock Pipe
Contract for fabrication and erection of penstock pipe has been given to north
hydro and Engineering Private Ltd. The following processes were followed for the
fabrication of the pipe.

 Cutting of the MS steel Plate to required dimension.

 Rolling of steel plate to required diameter.
 Welding of the pipe in open section.
 Inspection of the welding joints.
 Cleaning and coating of the pipe.

2.1 Hydro Mechanical Works Details

2.1.1 Materials & Equipment required at hydro mechanical works

Description of items Unit Required Stock Remarks

Welding machine Nos. 15 8 8 running

Grinding machine Nos. 10 6 4 running
Buffering machine Nos. 6 2 2 running
DG Nos. 2 1 1 running
Diesel lit 40000 9000
Hydra Nos. 1 1 1 running
tractor Nos. 1 1
Excavator Nos. 1 -
Welding Electrode(4,3.1) mm Kg 33000 800

Rolling Machine Nos. 1 1

Grinding Wheel(7” &4”) Nos. 5000 200

Cutting Wheel (7” & 4”) Nos. 4000 300

Welding Cable Meter 800 400

Chain Pulley (5 tons capacity) Nos. 6 3

Gas cutters (Hand cutting) Nos. 3 1

Primer lit 11,096 800

 Epoxy black coat lit 13,870 750
ABC cable meter 3000 3000

2.1.2 Manpower Available for the fabrication of penstock pipe

Designation Qty. Remarks
Site Engineer 2
Supervisor 1
Operator 2
Storekeeper 1
Fitter 2
Fabricator 1
Welder 5
Grinder Man 3
Cutter master 0
Helper & Painter 9
NDT level II 1
Other 2
Total 29

2.2 Cutting of the MS plate to required dimension

First step in the fabrication of the penstock pipe is to cut the MS plate to the
required dimension. Plasma cutting is being used for the cutting of MS plate. Following
are the details of MS plate.

Letter Assigned Dimension(l*b*t) Grade of Steel Dia of Pipe to be Qty(nos)

mm Fabricate (mm)
A (6700*2500*10) 250 BR 2100 795
R (6700*2500*10) 350 BR 2100 158
J (6400*2500*10) 350 BR 2000 70
U (6400*2500*12) 350 BR 2000 238
N (6400*2500*14) 350 BR 2000 114
- (4700*2500*14) 350 BR 14500 14
- (4700*2500*20) 350 BR 14500 5
- (9400*2500*20) 350 BR 14500 2
Image: - Plasma cutting device arrangement & Cutting of MS Plate

2.3 Rolling of steel plate to required diameter

After cutting of steel plate to required dimension next step to be followed is to
roll the steel plate into pipe by using rolling machine. We are using semi-automatic 3
roller cold rolling machine manufactured by Khalsa engineering works whose hydraulic
system is driven by 22 watt 3 H.P. (373-456) V and 39.2 A induction motor
manufactured by Bharat Bijlee.

2.3.1 Rolling Procedure

At first MS plate is feed to rolling machine by help of hydra as shown in fig
below. Then at first pass Edge preparation is done, i.e. Required diameter arc is obtain
by help of template which may involve action like hammering to obtain the arc of
required dimension.

Image: - Arc measurement by using template & Arc measuring template

Image: - Finished pipe after rolling & moving finished pipe with help of hydra
Gradually second pass and third pass results the required dimension pipe and tacking
(tack weld) is done to keep stricture rigid during lifting and repointing for the further
operations.

Image: - Tacking of pipe after rolling

2.4 Welding of the pipe (Longitudinal and Circumference Welding)

As steel plates are finished rolling it’s time to weld the open section. For these
purpose E7018 electrodes of diameter 3.15 mm and 4 mm are being used with length
of 450 mm manufactured by Ador Welding Limited. We use SMAW (shielded metal arc
welding) welding method and type is longitudinal butt welding. Following procedure is
being followed before welding. Also, acceptance criteria is ASME (American Society of
Mechanical Engineers) SEC.V (Section V i.e. NDT), AWS (American Welding Society)
D1.1 (Acceptance on material and design, Fabrication, Inspection, and Qualification)

 Edge preparation of specimen.

 Cleaning (Removal of surface impurities such as dust, rust, grease etc.)
 Backing of electrode to remove moisture.

During edge preparation v notch is created where two ends of plate meet whose
notch (Bevel) angle is 70𝑜 and width is 2.5-3.5 mm with depth of approx. 8mm by
grinding action.

After the edge preparation cleaning of welding area is done by using brushes and
cleaning tools.

Backing of electrode is done in oven at temperature range of (240 − 250)𝑜 C.

For welding, 95 A is supplied for root pass layer, and depending upon welding
rod diameter 117-120 A current is supplied for 3.15 mm diameter electrode where,
165-170 A current for 4 mm diameter electrode.

During welding three passes are performed from outside where cleaning is done
through grinding before starting a new pass. After welding of outer section a v-notch is
created before performing welding from inner section and DPT is run to inspect the
quality of weld. After DPT if everything is well inner layer welding is done which is
completed at 2 passes. Where cleaning and DPT is performed before starting a new
pass.

Image: - Backing electrode in oven & different types of cleaning brushes

Image: - Welding of pipe from outside & grinding welding layer before next Pass

Image: - Welding From inside Image: - Grinding welding layer before next pass

2.5 Inspection of the welding joints

It is very important to inspect the welding joints after welding to ensure its
quality. Following Inspection NDT methods are being appy to ensure the quality of the
welding.

 DPT (Dye Penetration Test)

 MPI (Magnetic Particle Inspection)
 UT (Ultrasound Testing)
 RT (Radiography testing)
2.5.1 DPT (Dye Penetration Test)
This is one of the widely used inspection method. In this method we use dye
penetrant to detect surface flaws or porosity of the welded joints. At first cleaner is
used to clean the surface of specimen after that penetrant is sprayed and left for dwell
period. After the dwell period developer is sprayed and left for dwell period. Finally
porosity or the surface flaws are detected as pink spot. Following table provides the
further details about the DPT chemicals.

Description Brand Identification Type

Dye Penetrant Orion 115PR Solvent Remover
Consumables
Solvent Remover Orion 115P Solvent
Devloper Orion 115D Wet Non Aqueous
Penetrant dwell time : 10 min Devloper dwell time : 10 min Light : Day Light

Image: - DPT Chemicals & DPT Showing Porosity of Welded Joint

2.5.2 MPI (Magnetic Particle Inspection)

Magnetic particle inspection is performed by magnetizing specimen. At first
cleaner is applied to clean the surface which is to be inspected, and then next step is to
applying magnetic ink to the surfaced. Finally a probe is run on the surface which will
cause magnetic particle to deposit at the surface flaws or the cracks.
Image: - MPI Chemicals (Cleaner & Magnetic Ink) & performing MPI

2.5.3 UT (Ultra Sound Testing)

Ultrasonic Test (UT) is not a regular test and is not performed in all joints. It is
operated in order to examine faulty joints during installation of pipes in their designated
area. After the pipes are assembled together in the installation site, UT is performed.
The UT machine consists of a probe and a screen that provides information in graphic
form

2.5.4 Radiography (X-ray Inspection)

Radiography Inspection uses X-ray inspection method the welding joint is placed
between X-ray source and screen/film. Internal cracks and flaws are seen in the screen
or film as more radiation will pass from cracks and flaws. It is also non-regular test as
ultra sound testing.

2.6 Cleaning and Coating of Pipe

The final step in the fabrication of penstock pipe is cleaning and coating of pipe.
After cleaning of the finished pipe Zinc Chromate Primer is applied and then coal tar is
applied as coating. Both the chemicals are manufactured by Chem Bond Chemicals
Limited.

Image: - Worker cleaning the surface of finished pipe / Primer & Coal tar used for the
coating of finished pipe.
3 Head Works (Installation of Hydro Mechanical Parts)
In this section we will discuss about hydro mechanical parts that are to be
installed at the head works. Following are the different hydro mechanical parts that are
to be installed at the head works.

3.1 Undersluice Gate

Undersluice gate is used to maintain water level and flow control of river. The
gate we are using is (3*3) m rope drum hoisting gate. The name itself refers to
movable gate allowing water to flow under it. This gate is placed in under sluice hence,
named under sluice gate.

3.1.1 Design Data

Operation Type Rope Drum Operated

Q’ty One (1)
Gate Opening 3.0*3.0 m
Design Head 10 m
Water Seal 4 way
Structural Material Fe 410 (eq. SM41)
Design Load 76.5 Ton.
Number Of Horizontal Beam 5
Load on Each Beam (𝒍𝟏 , 𝒍𝟐 , 𝒍𝟑 , 𝒍𝟒 , 𝒍𝟓 ) (8.156,16.82,17.754,17.063,16.716)
respectively
Diameter 274 mm
Effective Width 60 mm
Roller Material Cast Iron
Brinell Hardness BHN = 217 kgf 𝑐𝑚−2
Contact Stress 𝑓𝑐 = 9127.269 𝐾𝑔𝑓 𝑐𝑚−2
Between Wheel and
Main Roller Track
Ultimate Tensile 34.5 BHN
Strength
Factor of Safety 1.3
Permissible Contact 𝑓𝑐𝑟 = 9214.154 𝐾𝑔𝑓 𝑐𝑚−2
Stress
Thickness Of Track Plate 6.19 mm
Strength of Vertical Girder Bending Stress = 81.653 N𝑚𝑚−2
Shearing Stress = 3.907 N𝑚𝑚−2
Effective Diameter 130 mm
Roller Material Cast Steel
Effective Width 52 mm
Side Roller Brinell Hardness 217 Kgf 𝑐𝑚−2
Dead Weight of Gate 3.0 ton
leaf
 Contact Stress 𝑓𝑐 = 1795.862 𝐾𝑔𝑓 𝑐𝑚−2
Between Wheel and
Track
Permissible Contact 𝑓𝑐𝑟 = 9214.154 𝐾𝑔𝑓 𝑐𝑚−2
Stress
Total Starting Load For Lifting = 16.55 ton
For Lowering = -2.25 Ton
Motor Power 5.379 Kw

Image: - Installed Frame for Undersluice Gate

3.2 Undersluice Stoplog

Undersluice stoplog is used to temporally block the water whenever maintenance
is required for undersluice gate. We are using one (3.0*3.0) m electric chain pulley
operated stop log for the undersluice.

3.3 Intake Gates

Intake gates are used at intake for the flow control of water at inlet.

3.3.1 Design Data

Operation Type Rope Drum Operated

Q’ty One (1)
Gate Opening 2.5*2.2 m
Design Head 8.45 m
Water Seal 4 way
Structural Material Fe 410 (eq. SM41)
Design Load 40.425 Ton.
Number Of Horizontal Beam 5
Load on Each Beam (𝒍𝟏 , 𝒍𝟐 , 𝒍𝟑 , 𝒍𝟒 , 𝒍𝟓 ) (4.423,9.35,9.146,8.573,8.934)
Respectively
Diameter 274 mm
Effective Width 60 mm
Roller Material Cast Iron
Brinell Hardness BHN = 217 kgf 𝑐𝑚−2
Contact Stress 𝑓𝑐 = 6955.493 𝐾𝑔𝑓 𝑐𝑚−2
Between Wheel and
Main Roller Track
Ultimate Tensile 34.5 BHN
Strength
Factor of Safety 1.3
Permissible Contact 𝑓𝑐𝑟 = 9214.154 𝐾𝑔𝑓 𝑐𝑚−2
Stress
Thickness Of Track Plate 6 mm
Strength of Vertical Girder Bending Stress = 20.221 N𝑚𝑚−2
Shearing Stress = 1.536 N𝑚𝑚−2
Effective Diameter 130 mm
Roller Material Cast Steel
Effective Width 52 mm
Brinell Hardness 217 Kgf 𝑐𝑚−2
Dead Weight of Gate 2.5 ton
Side Roller leaf
Contact Stress 𝑓𝑐 = 1639.39 𝐾𝑔𝑓 𝑐𝑚−2
Between Wheel and
Track
Permissible Contact 𝑓𝑐𝑟 = 9214.154 𝐾𝑔𝑓 𝑐𝑚−2
Stress
Total Starting Load For Lifting = 11.032 ton
For Lowering = -0.335 Ton
Motor Power 3.585 Kw

3.4 Intake Stoplog

As in the undersluice stoplog intake stoplog is also used to temporarily block the
water flow for the maintenance of the inlet gate. We are using one (2.5*2.2) m inlet
stoplog operated by electric chain pulley.

3.5 Gravel Flushing Gate

Gravel flushing gate is used to flush out the gravels that are trapped by gravel
trap through the spillway.
3.5.1 Design Data

Operation Type Motor Operated

Q’ty One (1)
Gate Opening 1.0*1.0 m
Design Head 8.0 m
Water Seal 4 way
Structural Material Fe 410 (eq. SM41)
Design Load 8.25 Ton.
Number Of Horizontal Beam 3
Load on Each Beam (𝒍𝟏 , 𝒍𝟐 , 𝒍𝟑 , 𝒍𝟒 ) (1.971,3.144,3.135)
Respectively
Strength of Vertical Girder Bending Stress = 66.065 N𝑚𝑚−2
Shearing Stress = 2.845 N𝑚𝑚−2
Effective Diameter 130 mm
Roller Material Cast Steel
Effective Width 52 mm
Brinell Hardness 217 Kgf 𝑐𝑚−2
Dead Weight of Gate 2.5 ton
Side Roller leaf
Contact Stress 𝑓𝑐 = 733.157 𝐾𝑔𝑓 𝑐𝑚−2
Between Wheel and
Track
Permissible Contact 𝑓𝑐𝑟 = 9214.154 𝐾𝑔𝑓 𝑐𝑚−2
Stress
Total Starting Load For Lifting = 4.856 ton
For Lowering = -4.436 Ton
Motor Power 3.156 Kw

3.6 Gravel Flushing Stoplog

Here again, stop log is used for the maintenance of the gate. Gravel flushing
stoplog dimension is (1.0*1.0) m and manually operated with screw spindle.

3.7 Sand Flushing Gates

Sand Flushing gates are used to flush out fine sand that are settled at the
settling basin i.e. Desander by spill way which is provided at the bottom of the
desander.

3.7.1 Design Data

Operation Type Motor Operated
Q’ty One (2)
Gate Opening 0.8*1.5 m
Design Head 7.0 m
Water Seal 4 way
Structural Material Fe 410 (eq. SM41)
Design Load 8.438 Ton.
Number Of Horizontal Beam 4
Load on Each Beam (𝒍𝟏 , 𝒍𝟐 , 𝒍𝟑 ) (1.806,3.312,3.32) respectively
Diameter 244 mm
Effective Width 60 mm
Roller Material Cast Iron
Brinell Hardness BHN = 217 kgf 𝑐𝑚−2
Contact Stress 𝑓𝑐 = 3.329 ∗ 104 𝑡𝑓 𝑚−2
Main Roller Between Wheel and
Track
Ultimate Tensile 34.5 BHN
Strength
Factor of Safety 1.3
Permissible Contact 𝑓𝑐𝑟 = 9214.154 𝐾𝑔𝑓 𝑐𝑚−2
Stress
Thickness Of Track Plate 6.0 mm
Strength of Vertical Girder Bending Stress = 108.4 N𝑚𝑚−2
Shearing Stress = 3.826 N𝑚𝑚−2
Effective Diameter 130 mm
Roller Material Cast Steel
Effective Width 52 mm
Brinell Hardness 217 Kgf 𝑐𝑚−2
Dead Weight of Gate 0.5 ton
Side Roller leaf
Contact Stress 𝑓𝑐 = 733.157 𝐾𝑔𝑓 𝑐𝑚−2
Between Wheel and
Track
Permissible Contact 𝑓𝑐𝑟 = 9214.154 𝐾𝑔𝑓 𝑐𝑚−2
Stress
Total Starting Load For Lifting = 2.483 ton
For Lowering = -1.902 Ton
Motor Power 2 Kw
Image: - Installed Frame for Sand Flushing Gate

3.8 Desander Outlet Gate

Deaender outlet gate is for supplying water to the forebay which is further
supplied to the penstock pipe through bellmouth. We will be using 4 set of desender
outlet gate with dimension of (1.8*1.3) m which is manually operated with screw
spindle.

3.9 Coarse Trashrack

Coarse trashrack is used to block the bigger size of trash of the gravels bigger
than 50 mm.

3.9.1 Design Data

No. of Trash Rack 2

Clear Opening (W*H) 4.2*2.0 m
Design Head 6m
Bar Opening 50 mm
Inclination Degree 71 Degree
Bar Length 2.1 m
Opening Span 4.2 m
Bar Pitch 0.05 m
Screen Bar Design Head 6.0 m
Inclination 71 Degree
Design Load / Each Bar 300.1 kgf 𝑚−1
Max Shearing Force 3090.15 N
Max Bending Moment 1622.33 N-m
Bending Stress 81.77 N/𝑚𝑚2
Shearing Stress 2.58 N/𝑚𝑚2
Deflection 3.76 mm

Image: - Portion Where Coarse Trashrack Will be installed

3.10 Fine Trashrack

Fine trashrack is provided in forebay section in front of the bellmouth for the
filter of fine trash. Clear opening is (4.2*12.0) m with bar opening of 40 mm. Inclination
is of 75 degree.

3.11 Steel Lining in Undersluice

In Undersluice Steel lining is done at the bottom to protect the concrete lining as
the stone or the boulder following may hit the concrete and may cause damage to it.
We are using 12 mm thick plate for the lining.

Image: - Steel plate used for steel lining at undersluice

3.12 Bellmouth
Bellmouth is used to ensure the perfect feeding of water in the penstock pipe. It
also helps to avoid void or air gap inside the penstock pipe. In our project we are using
rectangular bellmouth of dimension (2120*2120) mm as shown in figure below.

Image: - Section Showing Bellmouth & Design Drawing

3.13 Expansion Joint

Expansion joints are provided to the system to avoid the damage to the system
i.e. Penstock pipe due to the expanding nature of the steel due to temperature variation
according to the environmental conditions.

Image: - Expansion Joint

Generally expansion joints are provided at the open section of the penstock pipe
i.e. section where pipe is not buried. In our project expansion joint are provided at
anchor block 6-9 and 19-20. And may be extended if more open section are likely to be
seen in design.
3.14 Air Release Valve
Air release Valve is used to flush out trapped air/void inside the penstock pipe
due to the siphoned area. In our project siphon is seen near suri khola crossing bridge
where we will be using air release valve. To permit isolation and servicing, air and
vacuum relief valves are normally equipped with a ball, gate, or butterfly shutoff valve.
4 Hydro Mechanical & Electro Mechanical Works At Power House
Power house is the heart of any power plant. It is the place where generation of
power takes place. In simple we deliver water that is carried by the penstock pipe to
the turbine in this placed for the generation of the electricity.

Image: - Power house construction

4.1 EOT Crane

EOT crane stands for the electric overhead travelling crane. This crane will be
used for handling & moving a maximum specified weight of the components called
capacity of the crane within a specified area. Following figure shows the schematic view
of the EOT crane.

4.1.1Reference Standard for Overhead Travelling Crane

1. ASTM A 370, Standard Test Method and Definition for Mechanical Testing of
Steel Products
2. ASTM A 388, Standard Practice for Ultrasonic Examination of Heavy Steel
Forging
3. ASTM A 488, Standard Practice for Steel Castings, Welding, Qualifications of
Procedures and Personnel
4. ASTM E 709 / ASME V, 1998, Standard Guide for Magnetic Particle
Examination of ferromagnetic materials
5. NEMA Standards for Motors
 6. IS 3177 Code of Practice for Electric Overhead Travelling Cranes and Gantry
Cranes other than Steel Work Cranes

Image: - Power House Crane Details

4.2 Turbine and auxiliaries

For the power generation purpose we are using two Horizontal Francis type
turbines with wicket gates, runner, spiral casing, draft tube, by pass valve, drain valve
with associated auxiliary and ancillary equipment in complete set to develop Rated
Output of 5,500 kW at Generator Terminal at Rated Net Head of 128 m and Design
Discharge of 5.05 m3/s per unit, capable of delivering continuous 11% overloading
capacity (at generator terminal). Runner is compose of 13% Cr, 4% Ni.

4.2.1 Reference Standard for Turbine

1. Design standard for bolts: VSM 14 334 or VDI 2230 part 1 or IEEE Std 810-
1987
2. Vibrations: ISO 7919-5, Mechanical vibration of von reciprocating machines-
measurements on shafts and evaluation criteria or VDI 2059, Part 5
3. International standard for model acceptance test of hydraulic turbines: IEC
60193
 4. Field Acceptance tests to determine the hydraulic performance of hydraulic
turbines, storage pumps and pump turbines: IEC 60041
5. Nut-Bolt calculation: ANSI B18.2.2-1972 and ANSI B18.2.1-1981
6. Shaft coupling: ANSI /IEEE Std 810-1987
7. Shaft Alignment: ANSI/IEEE Std 810-1987

Fig: - Common Base Frame for Mounting Turbine and Generator.

4.3 Governor
For the speed regulation and monitoring purpose we are using digital speed
governing equipment with electronic PID control.

4.3.1 Reference Standard for Governor

1. IEC 60308: International code for testing of speed governing systems for
hydraulic turbines
2. IEEE Recommended Practice for Preparation of Equipment Specification for
Speed Governing of Hydraulic Turbines, IEEE Std. 125.
3. ASME section VIII for pressure tanks
4. ASME Power Test Code, number 29, speed governing system for hydraulic
turbine-generator units.

4.4 Alternating Current Generator

We will be using two synchronous generator of capacity 5500 KW for the power
generation. Further generator will operate at potential difference of 6.3 KV at 50 Hz of
frequency at 750 rpm with 11% Continuous Overload Capacity with Cylindrical Rotor
Poles, Brushless Excitation System and Hydraulic Brakes.
4.4.1 Reference Standard for the AC Generator
1. Bolt calculation:
ANSI B18.2.1-1981: American National Standard or IEC: 60034 or IS 4722,
Square and Hex Bolts and Screws, Inch series
ANSI B18.2.2-1981: American National Standard or IEC: 34 Square and Hex
Nuts
2. Vibrations:
ISO 7919-5 Mechanical vibration of non-reciprocating machines
measurements on shaft and evaluation criteria,
3. Shaft coupling and alignment: ANSI/IEC/IEEE Std 810-1987
4. Test procedures for synchronous machines: ANSI/IEEE 115.1995 IEEE Guide:
Test Procedures for Synchronous Machines.
5. Installation of Horizontal generators and generators motors for hydraulic
applications: IEEE Std. 1095-1989
6. Rating and Performance: IEC 34-1-1992/IEEE C-50.12
7. Voltage Endurance Testing: IEEE Std. 1043/IEEE Std 1553
8. Thermal Cycle Testing: IEEE Std. 1310
9. Measurement of partial discharge: IEEE Std. 1434
10. Methods of determining Temperature rise of synchronous machines : IEEE
guide Test procedures for synchronous machines - IEEE Std. 115-1995
(Section 6)

4.5 Common Oil Pressure System

Common oil pressure system is provided for lubrication purpose of vital moving
parts of turbine and governor. System will use two pumps one will be main and other
standby. For hydraulic turbine generally oil with SAE (society of Automotive Engineers)
32, 42, 68 are used. Viscosity of oil used Ranges from (30-70) 𝑚𝑚2 𝑠 −1 as per the
requirements. We will be using ISO grade 68 turbine oil.
4.5.1 Description of Oil pressure system

Fig: - General Layout of Oil Pressure System of turbine (not followed in our project)

An oil pumping unit is provided for normal & emergency control operations of
turbine Guide vanes and normal operations of main inlet valve & generator brakes.
Pressurized oil is used to control the following equipment.

1) Main Inlet Valve (MIV)

2) Bypass Valve for MIV Valve
3) Generator Brake
4) Air Injection Valve
5) Guide Vanes
6) PRV

Two variable axial piston pumps, one as main and other standby (2.1 & 2.2) are driven
by electric motors (4.1 & 4.2). Check valves (6.1 & 6.2) prevent flow of oil from one
pump to another. Pressure valves (5.1 & 5.2) are provided to relief the excess pressure.
Check valve (16.1 & 16.2 ) maintains the unidirectional flow to the pressure line filter
(15.1 & 15.2), filters are provided with clogging devices which indicates the clogging
locally and also gives signal which is further processes in control panel. Normally one of
the filter remains in circuit and other in standby. Pressure gauges (13.1 & 13.25)
indicate the pressure developed by the pump before filter and manifold pressure
respectively.

Piston type accumulator (17.1 & 17.2) maintains constant pressure in the system
compensating for internal oil leakage. These can be isolated by shut off cum safety
block (18.1 & 18.2). Total effective oil of the accumulator meets the requirements in
case of emergency or pump failure of guide vanes close-open-close operations.

In addition to the two nos. A/C supply driven pump, a hand pump (24.0) is
added for operation during maintenance. Delivery of the hand pump is directly fed to
the system through check valve (23.0). An isolating valve (22.0) is provided to isolate
the hand pump circuit from the system. A pressure relif valve (12.0) provided to relief
excess pressure.

A Manifold block (28.0) is provided to mount the directional control valve and servo
valve. Pressure switch (27.0) is provided to give signal of low pressure on the manifold
block.

Return oil from the emergency control valves directly leads to the sump & other
return lines passes through a return line filter (34.0). In case of filter clogging, a
differential pressure switch fixed with the filter, gives local mechanical indication as well
as electrical signal. A check valve is also provided parallel to the filter to ensure the
return flow even in the severe most condition of filter clogging.

An electrical terminal box (25.0) is provided for pump loading/unloading. A tank

is provided in the system with following monitoring instruments/items mounted in the
oil sump.

1) Level indicator (10.0) to observe oil level in tank.

2) Level switch (8.0) gives the indication in case of oil level goes below/above the
specified low/high level.
3) Temperature gauge (9.0) to observe temperature of oil tank locally.
4) Drain valve (11.0) is used to drain the oil at the time of changing of oil or
cleaning of tank.
5) Quick release couplings (40.1 & 40.2) are provided on tank for connection offline
filter unit.
6) A silica gel with breather (7.0) is provided on the tank to observe moisture from
air entering the tank.
7) Suitable manhole is provided in the tank for cleaning purpose.
8) An anodized circuit plate (42.0) is mounted on the front of the tank which has
the hydraulic circuit diagram printed on it for reference.
9) RTD (38.1 & 38.2) are provided for the measurement of the oil temperature in oil
sump.
4.5.2 Specification of Turbine Oil

ISO Grade 68
AGMA Grade 2
Specific Gravity @ 60°F 0.873
Density, lbs/gal @ 60°F 7.27
Color, ASTM D1500 0.5
Flash Point (COC), °C 243
Viscosity (40 °C) 68 𝑚𝑚2 /sec
Viscosity Index 102

4.5.3 Working Scheme

Below mention are the schemes of operations.

1) Main Inlet Valve Operations

Direction poppet valve (31.1) is provided to control the position (fully open/fully
close) of main inlet valve. Main inlet valve open and close time is obtain through
line mounted throttle check valve (35.1 & 35.2)

2) Bypass Valve for Main Inlet Valve Operation

Directional control valve D.C. valve (31.1) is used to control the position (fully
open/fully close) operation of bypass butterfly valve. Flow control is achieved
through double throttle check valve (30.1) fixed with D.C. valve. The D.C. valve
is a decent type which requires only a pulse to change position of spool and
remains there until next pulse is given to the other solenoid.

3) Brake Operations

The brake mechanism requires low pressure for the operations, which can be
obtained by pressure reducing valve (48.0). Direction control valve (29.2) is
provided for control position of brake. A throttle check valve (36.0) is provided
for flow control during the brake operations. Pressure relief valve (49.0) is also
provided in line to drain excess pressure to the tank in case pressure in brake
line exceeds the required value.

4) Air Injection System

Direction control valve (29.3) is provided for control of air injection device
operation. Flow control is obtain through double throttle check valve (30.2) fixed
with D.C. valve & line mounted throttle check valve (47.0)

5) Guide Vane Operations

 Guide vanes are opened and closed by servo valve (32.0). A set of logic
elements with cartridges (43.1 & 43.2) is provided for emergency closing of
guide vanes which is operated by 3/2 directional poppet valve (31.2). A D.C.
valve (44.0) is also provided for manual operations of guide vanes.

6) PRV
PRV is used to release the excess pressure in the penstock during closing of
guide vanes. PRV control is provided with logic to operate the same in
conjunction guide vane servomotor i.e. whenever the guide vane close at a
faster rate, the pressure in the penstock rises; the PRV shall open till excess
water in penstock is relived. The PRV servomotor is opened and closed by oil
pressure. The direction of oil pressure to the PRV servomotor is governed by the
position of regulating valve which in turn by the pilot servomotor. One no. oil
tank with necessary instrument is provided for the PEV operations through the
use of pilot servomotor and the regulating valve.

4.6 Water Cooling System

A common cooling water system will be provided for 2 units to meet the cooling
water requirement of shaft seal, Generator bearing lub oil & OPU heat exchanger for
each unit. It is purposed to meet the pressure and flow requirements, water shall be
pumped from cooling water sump.

4.6.1 Reference Standard for Cooling Water System

1. ERW Pipe & Fittings should have relevant IS/IEC Standards
a. ASTM A 270 ERW pipes
b. ASTM B 16.3 Pipe fittings (malleable iron threaded)
c. ASTM B 16.39 Unions (malleable iron)
d. ASTM A 105 Grade 2 Valve material
e. IS 1239 Pipe Fittings
2. Valve Flanges:
a. ASME B 16.1 Cast iron valves and flanged fitting
b. ASME B16.5 Steel valves
c. ASTM F998-04 Standard spec(s) of Centrifugal pumps
d. DIN 43760 RTD
Fig: - Layout plan for water cooling system

4.6.2 Application
Cooling water is required for following purpose.

1) Heat exchanger of generator bearing lub oil system

2) Shaft seal
3) Heat exchanger of OPU

4.6.3 Description
For application stated above, pressurized cooling water is required. Water for this
purpose is pumped from cooling water sump. Further 3 nos. centrifugal pump (2 main,
one for each unit +1 common standby) shall be provided. A gate valve at each pump
inlet and outlet shall be provided for isolating purpose, a check valve also shall be
provided to maintain the unidirectional flow. A pressure switch shall be provided at
outlet of each pump to indicate high and low pressure condition.

A pressure gauge shall be provided in common header line for local indication. A
globe valve is provided, which shall be used for regulating the flow. Duplex coarse
basket filter (500 micron) is provided in common header line for coarse filtration of the
water. Normally one will be remain in the circuit and other in standby. Further Duplex
fine basket filter (200 micron) is provided to in common header line. Normally one unit
remains in the circuit and other on standby. Duplex filter are basket type & manually
changeover, back flushing also can be done manually operating the back flushing valve.
A pressure gauge shall be provided after the fine filter in common header line for local
indication. After bifurcation line, a globe valve is provided, which shall be used for
regulating the flow. A pressure switch be provided to give low pressure signal to control
panel. A pressure gauge also provided in line for local indication of pressure.

4.6.4 Control System

A suitable system shall be provided in LT distribution panel which is located in
control room. The motor shall be suitable for 400 V ± 10%, 3 phase, 50Hz AC supply.
Pipe & fitting shall be ERW MS (GI). Various control and check valve shall be cast steel
of pressure rating 10 Kg/𝑐𝑚2 .

4.7 Pressure Relief Valve (PRV)

As this hydropower project use long pressurized pipe line and have no surge
tank, by pass pressure relief valve will be used to avoid the damage due to transient
pressure (pressure wave that is short lived i.e. not static pressure or pressure
differential due to friction/minor loss in flow).

Fig : - Lay out plan for PRV

4.8 Bifurcation
Bifurcation is the section in penstock pipe where the water flow is divided into
two parts for each turbine as we are using two turbines for the power generation.
Image: - Fabrication of Bifurcation

Numbers of sickle plate and stiffener beam are used to withstand the water
hammering effect which we can observe in above image.

4.9 Earth Mat

The purpose of earth mat is to provide earthing system in power house for safty
and functional purpose. Following table shows the design data of earth mat.

Ground length used for design of earthmat (Power House) 34 m

Ground breadth used for design of earthmat (Power House) 24 m
Elevation Difference in 'X' axis 28 m
Elevation Difference in 'Y' axis 11.5 m
MS Flat size (Grid Conductor) 50*6 mm
Equivalent Diameter of conductor (d) 19.5 mm
No. of Galvanized M.S Rod (Vertical rods) 21
Length of each Galvanized M.S Rod 3m
Spacing between conductors 2m
Overall Resistance of earthing system (Rg) 0.09 ohm

Table: - Design Data of Earth Mat

Image: - Section Showing Earth Mat

4.10 Tail Race Gate

Tail race gate is which is used in tail race for flow control purpose. We will be
using uplift mechanism for the gate. Dimension will be (2.3*2.6) m and hosting
mechanism will be electric chain pulley operated.

Image: - Section where tail race gate will be installed

5 Factors Affecting Degradation of Penstock Quality and Measures
to be Followed for Proper Inspection and Repair
Faced with aging assets and limited resources, a more proactive approach is needed to
ensure continued safe and reliable operation of conventional and pumped-storage
hydroelectric powerhouses. One recently implemented strategy to help achieve this
has been the creation of an Asset Management group in many hydroelectric utilities.
This group is responsible for increasing equipment reliability and availability by
improving the underlying business processes used to (a) identify, plan, and execute
projects in a prioritized manner; (b) define and implement best practices for
maintenance across the system; and (c) ensure public and employee safety. The
generic goals established for Asset Management are to:

 Manage the complete hydro asset inventory using current asset condition
assessments
 Identify the highest priority projects based on facts which are used to establish
an asset’s health, risk exposure, etc.
 Manage risk by planning work according to fact-based priorities
 Improve long term planning of project scopes, schedules and budgets.
 Continue to add to the body of knowledge regarding the condition of each asset
and evolve the level of detail used in their assessment.

Specific Governing Code Requirements for structural assessment of in-service Penstocks

do not exist; however, useful guidance does exist and can be found in the following
documents

 Guidelines for Evaluating Aging Penstocks – Task Committee on Guidelines for

Aging Penstocks of the Energy Division of the American Society of Civil Engineer,
1995 Edition.
 ASCE Engineering Practice No. 79 – Steel Penstocks.
 USBR Engineering Monograph No. 3 – Welded Steel Penstocks.
 ASME Boiler & Pressure Vessel Code, Section VIII, Division 2

5.1 Degradation Mechanism Evaluation

Generic degradation mechanisms, for example, as noted in the EPRI's RI-ISI
report [“Revised RiskInformed In-service Inspection Evaluation Procedure,” EPRI TR-1
12657, Revision B-A, December 1999.] include

 Corrosion
 General Corrosion
 Localized Corrosion
 Pitting
 Crevice corrosion
  Under deposit corrosion
 Microbiologically influenced corrosion
 Stress Corrosion Cracking
 Flow Sensitive Mechanisms
 Erosion-cavitation
 Flow accelerated corrosion
 Fatigue
 Mechanical fatigue
 Thermal stratification
 Thermal transients
 Thermal transients
 Other effects
 Overload
 Embrittlement
 Fabrication defects

For penstocks, the prevalent degradation mechanisms are general and localized
corrosion

5.1.1 General Corrosion

Bare carbon steel will corrode, primarily by general corrosion, at a rate
determined by the water chemistry, the temperature, and the flow rate. The corrosion
rate will be influenced the most dramatically by the dissolved oxygen content. For
coated penstocks, corrosion will be essentially nil as long as the coating is intact.
However, all coatings will go into service with some number of holidays (voids in the
coating), coatings have some level of permeability to water, and coating life is often
less than the desired plant life, so that portions of the penstock will become
“uncovered” with time. General corrosion will occur at coating holidays from initial
construction or where holidays form over time. The initiation of corrosion will have been
delayed during the time that the coating has remained intact. It must be noted that the
corrosion rate is not a discrete value, but is represented by a distribution, typically a
normal or lognormal distribution.

5.1.2 Localized Corrosion

Carbon steels can also be susceptible to all forms of localized corrosion, including
pitting, crevice corrosion, and microbiologically influenced corrosion (MIC). However,
localized corrosion is usually far less significant than general corrosion and the
distribution of rates of general corrosion. Further, the existence of the ID coating
dramatically reduces the probability that a localized corrosion can initiate and begin to
propagate. Finally, the flow conditions for the penstock, that is, continuous flow at
relatively high rates nearly 100% of the time, further decrease the probability that
localized corrosion cells can initiate. The probability of localized corrosion is considered
low. Further, the general approach to characterizing general corrosion, specifically, the
use of UT thickness scanning with a relatively small transducer, the reporting only the
thinnest location in a grid, will detect localized corrosion.

5.2 A Case Study of Sundarijal Hydropower Plant Regarding Thickness

Degradation
The required thickness of the penstock is found to be 5.48 mm but from the data
available, the original thickness of the existing penstock pipe is about 6 mm. The
calculation earlier, suggests that the existing penstock pipe can be used for the
modified discharge of 0.79m3/s. From the RLA study of the penstock pipe, thickness of
different blocks varies from 6.0mm-10.5mm, reduced from 13 mm original thickness.
The average thickness of the pipe is found to be about 8.85mm. The graph is plotted
for required thickness (5.48 mm), original thickness (13 mm) and existing thickness.
Fig. 4 shows reduction in the thickness of penstock pipe across the pipe length. But the
thickness is not reduced below required thickness 5.48 mm. This shows that the
existing penstock pipe can be used for upgradation. The thickness of penstock has
reduced from 13mm to 8.85 mm (average thickness) after 82 years. The reduced
thickness is about 4 mm. The required thickness of the penstock is 5.48mm for
upgradation. This shows that existing penstock shall be safe to use for about 30 years.

Fig: - Graph Showing Across the Length of Existing Penstock.

5.3 Inspection of Penstock and Pressure Conduits

The main purpose for implementing a penstock inspection program is to ensure
that each penstock is safely and efficiently operated and maintained. Some of the
benefits that result from regularly scheduled penstock inspections are listed below:
  Improvement of facility and safety of personnel and public
 Prevention of damage to the environment
 Improvement of reliability
 Reduction of operation and maintenance costs
 Minimization of unscheduled outages
 Minimization of liability

5.3.1 Inspection Procedures

The procedures for inspection of a penstock or pressure conduit are listed below
in sequential order:

1) Perform an initial assessment, which includes a thorough visual examination of

the following items: penstock shell condition (interior and exterior), welds, bolts
and rivets, expansion joints and sleeve-type couplings, air valves and vents,
control valves, manholes and other penetrations, anchor blocks and supports,
appurtenances, linings and coatings, and instrumentation.
2) Record penstock shell thickness measurements using non-destructive
examination (NDE) methods (usually ultrasonic) at selected locations along the
penstock. This task could be combined with the initial assessment described
above.
3) Perform a detailed assessment using NDE techniques for specific items of
concern that were observed during the visual examination.
4) Simulate the emergency control system operation to ensure the emergency gates
or valves will close and that documentation (physical test or calculations) exists
to indicate they will completely close.
5) Perform load rejection tests for comparison against hydraulic transient analysis
results and design criteria to ensure safe operating conditions.
6) Readjust the governor to establish a safe wicket gate timing to prevent
overpressurization of the penstock and to ensure maximum response capability.
7) Have design personnel evaluate the data obtained during the penstock
inspection. This evaluation should typically include tasks associated with data
and stress analysis and a determination if the penstock is in accordance with
defined acceptance criteria.

5.3.2 Frequency of Inspections

The inspection frequency may vary from 1 to 5 years, but should not exceed 5
years. Factors to be considered in recommending the next inspection date include:

 Accessibility for inspection

 Overall condition of the penstock or pressure conduit
 Type of design and the age of the penstock or conduit
 Existence of significant public safety concerns
  Existence of significant environmental concerns
 The need to document the condition of the penstock or pressure conduit
 Criticality of the facility to power production and water operations

Once these and other pertinent factors have been addressed, the inspection
frequency can be established. Minimal guidelines for inspection frequency are as
follows:

 Monthly inspection: A visual observation of exposed penstocks should be

performed through a monthly walkdown by operations personnel. If this
observation is not practical because of excessive length, rough terrain, etc., then
the walkdown should be performed at least once a year.
 The interior and exterior surfaces of penstocks and pressure conduits should be
visually examined every 2 to 3 years to note the condition of the linings and
coatings.
 A thorough penstock inspection, which includes the procedures described in
section 5.3.1, should be. Performed every 5 years.

5.3.3 Inspection Records

To establish an accurate representation of the penstock condition at a given
hydroelectric facility, the in-service inspection program must be well documented and
implemented by facility personnel.

A log should be established at the plant to record the date, type of inspection
performed, and results of all inspections performed on penstocks. Inspection results
should be forwarded to the engineering staff or other appropriate personnel for review
and evaluation. These records must be maintained for future reference. A documented
chronology of inspections, results, evaluations, and repairs will help identify the
development of any adverse trends and is essential for the proper maintenance of safe
penstocks.

An inspection report should be prepared by one or more members of the inspection

team. The report shall document the following items:

 Dates of inspection
 Inspection participants
 Names of facilities inspected
 Description of inspection activities
 All technical investigations, data analyses, and design studies
 All recommendations made during or as a result of the inspection
Inspection reports should be distributed to all inspection participants and groups
associated with the facility. The reports should be kept on file by the responsible office
for a minimum of 10 years.

5.3.4 Pre-Inspection Work

The inspection plan is a key element of a successful penstock assessment.
Should include the following items:

1) Scope and goal of the inspection

2) List of personnel involved or required
3) A checklist of the items to be inspected
4) Dates and times of the inspection
5) List of clearance points and equipment to be locked out/tagged out to ensure a
safe penstock inspection

5.3.5 Initial (Visual) Assessment

An initial assessment is performed to determine the current physical condition
and geometry of the Penstock. Information obtained during this initial stage is used to
plan a more detailed assessment at a later date.

5.3.5.1 Penstock Shell

1) Dimensions and Shape

Measurements of the physical dimensions and shape of the penstock should be

undertaken during a field inspection to verify information shown on the design
drawings.

2) Alignment

Penstock alignment should be checked to verify substantial agreement with the original
design drawings. Penstock misalignment could indicate slope movement and settlement
that could cause a penstock rupture if the movements were of sufficient magnitude to
allow joints to open up or rupture to occur.

The inspector should look for signs of misalignment, including cracked thrust blocks,
ovaling of the penstock, and cracks in the earth surrounding the penstock. Pipe
movement may also cause misalignment of bolted sleeve-type couplings. Coupling
misalignment can stress the gaskets, resulting in leakage.

3) Ovalization/Out-of-Roundness

Measurements of the penstock diameter should be taken to determine the penstock

roundness. Horizontal and vertical measurements of the diameter should be taken. A
certain amount of out-of-roundness may be acceptable. If the measurements differ,
indicating ovaling of the penstock, an investigation of the cause of ovaling should be
undertaken.

Thin-walled penstocks are most susceptible to losing their shape and becoming out of
round. However, penstocks with an acceptable wall thickness also can lose their shape.
Some of the most common causes of penstock ovalization are listed below:

5.3.5.2 Interior Surfaces

1) Dewatering

Dewatering is preferred for penstock interior inspection. Caution should be taken when
dewatering a penstock because several problems may occur. For instance, if the grout
curtain at the upstream end of the penstock is not completely effective or if the
penstock has excessive leakage, water pressure can build up behind a tunnel liner or
buried penstock. Water pressure on the outside of a buried penstock or tunnel liner
could become high enough to buckle the penstock after dewatering. If this condition is
a possibility, the penstock can be dewatered slowly to allow the external water pressure
to decrease before a problem develops. Another potential problem to be aware of is a
clogged vent line (or a closed valve on the vent line) at the upstream end of the
penstock. Excessive negative internal pressures could develop when attempting to
dewater, which may result in collapsing or buckling the penstock.

If dewatering is not economically or technically feasible, i.e., if the penstock was not
designed for this condition, a submersible remote operated vehicle (ROV) might offer
one feasible method of inspecting the interior. Use of remote-controlled video
equipment or penstock-inspecting robots is relatively new technology. These devices
can perform inspections rapidly and safely inside slippery, steeply inclined penstocks.
Internal paint, rust, and erosion conditions are monitored on an external cathode ray
tube (CRT) linked to a camera mounted on the inspection unit. However, use of an ROV
may not be as effective as performing a hands-on inspection after dewatering of the
penstock. An ROV inspection may be of limited use if turbidity of the water causes poor
visibility.

2) Linings

The penstock interior may be lined or unlined. A penstock lining will hide any defects or
cracks in the steel. Look for areas of distress in the lining, such as stretching or broken
areas, which could indicate further problems such as cracks in the base metal hidden
underneath the lining. The present condition of the lining is important to the longevity
of the penstock. Even small areas of pinhole leaks or degraded lining will allow water to
seep between the lining and the base metal, trapping moisture and increasing the rate
of corrosion. The presence of rust or stains indicates that the lining is not performing as
intended. The inside surfaces of the penstock should be examined to verify that the
original surface is smooth and that the lining, if present, is intact. The condition of the
inside surface or lining affects head loss. The lining should be examined to verify that it
is protecting the penstock structural material. A determination should be made if any
lining is missing or if the surface is rough or smooth. If operating conditions have
caused layers of deposits, like calcium carbonate, that have been allowed to remain in
place, a determination should be made as to whether such deposits are detrimental to
the base metal underneath.

3) Organic Growth

The interior surfaces of the penstock may have become fouled with organic growth over
a period of time, thus restricting water flow. Also, marine organisms such as freshwater
clams or zebra mussels can reduce hydraulic capacity of a penstock.

4) Corrosion, Erosion, and Cavitation

The degree of erosion and corrosion, as well as the condition of the lining, are
important. Erosion or cavitation inside the penstock can be caused by turbulent water
(typically occurring at discontinuities and bends), high velocity, or scouring damage
caused by abrasive material carried in the water (typically occurring along the penstock
invert). Mismatched surfaces at inside joints should be checked to verify their integrity.
Corrosion can occur on the inside of a penstock. Pinhole leaks may occur at any
location, although general corrosion and deep pitting is more likely to occur in relatively
horizontal penstock regions and in crevices. Also, look for rust streaks or discoloration
which may indicate penstock deterioration. The extent of wall thinning caused by
uniform corrosion and erosion may be difficult to measure visually, so further testing
may be necessary to determine the average wall thickness.

5.3.5.2 Exterior Surfaces

Preferably, the exterior surface of the penstock is inspected while the penstock is
under hydrostatic pressure and in operation to aid in observing leaks. Before starting
the inspection, all debris or slides covering the penstock should be removed. Any
leakage observed should be investigated and the source identified. Leakage must be
evaluated immediately upon discovery by appropriate personnel and, based upon the
severity, should be repaired at the first practical opportunity.

1) Coatings

Penstock coatings will hide any defects or cracks in the steel. Look for areas of

distress in the coating, such as stretching or broken areas, which could indicate further
problems such as cracks in the base metal hidden underneath the coating. The present
condition of the coating is important to the longevity of the penstock. Even small areas
of pinhole leaks or degraded coating will allow water to seep between the coating and
the base metal, trapping moisture and increasing the rate of corrosion. Small rust
blisters or stains could indicate small pinhole leaks caused by pitting, leakage past
rivets, etc. The coating should be examined to verify that it is protecting the penstock
structural material.

2) Corrosion

Corrosion can occur on the outside of a penstock. Pinhole leaks may occur at any
location, although general corrosion and deep pitting is more likely to occur in relatively
horizontal penstock regions and in crevices. Also look for rust streaks or discoloration
which may indicate penstock deterioration. The extent of wall thinning caused by
uniform corrosion may be difficult to measure visually, so further testing using
ultrasonic techniques may be necessary to determine the average wall thickness.

3) Localized Buckling

Localized circumferential buckling is an indication of longitudinal overstressing of the

penstock. This phenomena only occurs if inadequate provisions have been made for
expansion and contraction. This defect is most commonly caused by thermal changes
that affect a section of penstock between two fixed points, such as anchor blocks. This
phenomenon is most likely to occur when the penstock has been dewatered and the
ambient temperatures exceed the penstock's normal operating temperatures.
Therefore, dewatering of the penstock for prolonged periods must be avoided during
the warmest seasons of the year.

4) Voids in Backfill or Concrete-Encased Penstock Sections

For buried or concrete-encased penstock sections, voids may be present in the backfill
or concrete. The external pressure from surrounding ground water in the area of these
voids can cause the penstock shell to partially collapse in the form of an inward bulge.

Voids in backfill are typically caused by ground-water erosion of the backfill material
near the invert of the penstock. Prolonged erosion of the backfill can undermine the
penstock foundation, leading to differential settlement and potential failure. This type of
defect can usually be detected by striking the penstock shell with a hammer at multiple
locations and listening for a hollow sound.

Voids in concrete are caused by poor consolidation of the fresh concrete during
concrete placement or by the trapping of excess water in the concrete "bleed water"
near the penstock invert. Typically, these type of voids are localized and relatively
small. However, voids large enough to cause damage to the penstock can occur. The
detection of voids in concrete is similar to the detection of voids in backfill.
5.3.5.3 Penstock Supports
1) Ring Girders

Ring girders, which are used to support long span elevated penstocks, are constructed
by welding steel plate rings to penstocks. All loads are transferred from the penstock to
the ring girder and support legs. The support legs are welded to the ring girder, then
attached to bearing plates. The bearing plates are attached to a concrete foundation.

Ring girders should be visually inspected for signs of deterioration and distortion.
Inspection of ring girders should also include the condition of the .coatings. The
potential for premature coating failure is greater at ring girders than at adjacent smooth
penstock surfaces because ring girder surfaces are irregular.

Often, ring girder supports must allow penstock movement caused by changes in
temperature. This movement is usually accommodated in bearings located under the
support legs. -Rocker, roller, and low friction slide bearings are commonly used for ring
girder support. The bearings should be inspected to verify their integrity. They should
be clean and well maintained to allow full penstock movement throughout the full range
of design temperatures. Clean, well maintained bearings will help minimize forces in the
penstock and anchorages.

2) Saddle Supports

Saddle supported penstocks typically span shorter distances between supports than ring
girder supported penstocks discussed above. Stress concentrations occur at the tip of
the saddle where "horn stresses" result in the penstock shell becoming unsupported.
Saddles are usually constructed from reinforced concrete and support the lower 120-
degree arc at the penstock invert. However, saddle supports may also be fabricated
from rolled steel plate. Sheet packing that may be lubricated with graphite can be used
as a cushion between the saddle support and the penstock. The sheet packing also
permits limited movement of the penstock relative to the support as a result of
temperature changes.

If required, the penstock shell at saddle supports is stiffened by welding steel rings to
the shell at each side of the saddle support.

Saddle support inspection should include a coating inspection and inspection for signs
of deterioration and high stress areas similar to ring girders. Localized buckling or
distortion can occur at the penstock's upper contact points with a saddle support. In
addition, the condition of the concrete saddles should be noted and investigated for any
signs of settlement or concrete deterioration. Inspection of the surfaces between the
saddle and the shell is difficult, but important, because significant corrosion may be
occurring in the contact area.
3) Anchor/Thrust Block

Anchor/thrust blocks are designed to provide restraint to exposed penstocks at changes

in alignment. They should be assessed to verify their support function has not been
compromised. Thrust blocks should be examined for signs of settlement and movement
and for any cracking or spalling of concrete

4) Unrestrained Joints (Expansion Joints and Bolted Sleeve-Type Couplings)

Unrestrained joints include expansion joints and bolted sleeve-type couplings. Typically,
unrestrained joints are not working if any water is leaking past the seal or if the joint is
seized. Look for leakage, cracked welds, base metal flaws, loose or missing bolts, and
heavily corroded areas. In unrestrained joints, scrape marks or unpainted surfaces may
be visible where the pipe has moved in relation to the follower ring.

5) Welded Joints

A representative portion of all structural welding performed on the inside and outside of
the penstock is visually examined for signs of rusting, pitting, or other structural
defects. For welded joints, look for cracked base metal or welds, surface flaws, etc.
Flaws in welds during construction can occur from high carbon content of the base
material, embrittlement of the heat affected zone, improper preheat, and improper rate
of cooling after welding. Typically, these problems are more likely to occur as the plate
becomes thicker or when the joint is made under adverse construction conditions

6) Stiffener Rings

Look for flawed welds, including undercut, base metal flaws, and heavily corroded
areas.

7) Penetrations

Penetrations would include items directly attached to the penstocks and exposed to the
internal pressure carried by the penstock. Some examples of penetrations are:
manhole, air vent connection, filling line connection, etc. Look for damaged or missing
parts, cracked welds, cracked or broken castings on valve bodies, broken or missing
bolts and rivets, heavy corrosion, and leakage from gasketed joints, packings, flanges,
couplings, and manholes. Check the surface of all penetrations for distortions, cracks,
and other defects, paying particular attention to the welds or riveting used for attaching
such parts and their reinforcement.

8) Drains

Penstock dewatering drains, located typically at low points along the penstock profile,
should be examined to verify that they are in working condition and are not leaking.
Valves that control these drains should be examined. Overtightened packing gland bolts
could lead to bolt failure and packing gland rupture. Also, the drains must safely
discharge water away from the penstock to prevent undermining of the penstock
foundation during dewatering.

Drainage systems for penstocks that are located in tunnels should be checked, if
possible, to verify proper operation. Drainage systems that are installed to relieve water
pressure against the penstock, thus protecting the penstock from possible collapse, can
become blocked over time. Blockage consisting of debris or waterborne minerals such
as rock fines or calcium can render the drains ineffective. The drains should be
maintained and cleaned on a regular basis.

9) Appurtenances

Appurtenances, which include bifurcations, transitions, bends, tees, elbows, and

reducers, may be particularly susceptible to vibration, aging, and lining loss. Look for
damage to the lining, cracked welds, loose or missing rivets, damage from cavitation,
broken tie rods, and heavily corroded areas. Casting defects, which include porosity,
cracks, slag, and sand, may also be present.

5.3.5.4 Operating Equipment

Penstock operating equipment includes standpipes and vent pipes, surge tanks,
gates, and valves, including bypass valves, filling valves, shutoff valves, piezometer
taps, and air valves.

1) Standpipes and Vent Pipes

Standpipes and vent pipes are usually located at high points along the penstock
profile and immediately downstream from gates. They should provide unrestricted
air inlet or air release to the penstock. In cold climates, the pipes should be
inspected for ice blockage. Standpipes and vent pipes should be inspected regularly
to verify they have not become blocked.

2) Surge Tanks

Surge tanks are installed to limit pressure rise and fall in penstocks. Surge tanks are
fabricated of steel plate, wood, or reinforced concrete.

Surge tank assessment must consider the type of surge tank, condition of tank
coatings and linings, and tank mechanical appurtenances. Surge tanks often have
roofs and vents that can become blocked similar to standpipes. The condition of the
ladders, handrails, grating, and other surge tank access equipment should also be
noted.
 3) Gates and Valves

Gates are normally provided to shut off water flow to the penstocks and are usually
located at the upstream end of the penstock. Penstock installations incorporate
many different types of gates to control flow into the penstock.

Because most gates are of steel construction, assessment techniques used for
inspection of steel penstocks may be appropriate. Inspectors should pay particular
attention to the condition of the coatings. Gate seals, which are often fabricated
from rubber but are also fabricated from alloy metals, tend to wear out. The
condition of the seals should be noted and the amount of leakage past the
emergency gates while in the closed position should be noted and documented.

Bypass, filling, and shutoff valves are often installed in penstocks for the purpose of
filling, dewatering, or redirecting flows. Butterfly, globe, and gate valves are typical
for bypass and shutoff applications. In addition to coating condition, assessment
should include the condition of the valve operators, packing glands, and moving and
stationary parts that may experience wear.

4) Piezometer Taps

Piezometer taps are typically located in the penstock several pipe diameters
upstream from the turbine and are used to measure flow. The taps, which are often
forged steel pipe couplings less than I inch in diameter, are welded through the
penstock shell; four taps located 90 degrees apart are common. The taps are often
equipped with petcocks or gate valves and are connected by copper tubing to a flow
measuring location in the powerhouse. Assessment should include verifying that the
piezometers are not blocked and that the taps, tubing, and valves are not leaking.

5) Air Valves

Air and vacuum release valve assemblies are installed along the penstock to vent air
to and from the penstock under service conditions and also during penstock filling
and draining. To permit isolation and servicing, air and vacuum relief valves are
normally equipped with a ball, gate, or butterfly shutoff valve. Malfunctioning of
these air valves could result in penstock rupture if, for example, they are installed to
mitigate transient pressures. Thus, assessment of air and vacuum release valve
assemblies must verify they are not plugged, restricted, or leaking, and that they are
operating properly and are in good working condition. In cold climates, the valves
should be protected from freezing. Where employed, heaters should be operational.

5.3.5.5 Vibration
Penstocks should be assessed for both flow-induced and equipment-induced
vibrations. Resonant vibrations can cause material fatigue and may cause penstock
problems if not corrected. The penstock should be inspected while operational, and
operators or maintenance personnel should document abnormal vibration. If excessive
vibration appears to exist, instrumentation should be used to record vibration frequency
and relative amplitude.

5.3.5.6 Geotechnical Considerations

Frequently, vegetation growth and changes to the area adjacent to the penstock
alignment affect the penstock and its foundation. Drainage can become restricted.
Adjacent soil and rock slopes move or settle. Topographical and alignment information
should be collected.

The inspector should note the type and location of penstock joints and any noticeable
misalignments. Span distances and ground elevations between penstock supports
should be checked and compared with the as-built drawings. Frequently, joint leakage,
distortion, or misalignment can indicate other problems that might require further field
and analytical evaluation.

Penstock foundations should be assessed for deterioration and movement. Foundation

movement may cause structural distress along the penstock itself. For example,
foundation settlement can overstress steel penstocks with welded steel joints that are
supported by steel ring girder foundations.

5.3.6 Detailed Assessment

A detailed assessment is only required if information obtained from the initial
assessment indicates an area of concern. Information obtained during the initial stage is
used to plan a more detailed assessment. Based upon this information, the base
material and welds of certain steel components may require examination with
appropriate NDE techniques. Destructive testing methods may be required in some
instances but should be avoided if possible.

The following NDE techniques may be used to evaluate discontinuities in the base
material or welded joints of the penstock shell and its various components:

1. Liquid Penetrant Examination (PT) - A PT is used to detect small flaws such as

cracks and pores which are open to the surface of the material being inspected.

2. Magnetic Particle Examination (MT) - An MT can detect cracks, porosity,

seams, inclusions, lack of fusion, and other discontinuities in carbon and low
alloy steels.

3. Radiographic Examination (RT) - An RT is used to detect porosity, inclusions,

cracks, and voids in the interior of castings, welds, and other structures. An RT
provides a permanent film record of defects that is easy to interpret.
 Radiography is limited by the direction of the discontinuity and accessibility, and
the film process is very slow and expensive.

4. Ultrasonic Examination (UT) - A UT is used to detect surface and subsurface

discontinuities. Ultrasonic examination can locate all internal flaws located by
other NDE methods. A UT allows very accurate detection, location, and mapping
of discontinuities within base material, welded joints, and heat affected zones.

5.4 Penstock Evaluation

Once the initial and detailed assessments have been completed and all the
pertinent data obtained, a penstock evaluation should be performed by a qualified
individual with substantial experience in analyzing and designing penstocks or pressure
conduits. The following analyses should be performed:

 Lower bound allowable stress determination

 Lower bound wall thickness determination
 Lower bound joint efficiency determination
 Maximum pressure at critical locations determination
 Stress analysis of related penstock components (shell, joints, supports, anchor
blocks, etc.)
 Factors of safety determination
6 Guidelines for Operation and Maintenance of Hydropower Plant
Operation and maintenance manuals, instructions and guidelines are all the
same. Basically, they are the directives for users, i.e., operators/ maintenance
personnel of the structures, equipment, instruments, accessories, etc. However,
while the manuals/ instructions are prepared specifically for specific equipment by
manufacturers/ suppliers, the guidelines being prepared by the regulatory authority
or on its behalf for general reference purpose and for standardization purpose of the
operation and maintenance activities, in no way, can be substitute for manuals or
instructions for operation and maintenance provided by the concerned
manufactures. It should also to be noted that the hydropower station equipment are
custom built, which cannot be fully assembled or tested at manufacturer’s shop.
Hence, they need to be tested after erection at the powerhouse; and records of
actual performance of the equipment including their operation characteristics need
to be established. It is to be kept in mind that this guideline is not a new invention,
but drawn mostly from existing norms, guidelines and engineering practices taking
also into account the prevalent O & M practices in Nepal. Due to absence of
appropriate provisions in Nepal Standard for O & M of hydropower plants, sub-
stations and transmission line, this guideline will refer to Indian Standard wherever
it is relevant keeping in mind that Nepal Integrated Power System will be connected
with Indian System in the coming years.

Any guidelines including the present one are to be taken as a dynamic process and
should be updated periodically as new O & M procedures and technologies are
developed and employed. The present guidelines has been formulated in an easily
understandable manner to help the operation and maintenance crews based on
collection and compilation of related information about O & M management and
technologies, which have been formulated by the developed utilities in many years.
The source of information is vast; hence, the process of making the guidelines
should not stop here but continue in future as well.

6.1 Operation of Hydropower Plant Facilities/Equipment (Starting

the System)
The operation of hydropower plants comprises: (i) operation of hydro-
mechanical works such as gates, stop logs, valves, etc. to regulate the
discharge through turbines, (ii) operation of generating equipment such as
turbines and generators, and (iii) synchronization into a Grid (Power supply
system). A number of checks are to be done particularly before starting the
machine. The general checklists for this purpose are as follows:
 For mechanical works:
a) At intake, check:
 bypass gates,
  position of intake gate,
 Power supply to gates.
b) At power plant, check:
 AC power for pump operation,
 HP compressed air,
 locking pin position,
 level and pressure in OPU (Oil Pressure Unit),
 spiral drain valve is closed,
 D.T. drain valve is closed,
 position of strainer valves ensure water flowing in cooling
pipes,
 gland seal valve open,
 air seal valve closed,
 top cover drain system okay,
 levels in pressure accumulator and oil sump of OPU system,
turbine gear bearing, lower guide bearing (LGB), upper
guide bearing (UGB) and thrust bearing,
 penstock pressure and pressures at spiral casing after
opening of MIV (Main Inlet Valve), OPU, stator cooling
water, thrust bearing, UGB, LGB, sealing water pressure and
air pressure for brakes
 working systems: top cover drain, oil leakage unit, oil
cooling unit, oil pressure unit, brakes, position of CO2
batteries, guide vane lock (on or off), jacking dejacking of
m/c, flow relays, emergency slide valve reset and working of
ventilation system.
 For electrical Works:
a) General checklist:
 DC system,
 Grid power,
 DG set power,
 Event logger, and
 Disturbance logger.
b) Check list for generator:
 brake system,
 cooling water for bearings,
 generator firefighting, if applicable,
 AVR condition, DC supply for field flashing,
 oil levels in bearing, IR values, jack position, and
 HP lubrication system, earth link for bus duct.
 c) Check list for transformers:
 cooling water system, firefighting system,
 transformer cooling oil pump position, Buccholz relay,
 oil level in conservator, color of silica gel, and
 IR of winding and core, BDV (Breakdown Voltage) of
transformer oil.
d) Check list for switchyard:
 compressed air in case ABCBs are used,
 SF6 gas pressure in case SF6 breakers are used,
 earthing switch position,
 Isolator position-close, Breaker position-off, and
 Line isolator position.

Note: Check lists given above are for starting of the machine after long shutdown. If
the starting of the machine is to be done after a short shutdown, certain checklists such
as position of stop log gates, AVR condition, IR values, Jack position, earth link for bus
duct, IR of winding and core, BDV of oil are not required. This applies for Black Start
as well, but black start is done without relying on external transmission network (i.e.,
using Diesel Generator or other power source). This aspect is dealt in the NEA Grid
Code.

The following are the activities to be carried out for operation of the hydropower plants
after the general check-up as mentioned above:

 For intake gate opening, check intake gate power supply and hoisting system,
give raising command and check gate position in raised condition.
 For Inlet Valve Opening, put oil pumps on ‘auto’ mode, open bye-pass valve
manually or give opening command to by-pass auto valve, check water pressure
on spiral side, and then give opening command to inlet valve on equalized
pressure.
 For turbine operation, put oil pumps on ‘auto’ mode to maintain required
pressure in pressure accumulator, check availability of Nitrogen cylinder and
check also pressure of the same for systems using compresses nitrogen, check
air pressure for maintaining proper oil level in pressure accumulator (if provided),
open cooling water for bearings, open shaft seal water, put brake on ‘auto’
mode, unlock guide vane lock, fix GV (Governor) opening limit, and put machine
on ‘auto’ mode.
 For generator operation, select AVR Auto/Manual mode as required, keep
firefighting system operative (where provided), switch on DC supply for
excitation flashing, at 30% of generator voltage DC supply from battery cuts off,
 at 90% speed switch on generator excitation (if not on auto), start machine on
‘Auto’ or ‘Manual’ mode as required.
 For synchronization, check grid voltage and frequency, check generator voltage
and frequency, reduce or increase generator voltage & frequency to match with
line voltage & frequency, put synchroscope in ‘ON’ position. Needle will start
moving and lamps will start glowing. Needle on 12o clock position and lamps on
dark position indicate that voltages and frequencies of grid and generator
respectively are matching, at equal grid & generator voltage and frequency,
close generator breaker, now generator is synchronized with grid, and then take
minimum prescribed load immediately.
 For checks after synchronizing and taking load, unit control board supply is
changed to Unit Auxiliary Transformers, Change excitation from “manual” to
‘Auto mode, transformer “Motor for cooling water supply” started, all parameters
in control room are matching and correct, and general checkup for machine and
other unit auxiliaries at all floors.

Following are the checks to be carried out at the “Time of Shift Change Over (Machine
Running on Load)”:

General: Check lighting, ventilation and air conditioning, check water levels in Forebay
& Tailrace channel, check availability of discharge, check communication systems, check
instructions and status of various equipment and work permit/shut downs/ breakdowns,
check general cleanliness of the area, equipment and control panel etc., check all
indication lamps are glowing, check with test push button that all fault indication lamps
are ok, physical check of all sub-distribution boards installed in the Power Station, check
all inlet exhaust fans are working, check all batteries are physically in good condition
and check battery chargers are in normal working conditions. Check operation of all the
installed instrumentations whether they are functioning correctly or not.

Turbine and Generator: Check temperature of thrust bearing, upper guide bearing
and lower guide bearing, check in normal working condition of cooling water flow and
pressure of all bearings at inlet & outlet, sealing water flow and pressure top cover
drainage system, stator cooling water flow & pressure and grease pump; check oil level
in housings of all bearings, check if there is vibration or abnormal sound in OPU pumps
and check grease in the container of centralized grease lubrication system; check
working of OPU pump 1 & 2, OLU pump, drainage pump & dewatering pumps, governor
compressor, general – purpose compressor, and cooling water strainers; check running
& vibration of machine and ensure nothing is abnormal, check water, oil and air flow
indicators, and check the physical appearance of various system such as manholes,
valves, indicators, etc.
Generator, AVR & Excitation System: Watch running & vibration of machine and
ensure nothing is abnormal, check for any sparking from the brush of slip ring, check
temperatures of winding and core (ensure that these are within limit), check that all
instruments and indicators mounted on unit control board, governor panel and AVR &
excitation panel are in ok condition, check for any abnormality, sound chattering in
busduct, and neutral cubical.

Control Room: Check that all parameters indicated on various panels are matching, all
indicating lamps are glowing (also check annunciations are ok), check movement of all
pointers & reset them, check all instruments mounted on panels are in working order,
check all relays are reset, check rear of all panels and mounting on this side for OK
condition, check emergency lighting system is ok, check position of circuit breakers for
outgoing lines, and check grid voltage & frequency.

L.T. Room: Check all indication lamps are glowing, have general look on instruments
and relays mounted on board, check various switches are in correct position, and check
whether supply to various distribution boards are ok.

DC Distribution Board, Battery Charger & Battery Sets: Check DC voltage is

correct, check batteries are in healthy condition, check DC supply is healthy by making
momentarily float off (this would ensure that batteries are connected with load), check
both batteries are in float, check all the switches on board are in correct position, check
that both chargers are functioning correctly, and check all cells of battery functioning
correctly, and check all cells of battery bank are healthy (their specific gravity and cell
voltage are correct. It should be done in morning shift only).

Main Transformer: See that oil level in conservator is OK and there is no leakage
from anywhere, check that oil pressure and water pressure are normal, check that oil
temperature and winding temperature are normal, check silica gel colour is normal, see
that oil and water flow indicators are normal, carry out checks of compressor and power
for healthy condition of Multi-type System (wherever applicable).

Switchyard: Have general look at switchyard including bus bars, jumpers etc. Ensure
that there is no sparking anywhere and everything is in order, check compressed air
system in case of ABCB is ok (if provided), check SF6 gas pressure in case of SF6
breakers and check position of all breakers, isolators & line isolator and cast a look on
all CTs, PTs, LAS, surge counters, wave traps and coupling capacitors, reactors and
capacitors and ensure that everything is in order.

Following are the routine maintenance to be carried out during each shift:

 Cleaning of all panels, instruments, and equipment installed in power station.

 Oiling and greasing of all equipment as per the manufacturer’s instructions.
  Topping up of oil in bearing, OPU sump.
 Replacement of lamps, fuses etc.
 Cleaning of trashracks.
 Inspection of forebay, bye-pass gates, intake gates.
 Draft tube gates and appurtenant works, and
 Any other works as assigned.

Note that inspection and observation carried out during each shift shall be logged daily
in control room log book. Also check the speed of the turbine which is displayed by
ratemeter and tachometer generally.

6.2 Black Start & System islands

Black start is the process of restoring an electric power station or a part of an
electric grid to operation without relying on the external transmission network.
Normally, the electric power used within the plant is provided from the station's own
generators. If all of the plant's main generators are shut down, station service power is
provided by drawing power from the grid through the plant's transmission line.
However, during a wide-area outage, off-site power supply from the grid will not be
available. In the absence of grid power, a so-called black start needs to be performed
to bootstrap the power grid into operation.

To provide a black start, some power stations have small diesel generators, normally
called the black start diesel generator(BSDG), which can be used to start larger
generators (of several megawatts capacity), which in turn can be used to start the main
power station generators.

Total System Black Out: The system is said to be under total black out when
all Regional utility generation has ceased to operate and there is no supply from
external interconnections to the Western grid and it is not possible for the total system
to function again without black start.

Partial System Black out: Blackout of a particular constituent system either

partially or fully or of more than one constituents’ systems.

System islands: In case, part of the system is separated from the grid due to
system splitting or through defense schemes and operates independently, it is called
System Islanding.

Normal System Conditions: System will be declared to be normal when all

islands are re-connected, all emergency and essential loads restored and adequate
transmission restored enabling States to draw their scheduled requirements.
6.3 Guidelines for Maintenance of Hydropower Plants
The following periodic inspection checks that are recommended for maintenance.
The components covered by the inspection checks are (i) civil structures, (ii) hydro-
turbines and auxiliaries, (iii) generator components, (iv) power transformers, and (v)
hydro-mechanical equipment and hoisting arrangement. This section also deals with the
capital maintenance or overhauling that requires dismantling and reassembling of
hydro-generating unit(s) along with the typical maintenance encountered in the hydro-
turbines.

6.3.1 Maintenance of Civil Structures

6.3.1.1 Dam/Weir and Headwork Structures

There are no legislations, guidelines, national practice codes on Dam Safety in
Nepal, which should strictly be followed. The first dam (19 m high Phewa Dam located
near the city of Pokhara) of Nepal failed in 1975 due to piping in its foundation. It was
reconstructed and completed in 1983. This newly constructed dam consists of concrete
spillway portion and concrete abutment besides the earth-fill portion. The spillway with
4 gates has a total discharging capacity of 1,000 m3 /s, the power and irrigation intake
capacity has 8 m3 /s. For power generation at full load of 1000 kW requires 2 m3 /s of
water and irrigation facilities for 320 ha of land are provided. As the dam is located at
the outlet of Phewa Lake, erosion of ogee portion of the spillway due to silt flow is
minimum in this dam as against the eroding experiences found on the ogees of the
weirs of the run-of-river projects operating in Nepal. Some longitudinal cracks occurred
on the dam crest of 114 m high dam on Kulekhani river when for the first time the
storage reservoir level reached its Normal Water Level (NWL) in November 1983 are the
next event faced by the storage dam component of the civil structures of hydropower
plants existed in Nepal. As soon as this event occurred, a team of experts was invited
for inspection. The observations of the inspection were as follows:

 A noticeable longitudinal crack was seen in the centre of the crest parallel to the
dam axis nearly along the whole dam crest. Opening of this crack was variable.
It had maximum width of about 15 cm in the middle and was narrowing
towards both the abutments;
 In addition to continuous crack in the centre of the crest longitudinal cracks
were also seen on both the upstream and downstream shoulders of the dam
crest. However, opening of the cracks on the upstream shoulder was greater
(maximum about 15 cm) than that of the cracks on the downstream shoulder
(maximum about 5 cm); and
 Leakage water gauge was showing that the leakage quantity was decreasing
from 55.79 l/sec at reservoir level 1530.074 m (on Nov. 9, 1983) to 48.9 l/s at
 reservoir level 1529.076 (on Dec. 29, 1983), and the leakage water was
completely clear.

The inspection team based on these observations concluded the following:

i) The longitudinal cracks must have been resulted from differential settlement of
different material zones of the dam body; and

ii) Clear leakage water is the indication of the absence of transverse cracks in the core,
thus, the cracks were considered to be not dangerous. However the team suggested
the following:

a) To seek services of an international consultant with relevant experience in

this field for receiving suggestions to take appropriate measures, and

b) Some improvement in the monitoring system.

Later on, an international expert (Mr. I. L. Pinkerton), who had provided his services an
independent expert at several stages of construction of this dam was invited. During his
visit to the site, a trench of about 3 m depth was opened on the dam crest to examine
the crack.

It was found that at this depth the crack was bifurcating and was slightly dipping
towards upstream. However, the opening width of the crack was decreasing quickly
with increment in the depth. According to suggestion made by Mr. Pinkerton the cracks
in the core were filled with betonite and since then the dam has no problem in this
regard. Nearly same time, noticeable cracks and signs of movement were seen on the
hill slope behind the intake gate control shaft. A possible landslide at this place could
block the intake and endanger the safety of the dam as well. Japanese specialist from
Nippon Koei also visited the site. The following remedial works were carried out
according to the suggestions made by Mr. Pinkerton and the Japanese experts:

 Extensive surface drainage were provided;

 Opening of the cracks were filled with clayey soil;

 Removal of the upper sliding mass was carried out; and

 Sliding mass located just behind the intake gate shaft was provided with suitable
anchoring into the bedrock.

After treatment of this landslide, monitoring was carried out several years, which
indicated that the above mentioned measures were appropriate. A sloping intake as
well had to be constructed under KDPP (Kulekhani Disaster Prevention Project) at the
side of the Kulekhani-I Dam due to the reason that there was possibility of
encroachment of the existing intake by increased sedimentation caused after the
rainstorm of 1993 July. The sloping intake constructed was virtually an inclined shaft
structure with full opening which shall be closed by concrete stop logs one by one from
the bottom depending on the actual sediment surface elevation around the intake. The
Mandu head pond and intake structure of Kulekhani-II HPP that was also completely
destroyed by the debris flow containing numerous boulders occurred during the same
flood event. For Kulekhani-II operating in tandem with Kulekhani-I, besides covering
the destroyed headpond of Mandu intake with concrete structure, monitoring of the size
of riverbed of Khani Khola was initiated in order to take up the counter measures in a
timely manner against (i) closure of the tailrace outlet due to rising of the river bed,
and (ii) inundation of the Kulekhani-II power station and switchyard by flood from the
water level rise due to rising of the river bed. For existing dam as described above the
maintenance/remedial measures are taken case by case based on events occurred
rather than scheduled type maintenance, while for the weirs/ headworks of the run-of-
river type hydropower plants, the scheduled maintenance works relevant particularly for
the Nepalese context being performed consist of the following:

 Epoxy and magma quartz coating application in ogee surface;

 Underwater repair/concrete works at radial gates;
 Protection of sliding down of rip-raps on the river banks during rainy season by
Way of construction of gabion walls;
 Repair works such as high strength concreting on the downstream of
undersluices/replacement of plum concreting of downstream apron with RCC
apron and construction of cut off wall at the end;
 Removal of sediment/boulders from intake zones and from downstream of
undersluices;
 Gabion protection works for flood control;
 Strengthening of foundation of desanding channel outlets;
 Painting works, if necessary.

6.3.1.2 Conveyance System

Generally the maintenance/ cleaning and repair works to be performed relevant for the
water conveyance system are as follows:
 Open Canals: Rarely the power canals are unlined, because they suffer from
erosion of the banks, from subsidence of cuttings in sidelong ground, and from
obstruction by floating debris and siltation. Such canals are only suitable for very
small interceptions. Maintenance of such canal consists largely of keeping the
channel clear of debris, patching the banks, and encouraging the growth of
vegetation on the exposed slope cuttings. By the judicious use of fences in
vulnerable areas, the effect of drifting and debris may be minimized. In general,
the maintenance of open power canals should include inspection of blockages.
Any stones, silts or vegetation should be removed from the canal. It is important
to repair any damage as soon as it appears. If leaks are not attended to, they get
worse and sometimes wash away the ground that holds the canal. Drainage to
carry rainwater away from canal should always be inspected and cleaned or
 repaired as necessary. Any repair and/or maintenance of the canal should not go
beyond the original design of the canal itself.
 Aqueducts: Aqueducts could, both, be open and closed. The open aqueducts,
lined or unlined, will have the same problem as it is in the open canals. The
comparatively high maintenance cost of open aqueducts has led in recent years
to adoption of piped aqueducts. Erosion and floating debris problems scarcely
arise on piped aqueducts, but for inspection purposes fairly frequent manholes
must be introduced together with catch pits to intercept rolling stones and sand
which seem to find their ways into any and every form of aqueduct. The catch pits
require clearing out by the maintenance squad at least once a year, and the
pipes should be swept through at the same time. The manholes, in conditions of
severe frost introduce a problem of their own - there is often a little water in a
piped aqueduct, this water will probably freeze, and with the thaw long strips of
quite thick ice will start to float down the aqueduct, these often become wedged
at a manhole, resulting in a blockage and overflow with consequent erosion
around the manhole, which may endanger the foundation. The design of
manholes, as is the provision of light baffles to guide floating ice, is receiving
special attention for locations of such climatic conditions. The piped aqueducts
may have been laid in trenches or above ground on stools. In case the pipe is
laid above ground on stools, care must be taken to ensure that local hill water
does not undermine the stools, and in case, where the pipes appear partly above
ground, there must again be adequate drainage to prevent any ponding against
the pipe. These points should be checked periodically by the maintenance squad.
The maintenance squad should also attend the patching of concrete in pipes,
pipe supports and manholes in addition to the internal and external paint works, if
any.
 Desanding Basin, Forebay and Daily Pondage: If the desanding basin forms an
important part of hydropower scheme as it is the silt tank and device for excluder
of silt that determines the wear on the turbines, the forebay/daily pondage have
also their own roles to play. There is evidence of siltation even in the daily
pondage reservoirs, e.g. the removal in quantum ranging from 10,000 to 12,000
m3 of silt per year from the daily pondage reservoir of Chilime hydropower plant
has been reported. For the desanding basin other than adoption of proper silt
flushing through operation of the upstream and downstream gates by following
the operation manual, it requires very little maintenance. The occasional repair of
concrete gates and flushing passage and other civil structures may be carried out
in the suitable time. Flushing valves/gates may need attention, as there are
moving parts, which need to be lubricated about once a week. The trashrack
contained in the forebay will need maintenance of clearing as it is here that all the
water borne vegetation and floating debris is prevented from entering the
penstock. During rainy period it may be necessary to clean even twice a day. For
the trashrack cleaning special device might have to be installed.
 Tunnels: A tunnel should receive comparatively frequent inspection especially
during its early life say at the end of the first year’s use and again after two more
years. As a result of these inspections it should be possible to forecast the period
that may reasonably allowed to lapse until the next inspection may well be five
years in the case of a normal-sized tunnel under moderate pressure, while the
large sized tunnels really subjected to high pressures, should be inspected more
frequently. The draining, inspection and refilling of the tunnel is normally
organized by the station or area superintendent, but much of the detailed work
and organization will fall to the maintenance squad. The maintenance foreman
 must be fully acquainted with the procedure and with details of the time that
should be taken over emptying and filling.
When emptying/dewatering a tunnel, it must be borne in mind that natural ground
water and water that has seeped out of the tunnel into the rock will tend to return
to the tunnel; hence if pressure in the tunnel is allowed to fall too rapidly, external
pressures may cause serious damage to tunnel linings, particularly to the
comparatively flat inverts of horseshoe or D-shaped tunnels.
A tunnel can usually be filled a little more quickly than it is emptied, but
reasonable time should be given for stresses to distribute themselves and for
temperatures to settle down and, on a long length of tunnel on an easy gradient,
the rates of filling must be slow enough to ensure that there is no violent surging,
resulting in the trapping of air and roof slapping. It is quite easy to do serious
damage to the tunnel roof by filling too quickly.
At the tunnel intake there must be an adequate air shaft downstream of the main
gate. This shaft usually vents into the gatehouse which should have ample
louvers and, during tunnel filling, all the doors and windows of the gatehouse
should be properly opened, or they may easily be damaged by bursts of trapped
air escaping from the tunnel.
If there is a steel pipeline at the downstream end of the tunnel, the early stages of
filling should be carried out with the utmost care so that the pipeline is stressed
gradually and is not subjected to violent temperature .changes. A by-pass valve
at the tunnel intake, for use in filling the pipeline, is a useful adjunct, as it is very
difficult to ensure that a large main gate is cracked open by the very small
amount that is usually necessary.
The maintenance gang will play an important part in the tunnel inspection and
should be equipped with powerful electric or paraffin pressure lamps giving a
diffuse light and not a beam. A complete and accurate record should be made of
all apparent damage to the tunnel lining; even small faults may increase very
quickly and become serious, and any points where water is seeping or running
into the tunnel should be noted. Clear chainage markers in the tunnel are of great
assistance in locating defects, for comparison after each inspection.
If on inspection it is found that some remedial work is necessary, it is usual,
unless the work is very obviously of a vital nature, to refill the tunnel and continue
generation of power until all the necessary stores, tools, etc., have been got together,
and until the area generation program has been adjusted to allow for a
prolonged shut-down of the tunnel concerned. It is unwise to start on the repair
with incomplete stores and equipment in the hope that the balance will be
forthcoming. The planned approach leads to better and more economical work,
and affords the opportunity of adding minor repairs to the major program,
including the cleaning out of sumps, repainting of the main gate, etc.
 Pipelines/Penstocks: Refer chapter 5 for maintenance of penstock

It is to be noted here that in the 6.2 MW Puwa Khola Hydropower Plant there is not
only a threat to the penstock alignment especially during rainy season, but also the
water leakage due to crack development at the head tank/forebay due to fragile
geology in the vicinity. In such case, the penstock alignment must be always under
close watch along with all possible measure with crack filling, repair works with high
strength concrete in the head tank/forebay, improving the penstock support blocks,
constructing saddle supports, etc. such problems, however, require a thorough
geological investigation.
6.3.1.3 Powerhouse Structures
The major items to be attended and necessary repair works undertaken during
maintenance of powerhouse structures are leakages, river and slide protection works in
the vicinity and regular painting of powerhouse building.

6.3.1.4 Tailrace
The tailrace is usually lined with concrete for a short distance, to a point where
the greatest turbulence has subsided. Up to this point, maintenance is usually very
light, but thereafter, in the original river bed, some minor trouble may be expected.
The tailrace lining usually consists of a base slab and concrete retaining walls.
The tops of the retaining walls should be sloped to avoid any standing puddles, which
may result in crazing. Adequate weep holes are necessary and should be extended a
few inches from the face of the wall to avoid unsightly staining.
Screens may be provided in the tailrace to prevent fish or any other animals
swimming into the machines, in which case efficient tackle is necessary for lifting the
screens for periodic cleaning. Though the tailrace screens are covered by the intake
screens, it is surprising how much trash reaches them. It is every bit as important to
keep tailrace screens clean as it is to maintain free passage through the intake screens.
Owing to fluctuating load on the turbines, conditions downstream are not as they
were in nature. The greater floods may have been abolished or much reduced by the
reservoir (if the plant is with the reservoir), but the equivalent of a minor flood occurs
each time load is taken up quickly by the power station; so that these minor floods are
frequent and have an unnaturally rapid rise and fall, which may easily lead to scouring
of the river bed and banks to an objectionable degree and for surprisingly long distance
downstream of the station.

6.3.1.5 Specific Inspection of Civil Structures

The specific maintenance check of civil structures and of surrounding protection
works / areas for crackers, settlements, instabilities, etc. needs to be carried out after
monsoon, earthquake and/or GLOF (Glacial Lake Outburst Floods) in order to take
timely the remedial measures. Similarly, monitoring of discharge at all the streams and
adits before and after water filling is to be done.

6.3.2 Maintenance of Hydro-turbine & Auxiliaries

Routine Inspection and Maintenance

The following daily, weekly, monthly, annual and five yearly inspection checks are to be
done for the routine maintenance of hydro-turbines & auxiliaries.

Daily Maintenance Checks:

S. Items/Components/parts Checked for

No. to be checked
1 Foundation gallery parts and Any leakage in draft tube manholes, spiral
expansion joints casing manhole, expansion joint, cooling water
tapping.
2 Vacuum Breaking Valve/ Air The working of vacuum bearing valve and see
Admission Valve (if provided) that there is no abnormality in the springs,
seals, etc.
3 Water Seal i. The position of leakage of the seals and see
that there is no excessive splashing and water
level do not rise in top cover.
ii. Note the water pressure of water sealing.
4 Turbine guide bearing i. Oil levels (stand still machine/running
machine).
ii. Note the temperature of bearing and check
that the temperature of oil and guide bearing
pads are within limit.
iii. Note the maximum and minimum
temperature and compare with readings of the
previous day.
iv. Any oil leakage from the bearing housing
and check that oil is flowing above the bearing
pads.
v. Check cooling water system and oil coolers.
5 Guide apparatus i. Any leakage from GV (Governor) servomotor
and its piping
ii. Guide vane link breakage.
6 Oil Leakage Unit i. Any leakage from pipe line joints.
ii. Satisfactory running on "Auto"
7 Tap cover drain system i. Main supply "ON".
ii. Vibration/ noise in the pump motor
iii. Any leakage from the water piping
iv. Working and water pressure of the ejector.
8 Centralized Grease i. Any leakage from grease pipes, unions and
Lubrication System nipples.
ii. Grease container is filled with grease.
9 Oil pressure System i. If there is any abnormal sound in the running
of the motor and pump unit of OPU.
ii. The oil level in pressure accumulator and oil
sump.
iii. Any oil leakage from oil piping and its
valves.
iv. Oil level recorders as also oil film in the
tailrace.
v. Overheating of motor.
vi. Note the timing of OPU pumps running and
compare with previous day running hour. Any
increase in leakage in the system can be
 watched.

Weekly Maintenance Checks:

S. Items/Components/parts to Checked for:

No. be checked
1 Greasing of Guide vanes and i. Grease in the grease container.
servomotor with centralized ii. Any leakage.
grease lubrication system and iii. Working of end pressure relay and
manually. solenoid valves, if defective, should be
reported.
2 Throttle filters Cleaning of throttle filters (if provided) in
the governor mechanical cabinet.
3 Governor Compressor air Cleaning of governor compressor air filters
filters and checking of oil levels.
4 Oil of OPU of the running Checking physically oil of OPU of the
machine running machine after taking sample
through sampling cock, do the crackle
test for detecting presence of water. Take
remedial measures.
5 All the bearings Oil level of all the bearings.
6 Coupling flanges and oil Check working of shaft at coupling flange
header servo tube. and at oil header servo tube.
7 Cooling system Any leakage.

Monthly Maintenance Checks:

During monthly maintenance checks, all the checks covered in weekly

maintenance checks as indicated above are carried out, but while carrying out these
checks more attention is paid and short shutdowns (if required) for rectification are
taken.

Annual Inspection and Maintenance:

After successful running of plant for about one year, few weeks are required to
be allocated to inspect rotating parts, control equipment and measuring instruments,
etc. and analyse cause of change in the performance characteristics (if any).
Modify/repair/replace, whenever required, the worn out parts in order to prevent forced
outage of machine at later date.

Following inspection and checks should be carried out during maintenance:

S. Items/Components/parts to Checked/ inspected for and remedial

No. be inspected and checked measures taken
1 Water Path Parts i. Condition of water path system. The
damage due to cavitations and wear to be
rectified.
ii. Painting of spiral casing, penstock, draft
tube.
iii. Condition of stay vanes, guide vanes and
under water parts for wear, tear, etc.
2 Runner i. Condition of the surface of the runner
hubs, cone, blades and buckets. The
damages due to cavitations and wear to be
rectfited by welding and grinding. It is to be
ensured that hydraulic profile of the blades
is not disturbed.
ii. The runner blade seals to be checked by
pressurizing the system, change seals (if
necessary).
3 Guide Apparatus i. The pressure of rubber sealing cords and
the tightness of the rubber sealing between
the adjacent guide vanes in fully closed
position of guide apparatus (wherever
provided).
ii. Guide vane bedding in fully closed
position.
iii. Change grease in the regulating ring.
iv. Replace damaged shear pins.
v. Check cup sealing of guide vane journals
and replace (if necessary).
vi. Check the bushes of guide vanes and
change the worn out bushes of guide vane
journals (if possible).
vii. Water jets, needles, deflectors and their
servo-mechanism (if the turbine is Pelton).
viii. Inspect the servomotor and change the
seal (if these are worn out).
4 Guide Bearing i. The condition of rubbing surfaces of guide
bearing. Clean the surface and polish it with
the help of chalk powder.
ii. Adjust the clearances by moving the
segments with the help of adjusting bolts.
iii. Thorough cleaning of housing is
necessary.
iv. Check all the RTDs and TSDs, replace
damaged ones.
5 Shaft Gland Seal and i. The condition of rubbing surface of sealing
Air Seal rings. In case found damaged, change the
same.
 ii. Pipe lines and piping joints for leakage. If
found any, attend the same.
6 Emergency Slide Valve i. The functioning of emergency slide valve
and the condition of inner surface.
ii. Swift return of the valve in its original
position after emergency operation should
also be checked.
7 Centralized Grease Satisfactory working of CGLS system and
Lubrication System attend wherever fault is located.
8 OPU i. Leakage and attend leakage (if any) from
any valve or flanged joints, etc.
ii. Provide proper lubrication to the bearings
of pump motor.
iii. Filter and repair, if required.
iv. Clean oil sump, refill with centrifugal oil.
v. Setting of the pressure relays for proper
sequence of operation of pumps.
9 Oil Leakage Unit i. The satisfactory working on auto as well
as manual.
ii. Clean the tank.
iii. The pipeline joints and valve for leakage,
attend wherever necessary.
10 Oil Cooling Unit i. All the oil and water pipe lines for leakage
and attend if necessary.
ii. The satisfactory working of all cooling
unit.
11 Governor Mechanical i. Filter the throttle; replace the same if
Cabinet (if applicable) found damaged.
ii. Attend leakage of oil through pipe line
joints and valves.
iii. Auto rod setting. Set the same, if found
disturbed.
iv. Alignment of feedback wire rope pulleys.

Five Yearly Maintenance:

After every five years it is necessary to inspect / check the machine more
critically for Abnormalities like fatigue defects for excessive wear and tear of some parts
or any change in Original parameters/clearances, etc. This exercise becomes very
essential in cases where Performance level has been observed to have gone down in
five years of operation.

Capital Maintenance
Capital maintenance or overhauling of hydro-turbine set is usually done after
about 10 years of operation or as and when necessary. During this maintenance, the
whole unit is to be stripped off and all the defective/worn out parts/ components
repaired/ replaced with new ones. Then the unit is re-commissioned as per originally
established commission practice of the power plant. After capital maintenance, the units
are subjected to all the periodic maintenance outlined in above sections before it
reaches the next cycle of capital maintenance. Following checks are to be exercised
during capital maintenance of hydro turbine set.

S. No. Items Checks to be exercised

1 Turbine Bearing i. Dismantling, inspection, cleaning, measurement of
clearances, polishing of guide pads, centering of shaft,
reassembly, setting of clearances, filling of oil sump with
filtered oil.
ii. Checking of the temperature sensing device. Replace
with new ones, if necessary.
2 Gland Seals and Dismantling, inspection, cleaning and reassembly.
Isolating Air Replacing of worn out rubber flaps or carbon segments,
Inflated if necessary.
Seals
3 Guide Vane Dismantling for inspection and cleaning. Reassembling
Servomotor and replacing the seals with new ones, if necessary.
4 Guide Vanes Bush Dismantling, cleaning and inspection for wear and tear,
Housing replacing with new ones, if found necessary. Replace
seals as well, if necessary.
5 Guide Vanes i. Guide vanes are reconditioned and proper bedding in
closed position is ensured.
ii. Repair of guide vane journals to remove ovality.
iii. Alignment of complete guide vane with all journals.
6 Governor i. Cleaning and checking OPU pumps. Replace bushes,
bearings, etc., if found worn out. Attend also the pump
motors.
ii. Clean OPU sump and pressure accumulator and refill
with filtered oil.
iii. Attend oil pipeline flanges and valves for leakage.
iv. Check setting of pressure switches installed for Auto
operation for OPU pumps.
v. Attend Governor mechanical cabinet (if provided) for
leakages, loose links. Clean main and pilot slide valves.
Set Auto rod as per designs. Alpha Beta setting may also
be checked in case of Kaplan turbine.
vi. Check electrical circuit. Tightening of all the
connections should also be done.
7 Under Water Parts i. Inspect condition of spiral casing, runner chamber,
draft tube cone, compensating ring and draft tube, and
rectify defects by welding and grinding.
ii. Penstock filling line valve, spiral drain valve, draft tube
drain valve should also be checked and repaired.
iii. Cleaning and painting of penstock, spiral casing and
 draft tube liner.
8 Runner i. Dewatering of draft tube.
ii. Fabrication of platform in the draft tube for inspection
of runner chamber/static labyrinths.
iii. Inspect blades/ buckets of the runner and make up
profile by welding and grinding, if found damaged due to
erosion and cavitations. After weld repair, heat treatment
and dynamic balancing is must before installation.
iv. In case the runner is found to be irreparable, arrange
to replace the same with new one.
9 Turbine Auxiliaries i. Drainage pump motor set for top cover drain.
Inspect top cover drain system, overhaul the ejector
and drainage pump.
Check pipelines and valves. Replace gasket and other
parts, if necessary.
ii. Oil cooling unit
Overhaul cooling pumps.
Attend all the valves and pipe line for leakage.
iii. Centralized Grease Lubrication System.
Overhaul greasing pump.
Check whole greasing lines. Replace worn out valves
and gasket, etc.
Check all the nylon pipes connected with the guide
vane bushes. Replace damaged pipes.
Check that all the guide vanes are receiving grease
properly.
iv. Clean Water System
Clean water pipes are dismantled, cleaned,
reassembled with new gaskets.
All the valves are attended for any leakage.
v. Oil leakage unit.
Check the oil leakage unit and overhaul the pumps.
Clean tank and check that float is properly working.
Check all the pipe lines and valves for leakage.

6.3.3 Typical Problems in the Maintenance of Hydro-turbines

The typical problems in the maintenance of hydro-turbines encountered are
damages in runner chambers and runners due to erosion, cavitations & cracking, failure
of turbine bearings and leakage of water through guide vane seals and turbine gland
seals etc. They are discussed in the following paragraphs.

Erosion

The damages in runners, chambers, guide vanes and other underwater parts
have assumed serious proportions especially in the Nepalese context due to
predominance of run-of-river hydropower plants in the Nepal Power System. The rivers
of Nepal carry enormous silt loads particularly during summer monsoon so much, so
that the power stations had to be closed down to prevent serious damage to the
turbine parts and the water conveyance system. Even with greater attention being paid
to desilting arrangements, heavy damages have been observed on the runner, labyrinth
seals, guide vanes, inlet valves, shaft seals and draft tube cone. The wear due to silt
occurs so fast that the unit has to be taken out for reconditioning every few years. The
remedy appears to lie in effective desilting arrangements and manufacturing of turbine
parts with harder and erosion resistant materials like stainless steel of proper grade. In
the Chilime hydropower plant (22.1 MW), even in the peaking pondage reservoir in the
water conveyance system enroute to powerhouse, sediments used to be trapped. The
annually removed sediment from the pondage reservoir amounted in the range from
10,000 to 12,000 m3 per year.

Cavitations & Cracking

The phenomenon of cavitations occurs due to the vaporization of flowing fluid in

a zone of excessive low pressure. Normally the discharge side surface of buckets or
blades, areas on the crown on the throat ring and the tip of blades and the upper
portion of draft tube liver are affected by the action of cavitations. The problem of
cracking of runner and pelton buckets can be due to (i) faulty design and fabrication,
(ii) poor metallurgy, and (iii) metal fatigue. In order to minimize cavitations following
steps are appropriate:
 Annually inspect the runner and other turbine parts and take remedial measures.
 Operate the machine as per the instruction given by the manufacturers. Mind
that the unit should not be run below certain specified load to avoid cavitation
prone zones.
 Cavitations can be effectively controlled at the design stage itself by way of
ensuring proper submergence, use of cavitation resistant material and adoption
of optimized runner profile based on model test.
 Vibrations, excessive noise and cavitations are also experienced as a result of
draft tube pulsation and surges at no load or part gate opening. For minimizing
the pulsation of the draft tube, the following measures are to be taken:
o Air admission through air admission/vacuum breaking valve installed at
top cover.
o Provision of fins of flow splitter in draft tube to break the vortex flow.
o Provision of a by-pass arrangement for releasing the pressure built-up
below the top cover

Failure of Turbine Guide Bearing

A number of cases of turbine guide bearing failures have come to notice

depending upon types of guide bearing designs (plain water cooled bearing, bath type
bearing and grease lubrication bearings). In the case of plain water cooled bearing,
either ferrobestos or rubber lined pads are used against a welded shaft sleeve. The
ferrobestos lined bearings have given considerable trouble at one of the power plants in
India and these had to be replaced by rubber lined pads. Complaints of excessive oil
splashing have been recorded about the rotating bath type bearing, while the grease
lubrication bearings have a tendency to clog when in contact with the water and it is
very essential to use grease with the right type of properties.

Shaft Gland Seals

Two types of shaft gland seals (i) carbon or ferrobestos segment (ii) Rubber flap
are generally in use. The maintenance of rubber flap type gland seal is simpler and
easier over the carbon or ferrobestos segment. Only the precaution to be taken during
assembly of rubber gland is to see that the jointing of the rubber seal is done in the
proper way. It is, however, to be noted that the quality of rubber used plays a very
important role for satisfactory performance of the rubber gland. The shaft sleeve should
also be checked, it should be circular and smooth and properly secured on the shaft. In
case of carbon or ferrobestos segment type of shaft gland seals, the seal segments are
housed in stuffing box, which being always in touch with the shaft is subjected to
excessive wear and tear. The overhauling of the staffing box becomes necessary when
it is observed that consumption of cooling water has considerably increased or
excessive water in top cover appears to be coming. Normally the maintenance of this
type of seals is required to be done annually. In the event of breakage or damage to a
carbon segment, it is advisable to replace the whole set of carbon segments. In very
rare case only, the damaged segment is replaced. Whenever reassembly of the gland
seal with existing gland ring or new ring is done it is important to ensure:
 All carbon/ferrobestos segments are carefully examined for any chipping or
damage.
 All stainless steel facings are flat and square with the gland sleeve and there are
no steps at the facing joints.’
 Stainless steel facing and sleeve are completely free from grease.
 Ensure proper bedding of segments with shaft sleeve.
 All segment to segment and segment to stainless steel mating surfaces are
perfect.
 All garter springs are assembled to obtain even tension all around.
Alignment of segments in the lower assembly is carefully checked with a hard
 Wooden peg or similar device before fitting retaining pins.

Guide Vane Servomotor

In the guide vane servomotor, main source of trouble is rubber cup seals, which
need to be replaced after a few years. Normally rubber seals are replaced during capital
maintenance. It is important that all the parts are match marked before dismantling so
that reassembly is correctly done.

Governor

Governors are of four types (i) mechanical (ii) governor employing magnetic
amplifier (iii) governor employing electro-hydraulic amplifier, and (iv) digital governor.
The digital type of zthe governor is maintenance free and fast response modern day
governor, while the other three types of governor may require maintenance because of
the following reasons:
 Chocking of oil parts and throttles.
 Wearing out of throttles due to which oil leakage becomes more and
readjustment of governor becomes essential. In this case, governor should be
opened and all the throttles, etc. should be cleaned. Filters also should be
cleaned, and after cleaning and reassembly, governor parameters and
characteristics should be readjusted so that there is no hunting of the governor.

Governing Oil System

The normal problem, which had been faced in different hydropower stations, is
entry of water in the governing oil system particularly from top cover through oil
leakage pumps which caters leakage of servomotor oil. Its sump being located well
below the level of servomotors in the top cover may not be properly sealed, thus
providing access to the top cover water which may ultimately delivered to the OPU
sump. To eliminate this problem the oil leakage unit delivery should be isolated from
the OPU sump and connected to a separate tank.
The oil sump should be properly cleaned and filled with filtered oil. The oil
samples should be got tested for verification of the desired properties. Regular
centrifuging of oil with the help of De-Laval type oil purifying machine would go a long
way in enhancing the life of the oil. In certain case, oil retained its properties even up
to 15 to 20 years of continuous use. During annual overhauling, the OPU sump and
pressure accumulator should be completely emptied and cleaned. The strainers should
be inspected and repaired, if necessary. The OPU pumps require maintenance when
they develop excessive noise or vibration. This may be due to some worn out bearing,
screw/impeller and body of the pump, which would be replaced. Sometime oil level in
sump is found decreased which may be due to system leakage in the system. This
requires to be attended.

6.3.3 Maintenance of Generator & Auxiliaries

6.3.3.1 Routine Inspection and Maintenance
The following are the hourly, daily, weekly, monthly, quarterly, half-yearly and
yearly maintenance checks to be conducted on the generator components.

Hourly Maintenance Checks

Hourly maintenance check is done to keep the temperature record on log sheet for core
and winding, hot and cold air of the stator. Similarly, the temperature of Thrust Bearing pad
and oil as well as the same of Guide Bearings are measured by RTD & TSD and recorded on log
sheets. The checking of the temperature of cold & hot water of oil pipeline / external oil cooling
system is also done on hourly basis to keep record on log.

Daily Maintenance Checks

The daily maintenance checks are normally done for the following:
S. No. Assembly / Item Check for Remarks / Remedial
 Measures
1 Stator / Core i. Abnormal noise around stator i. Checking for core
through periodic listening looseness especially at the
ii. Temperatures through frame joints. If abnormal add
temperature scanners additional paramax paper in
core joints.
ii. Check cooling system.
2 Stator winding/ Winding temperature through Check cooled air & cooling
stator coils temperature scanners system.
3 Guide & Thrust Bearing temperature by R.T.Ds Abnormal vibrations,
Bearing / Bearing Balancing of rotor,choked oil
Pads coolers, contaminated oil,
bearing clearances.
4 Bearing Oil/ Oil Gauge level is checked visually i. High –due to water
Level leakage.
ii. Low – leakage of oil from
Housing.
5 Air coolers / Water leakage is checked Plug the leaking tubes
cooler tubes Visually
6 Slip ring and Check visually sparking mix of Cleaning
brushes / Dust / oil
Brushes
7 Brake and Jack / Check by pressure gauge Check for leakage pipe line,
Air Pr. joints.
8 D.C. exciter / Check visually commutation
commutator
brush gear
9 Brushless Check by periodic listening: Checking for core looseness
excitation system Abnormal noise around stator
/ AC exciter and
rotating Diodes

Weekly Maintenance Checks

The weekly maintenance checks are done for the following:

S. No. Assembly / Check for Remarks / Remedial Measures
Item
1 D.C. Exciter: Visually check for accumulation of Smoothen collector surface clean,
i. Cooling ring dirt and pitting. compare IR value
ii. Brushes Sparking, chattering, wear and Brushes are not sticking in their boxes
iii. Commutator Clearance adjust Brush.
Rough or high spot on commutator/
smooth surface
2 Brake / Lining Air leakage, excessive wear Attend leakage / check air pressure,
Visually clean track, change lining.
3 Brake / Track Clean liners & oil sludge / Clean Drain Trap and clean Brake
Moisture trap visually Track

Monthly Maintenance Checks

The monthly maintenance checks are done for the following:
S. No. Assembly / Item Check for Remarks / Remedial
measures
1 Slip ring & Brush Clean the brush rocker, brushes, Special care be taken to
Rocker slip rings and surrounding areas clear carbon dust from "V"
shaped insulation pieces
fitted between slip rings.
2 Slip ring and Check distance of brush holder
Brush Rocker from slip ring and keep it as
specified in the drawing
3 General i. Blow with compressed air the To be cleaned, if necessary
internal surface of the generator.
ii. External inspection of current
carrying leads; PMG (Permanent
Magnet Generator), Bus Bars,
Terminal Blocks, Panels, etc.
iii. Check the condition of lighting
inside the barrel
4 Oil Pipe Line i. Check the operation of the
electrical contact pressure gauge.
ii. Check conditions of gland
packing of the pump and see that
air is not being sucked into the
system.
iii. Check the operation of D.C.
pump motor set (if provided)
5 Stator Core/Back Check visually Adjust core packing of jack
of stator core screws, insert paramax
paper.
6 Field winding / Check visually or through filter Clean through compressed
Field Coil top Gauge air.
7 DC exciter/ Check visually Replace brushes, clean
commutator, Brush commutator and risers.
gear, Air filter Clean with detergent
solution. Dry the same.

Quarterly Maintenance Checks

The quarterly maintenance checks are done for the following:

S. Assembly / Check for Remarks / Remedial Measures
No. Item

1 Slip ring/ Brush i. spring tension i. Use a precision spring balance for
Rocker ii. Check pitting and adjusting spring tension. The carbon
grooving slip ring. brushes can be used till it is not
iii. Check carbon brushes possible to measure / adjust spring
for absence of pitting and tension.
severe wear and tear. ii. In case of excessive grooving
rectify by grinding.
iii. In case the damage is excessive,
replace complete set.
2 Guide Bearings Analysis of oil from oil bath Record to be kept
3 General Check connections of
current carrying leads &
cables. Tighten the bolts, if
required after removing
the insulation.

Half-Yearly Maintenance Checks

The half-yearly maintenance checks are done for the following:

S. No. Assembly / Item Check for Remarks / Remedial measures
1 Stator i. Visual inspection of the Cleaning to be done such that
overhang parts of the stator the dust does not collect inside
winding. machine.
ii. Checking of the fixing of
winding, condition-winding
joints with bush bars, etc.
iii. Clean the winding with dry &
clean compressed air.
2 Slip ring and i. Check IR value of rotor Keep a record.
Brush Rocker through slip rings before &
after cleaning slip rings.
ii. Check all fasteners of slip
rings, brush rocker & current
carrying lead
3 Thrust Bearing Analysis of oil from oil bath Record to be kept.

Yearly Maintenance Checks

The yearly / annual maintenance checks are done for the following:
S. No. Assembly / Item Check for Remarks /
Remedial
measures
1 Stator i. Check overhang parts of stator winding, bush paramax paper
bars, inner periphery of stator core (if possible), glued with epoxy
parts of stator winding in slots (specially at varnish and core
sector joint) binding & spacers between the bolts retightened.
winding bars/ bandage rings. After repairs spray
ii. Check looseness or overhang bush bars slot the top & bottom
wedges, etc. packs with loctite -
iii. Check the fixing of stator active iron (core) 290.
with the frame body in all possible places,
Tighten the studs of pressing plates, if Check visually for
necessary. contaminations
iv. Check pins & fixing of stator with and clean with dry
foundations. compressed air.
v. Check D.C. resistance, IR and PI Value Check visually
vi. Check functioning of RTDs of stator. cleanliness and
vii. Blow the windings, active iron and bandage general condition.
rings etc. with dry & clean compressed air. Then clean the
viii. After cleaning apply Redgel coat on the end windings.
overhang.
ix. Joint bolt tightness and dowel pins of the
 frame.
x. Tightness of the core
xi. Core duct
xii. Stator winding
2 Rotor i. Check rotor winding and insulation condition 1. Carry out
of current carrying leads. additional wedging
ii. Check the condition of interpolar connection. if required.
iii. Check the condition of damper winding. 2. In case, the
iv. Check the locking of pole wedges. wedges are
v. Check locking of rim wedges loose,contact
vi. Check the gaps of spider arms, brake tract. manufacturer
vii. Check tightening & proper locking of all before attempting
fasteners. any rectification.
viii. Clean rotor from dust by blowing 3. Keep a record.
compressed air free from moisture.
ix. Measure DC resistance and IR value of rotor
winding.
x. Check the pole coils for inter turn fault.
xi. Rotor assembly (tightening of fasteners) –
tighten all the approachable fasteners on rotor
assembly including tightening pole and rim keys
& local all of them.
xii. Check the rotor gap.
xiii. Check vibration.
3 Slip Ring & Brush i. Interchange polarity of slip rings. 1. While cleaning
Racker ii. Carry out thorough cleaning of slip ring area. avoid using
Stop oil leakage in this area. insulating paint
iii. In case the original insulating enamel is removers.
peeling off remove the balance enamel and 2. If the slip ring is
apply fresh enamel running out, correct
iv. Check visually general conditions and it. Any grooves etc.
cleanliness. to be removed
by oilstone,
grinding or turning
to
prevent excessive
sparking. All the
insulated parts are
to be cleaned by
dry compressed air.
4 Thrust Bearing i. Measure insulation resistance of T.B. disc.
ii. Check calibration of the TSD’s & RTD’s of
thrust bearing.
iii. Check the working surface of thrust bearing
pads, scrapping, if required, should be carried
out with respect to T.B. disc after applying lard
(animal fat) on the pads and giving rotation to
the unit. Load sharing on T.B. pads and the
verticality of the unit is to be checked thereafter
iv. Check visually the condition of weld seam of
oil bath & oil pipe lines for leakage.
v. Check the condition of insulation of RTD
leads.
5 Guide Bearing i. Measure insulation resistance of G.B. pads. 1. If the pad
ii. Check calibration of TSD’s & RTDs of GB. clearance has to be
iii. Measure and record guide bearing reset the shaft must
 clearances. be centered first.
iv. Check bearing insulation and vapor seal 2. Replace
insulation by measuring IR value. insulation, if
v. Check each pad for (a) absence of scratch needed.
marks (b) heavy damage on bebbit surface of 3. Full set is
pads replaced from
vi. Check the friction surface of the bearing spares
journal. 4. Carry out its
vii. Wash pads & journal with aviation petrol polishing, if
and then carry out assembly of the guide necessary.
bearing. 4. Oil bath is to be
viii. Check the condition of welding seems of oil finally flushed
bath & leakage from them and oil pipe lines. with fresh turbine
ix. Clean all inner surfaces of oil bath, wash oil to be discarded
them with kerosene and dry with clean cloth. after use.
x. Check operation of the level relay and its
calibrations.
xi. Check welding of pad support block with oil
bath.
xii. Check looseness of pad and pad support
bolts.
6 Air/Oil coolers i. Visual and pressure test in the cooler tubes. 1. Clean inside &
ii. Check water boxes for clogging by opening outside of tubes.
them. Check for any tube
iii. Check the gasket between oil cooler and oil leakage by
bath & between air cooler and stator frame. pressurizing to a
pressure slightly
more than
maximum expected
working pressure.
2. In case of
clogging, clean with
wire/nylon brush.
Remove all dirt, etc.
& finally clean with
fresh water & dry.
3. Gasket to be
replaced, if
necessary.
7 Upper and Lower i. External inspection 1. Tightening of the
Brackets ii. Check fixing of the generator cover plate. lock nuts in the
iii. Check all fasteners of upper and lower air radial jacks, if
baffles. required.
iv. Check the value of air gap between air 2. These gaps are
baffles and rotor. to be compared
v. Clean the brackets of dir& dust. with original values
vi. Check fastening between upper bracket & and
stator and foundation plates. maintained as such.
vii. Check foundation bolts tightening for stator 3. Cleaning can be
and lower bracket. done more
viii. Check all fasteners for locking / tightness. often if possible.
8 Overhauling of i. Check thickness of brake pad. 1. Record is to be
Brake system. ii. Check if excessive brake dust is generated maintained.
and find its cause. 2. Clean the
iii. Check function of the breaking system on affected areas.
manual and auto and the operation of limit 3. Record is to be
 switches of brakes. Check leakage through maintained. In
pipelines during braking. case of any
iv. Check the condition of brake track and its problem brake
holding with the rotor. panel
v. Open brake-cum-jack assembly. Clean the & brakes are to be
inner surface of dust with kerosene and checked & rectified.
reassemble. 4. Replace the
vi. Brake limit switch. gasket, if required.
5. Proper operation
and cleaning.
9 General i. Check the vibrations at TGB (Thrust Guide
Bearing), UGB & LGB (Lower Guide Bearing) at
predetermined points.
ii. Check the calibration of all electrical
measuring instruments.
iii. Check the sensitivity and stability of
generator electrical protection scheme.
10 Oil pipe line i. Completely clean the oil tank & T.B. oil bath. Separate oil sample
ii. Clean the oil pipe line after disconnecting it. for each
iii. Check the operation of the valves of the pie bearing should be
line. sent for
iv. Check all sample for acidity, viscosity, chemical analysis &
moisture content foreign material & sludge- record to be kept.
formation.
v. Clean holes for oil entry into the
T.B. housing
11 HP Lubrication Inspect bearing & grease. Check the condition Replace the hoses,
system of the hoses as well. if necessary.
12 PMG/ Air Gap General condition & cleanliness. Check air gap,
Winding clean the stator &
field windings.
Check the open
circuit voltage and
if less than
specified, re-
magnetize.
13 Shaft run out & Readjust, if
centering & rotor necessary
level
14 Water flow relays, Visual inspection Clean water
flow indicators & passages, if
flow meters necessary, remove
silt, check
movement of flap
and electrical
contacts.
15 Electrical Electrical joints by way of tightness Tighten all electrical
connections joints.
16 Generator Check for proper operation
Auxiliaries
17 Cooling water Check for proper operation Clean and replace
valves glands where
needed.
18 Over-speed Check for proper operation
devices
Note: The need to focus particular attention to a specific area of the generator or the need to perform specific
investigative tests is often determined by past operational experience, the accumulated maintenance history of the
unit, unusual operating conditions, or unusual changes in the unit's performance. Unusual operating conditions may
include excitation disturbances, unusual or abnormal vibration or noise, voltage or power surges, overloads, loss of
cooling water, or unexplained excursions in generator temperatures.

Capital Maintenance

For capital maintenance of hydro-generator, the generator is first dismantled. The

procedure for dismantling is as follows:
 Record insulation resistance value of stator, rotor and exciter;
 Decouple generator shaft and turbine shaft after recording guide bearing clearances, air
gaps between stator and rotor, air gaps of main, pilot exciter & PMG etc. if mounted on
shaft;
 Dismantle other components one by one in proper sequence till rotor is free to be lifted.
 Rotor should be taken out very carefully and kept in rotor assembly pit duly bolted with
base place. Rotor rim needs to be supported by blocks and jacks all around the
circumference;
 All stator air coolers are to be dismantled and kept for testing and repair;
 Breaking and jacking units are to be dismantled;
 All cares are to be taken during dismantling to ensure safety of all components,
fasteners, pins and temperature sensors, etc.
 Prior arrangement of proper T & P, special T & P, slings, D-shackles etc. is also
necessary.

After dismantling, the maintenance of generator components is carried out one-by-one as

follows:
S. No. Generator Maintenance Activities
Components
1 Stator Frame All the joints, tightness of bolts and location pins, etc. are
checked. They are retightened, if necessary.
2 Stator Core winding. Tightness of core especially at the top and bottom packets is
checked;
Any local looseness between punching can be filled up with
paramax paper glued with epoxy varnish & core bolt retightened.
After repair spray top and bottom three packets with locite -
290;
Clean core duct with dry compressed air;
Clean the ends of winding;
Measure IR value of winding after thorough cleaning. After
assembly dry out if IR is low;
Carry out Electronic Core Imperfection test also to ensure
healthiness of core;
After rectifying all defects and thorough cleaning of the inner
bore and overhang portion is done and winding is to be spray
painted. Paint used should be specified insulating paint.
3 Rotor The rotor is to be thoroughly cleaned with dry compressed air;
Check general condition of coil and pole, clean with dry
compressed air;
Check the coil joints for any cracks due to overheating, etc.;
Check field coils and rotor leads for inter twin fault. Measure
impedance of coils by applying 60 to 100 VAC, 50 c/s. if the
impendence of some coil is very low (<4%), they must be
 checked for possible inter turn faults;
Shaft is to be checked specially at G. B. (Guide Bearing)
journals for any marks, roughness etc. Remedial measures are to
be taken if marks, roughness is found.
Check top and bottom rotor fans. If found damage replace the
same;
Check tightness of all the joints of rotor spider and extension
arms;
Check tightness of rotor rims, pole key, rim keys, etc;
Check rotor gap.
Check vibration.
After rectification of all defects and thorough cleaning, spray
paint the rotor pole with insulating red-gel paint;
Keep the rotor covered with appropriate cloth to prevent
deposit of dust and fire safety;
All safety precautions for external damage, fire, etc. are to be
taken during maintenance period.
4 Brush gears and slip rings Check if there are grooves, roughness high points use oil
stone for rectification;
Check brush gear connections, clean all the insulated parts with
dry compressed air.
5 Guide &Thrust bearings i. Guide Bearings
Check condition of housing;
Check condition of pads. If required bedding is to be done;
In case babbitt material found damaged or thinned, rebabbitt
pads with proper grade of white metal;
Check insulation of pads. If found damaged, replace the same;
Check IR value;
Check all RTDs & TSDs and calibration of temperature
indicators.
ii. Thrust Bearing
Check condition of pads. If found some damage to babbitt
material, get rebabbitting done;
Get bending of pads done to ensure removal of high points
and having desired contact area;
Check bearing insulation by measuring IR value. Replace
insulation if found damaged;
Check insulation of vapor seal also and replace, if found
damaged;
Check housing, pivot points of thrust bearing;
Check all the pressure gauges and level indicator;
Check all RTDs (Remote Temperature Device) & TSDs
(Temperature Sensitive Device) and calibration of temperature
indicators.
6 Air and Oil Coolers Clean inside and outside of coolers;
Check for any tube leakage by pressurizing to a pressure
slightly more than maximum expected working pressure;
Change full set of tubes or change only leaking tubes, if more
than 10% tubes are leaking;
After repair paint the body of cooler.
7 H.P. Lube System Inspect bearing and grease;
Check the condition of hoses. Replace if necessary;
Check for any leakage and take remedial measures;
Check pressure gauges.
8 Flow relays, visual flow Inspect, clean water passages and remove silt;
indicators and flow meter Replace all defective meters.
9 Braking and jacking Check brake units and clean inside and outside of the unit;
system Change seals;
Carry out hydraulic test;
Clean the filters, bowl of lubricator;
Check brake track, tighten dog clamps;
Check working of brake limit switches;
Replace brake lining, if necessary.
10 General checks Check condition of current carrying leads;
Check all water & oil valves for their proper working;
Check general operational healthiness of all aux

6.3.4 Routine Maintenance of Power Transformers

The maintenance of power transformers is also an ongoing process as the
maintenance of other major generating equipment and their components. The
preventive or routine maintenance is being carried out rather than acting when a fault
occurs. The inspection procedure and action required (if unsatisfactory condition
indicated) are given below in a tabular form. The time schedule of periodic maintenance
has also been given in the table.
S. No. Item to be Inspection Procedure Action required, if unsatisfactory
inspected condition indicated
A. Hourly
1 Ambient Take air or water temperature Record the temperature
temperature respectively near transformer
or at the inlet depending on air
or water cooled transformers.
2 Winding Check for abnormalities in If the temperature indicated is more
temperature relation to ambient than envisaged as per loading
temperature and load condition, check:
That radiator valves or cooler
circuit valves are all open;
Fans operate at set value of
temperatures;
Fans/oil pumps are in circuit;
Calibration of OTI (Oil
Temperature Indicator) and WTI
(Winding Temperature Indicator).
3 Oil temperature - Do -
indicator reading
4 Load (Amperes) Check against rated figures Reduce load (if it exceeds the
specified limits)
5 Voltage Correct tap position in line with voltage.
6 Transformer/ Check for any abnormality in Tighten any looseness in external parts.
shunt reactor Sound If abnormal sound persists, complete
humming and checking will have to be done.
general vibration
B. Daily
1 Oil level in Check oil level from oil gauge Top up, if found low;
transformer/shunt Glass Examine transformer shunt
reactor reactor for leaks;
Tighten gasket joints at the leak
points.
2 Oil level in Check oil level from the Check sealing gasket between
 diverter switch gauge glass diverter switch and
transformer/reactor tank, if oil
leakage is found;
Top up oil.
3 Oil level in Check oil level from the oil If low, top up oil;
Bushings gauge of the bushing in which Examine bushing for any oil leakage.
oil remains separate from the
tank oil.
4 Pipe work and Check for oil leaks If leakages are observed, tighten
accessories for evenly the gasket joints. Replace
leakage “O” ring or washer suitably.
Replace gasket, if needed.
5 Relief vent Check for any crack If cracked/ broken, replace;
Diaphragm If broken, ensure from other
protections provided that there is no
fault inside the transformer.
6 Fans/oil pump Check that fans/oil pumps are Check connections;
Running running as required Correct them if found defective.
C. Weekly
1 Leakage of water Check by opening the end Plug the tube leaking
into cooler covers of cooler.
2 Operation Change over from one cooler
sequence of oil to the other
pump and the
cooler
3 Operation of anti Check anti condensation Set them right if not working
condensation heaters are working
heater in
marshalling box
and OLTC motor
drive panel.
D. Monthly
1 Dehydrating Check colour of silica gel If more than half of silica gel has
Breather Check oil level in the oil turned pink, change by spare charge.
cup and contamination of The old charge may be reactivated for
oil visually use again.
Check that air passes are Add oil, if required to maintain oil
free level. Replace oil, if contaminated.
Ensure free air passes
2 Maximum pointer Record the maximum oil and Check whether the readings are within
of OTI and WTI winding temperature readings permissible limits. Reset maximum
3 Operation of fans In mixed cooling in Ensure smooth running of fans
ONAN/ONAF, if the
temperature of oil has been
less than the fan control
setting temperatures, operate
the fans manually to check
their running.
E. Quarterly
1 Bushing Visual inspection for cracks Clean dirt deposits. If cracks are
and dirt deposits observed, cracked bushing should be
rectified/replaced.
2 Cooler fan Check contacts and manual Lubricate bearings. Replace worn out
bearing Control contacts. Clean fans and adjust controls.
and control
 pumps
3 External earth Check all external connection If loose, tighten them.
connections for discoloration or hot joints
4 OLTC Examine contacts, check Replace all the worn out and burnt
step by step mechanism contacts. Set limit switches in position.
operation, end position limit Clean/replace brake shoe lining,
switches and brakes lubricate all bearing and coupling points
Check that wiring is intact suitably.
and all terminals are tight. Tighten terminals, if found loose.
5 Marshalling box Check wiring and that Tighten them, if found loose.
terminals are tight
6 Oil in Transformer Check for dielectric strength Take suitable action to restore quality of
and diverter and moisture content oil.
switch
7 Insulation Measure IR value between Compare with previous values. The
resistance windings and to earth comparison should be done with these
values where transformer/reactor is
connected externally to the line and bus
ducts. If the values are low, measure IR
values after isolating it.
8 Oil bag sealing Check pressure of oil outside If oil is present, check leakage in the
arrangement the oil bag in the conservator oil bag by applying air pressure
where provided
F. Half Yearly
1 Alarm, trip and Check operation of alarm/trip In case of faulty operation, check
protection circuits contacts of each protection by contacts and wiring circuits.
actual initiation and also check
display and annunciation on
the panel.
2 Oil in bushings Check BDV and moisture Replace with fresh oil
content of oil.
3 Vibration level of Measure vibration level Compare with previous values.
tank walls for
shunt reactors.
G. Yearly
1 Oil in transformer Complete testing of oil. Filter to restore the quality or replace, if
/ shunt reactor DGA (dissolved gas analysis) the values have reached discarding limit.
of oil.
2 Oil and winding Calibrate and also check Adjust if found reading incorrectly.
temperature difference between WTI and Replenish, if required
indicators OTI by feeding current to the
WTI pocket heating element.
Check oil in the pockets.
3 Magnetic oil level Check oil level in conservator If oil level indication is not correct,
gauge and by dipstick method. check the float.
prismatic level Clean the oil gauge glass
indicator Replace glass, if cracked
4 Buchhloz relay Mechanical inspection: Buchhloz contacts should operate
Close valve between when oil level comes below Buchhloz
Buchhloz and conservator and relay level.
lower oil level.
Check the movement of Make the movement smooth
floats for rise and fall.
Check tightness of mercury Tighten clamps, if loose.
switches.
 Check the operation of alarm Check contacts, if abnormality found.
and trip contacts by air
injection. To be sealed to avoid ingress of
Clean cable entry terminal moisture
box.

5 Fan motors Check IR value of motor Dry out, if found low. Check balancing of
winding, noise and vibration of fans.
fans
6 Tanks and Check painting and surface Replace any component found
accessories finish damaged.
Mechanical inspection of all Touch up/repaint, if required
accessories
7 Gasket joints Check the tightness of bolts. Tighten the bolts evenly to avoid uneven
pressure
8 Earth resistance Check earthing resistance Take suitable action, if earth resistance
is high.
9 OLTC Diverter switch servicing Draw out diverter clean & tighten
Check the contact of diverter contacts.
switch for burning or pitting Recondition/ replace, if required.
marks
10 Bushing top Check contact joints. Adjust arcing horn gap & retighten
connectors and Clean arcing horns and check
arcing horns gap

11 Air bag sealing Check healthiness of air bag Clean if required

arrangement
where provided.
12 Cable boxes, if Check for sealing arrangements Replace gasket, if leaking. Replace
provided for filling holes. Examine compound, if necessary.
compound for cracks.
13 Lighting arrestors Examine for cracks and dirt Clean or replace
deposits.
Measure IR value of each In case IR value is poor, replace.
stack
Measurement of leakage
current
14 Off circuit tap Move from minimum to Compare resistance value with previous
switch maximum tap position & return results. If resistance is high, tap switch
to minimum position. contact to be attended to.
Check resistance
measurement at each tap.
15 Condenser Measure power Dry out bushing if values are abnormal
bushing factor/capacitance and replace oil, if required.
measurement
16 Electrical tests Carry out: Compare with previous values. In case
Resistance measurement at of abnormality, investigate causes.
all taps for transformers with
off circuit tap switch and at
maximum, minimum and
normal taps for transformers
with OLTC,
Magnetizing current at 415
volts.
IR values after isolating the
 transformer.
Turn ratio
17 Oil coolers Clean oil coolers. Check for Flush cooler tubes, repair leaky tubes. If
leaky tubes more than 10% tubes are leaking,
replace the total tube nest.
H. 7-10 Yearly
As there is continuous deterioration of oil and insulation in a transformer, it is preferable that the core
and windings and the inside surfaces of tank be thoroughly cleaned for any deposits. This can be done
while the transformer is in position. Close all valves connecting the cooler circuit/radiators to be the tank.
Drain oil from the tank while letting the dry air to go inside. Clean core and winding by hosing down
clean dry oil through the inspection cover. Remove dirty oil from the tank and wipe off this oil from the
tank bottom. Let there be a continuous entry of dry air into the tank while the cleaning activity is on so
that there is a minimum contact of the transformer core and windings with the atmospheric air. Similarly,
drain oil from cooling circuit and radiators and fill dry clean oil.

Where transformer windings are to be taken out due to any reason such as to repair a damage, thorough
washing due to sludge formation or for thorough inspection to locate a fault as a result of DGA or some
other tests, after carrying out the necessary works for which the transformer was opened, do the
following also:
Tighten all coil clamping screws to remove looseness from the windings, if any;
Tighten all nuts and bolts whether metallic or made if insulating material on mechanical and electrical
joints;
Tighten core yoke bolts, core-clamping screws, etc.

I. 20 Yearly
1 Life assessment DP and Furan content Under the normal operating condition
tests measurement transformer has a useful life of about
2530 years. This may vary considerably
depending upon the overloads it has
carried and the temperature at which it
has worked during its span of operation.
Therefore, for any future planning it
may be worthwhile to know well in
advance the remnant life of the
transformer in service. This can be done
by assessing extent of degradation of
cellulosic paper through furan content in
transformer oil or/and degree of
polymerization (DP) of paper. It is
proposed to carry out this study after a
period of 20 years of service. After
knowing the remnant life of a
transformer, the action can be planned
in conjunction with life assessment
studies on generating unit.

Besides, the partial and complete services as follows are recommended for
transformers.

Equipment Type of Maintenance / Service and Activities Time

Name Interval
Transformer (a) Partial Service 1 Yr
Perform diagnostic tests as per manufactures instructions. They
include:
oil tests (dissolved gas analysis, dielectric test, colour test, acidity
 test and interfacial tension test),
Test for gas in the nitrogen blanket (if applicable).
External inspection & maintenance
Inspection of the transformer includes the concrete pad, bolts,
grounds, bushing, oil leakage, paint condition, and all connections,
Maintenance includes checking all temperature and pressure
switches to ensure operation at the proper values, checking gauge
calibrations, lubricating, cleaning, adjusting aligning and checking
control circuits, testing operating fans and oil pumps (if applicable)
and making any needed repairs, recording all required gauge,
meter and counter readings and performing the tap-changer
maintenance if so supplied.
Check the nitrogen pressure (if applicable) and add nitrogen as
required. Also check the oil conservator system (if applicable).
For placing the transformer back in service, test all alarms and
switches, clean and/or repaint/ touch up transformer, clean-up
work area, remove personnel protective grounds, do a walk around
inspection, release clearance on transformer, return to normal
status and place transformer back in service
(b) complete Service For complete service, in addition to the activities 5 Yr
enumerated above in (a), the following additional activities will
have to be carried out:
For diagnostic test, perform turns ratio test and power factor
test.
Drain and process oil if the oil test indicates a problem. For phase
shifting and tap-changing transformers, drain the tap changer and
inspect the contacts, spring mechanisms, operating cabinet, etc. as
per manufacturer’s instruction.
Internal maintenance
accessing the tank includes removing the cover, ventilating,
testing the oxygen level, and visually inspecting the interior,
Check for loose bolts including blocking, and insulation condition.
Also, check to ensure all leads are secured and properly placed,
check for any signs of arcing or abnormal discoloration of the
insulation that would indicate overheating,
verify that all tools have been removed from the tank,
replace cover and seal,
Vacuum the transformer, if so designed, to specifications
Refill with oil to proper level. For placing back in service follow
the same procedure as during partial service.

6.3.5 Routine Maintenance of Hydro-Mechanical Equipment

The major hydro-mechanical equipment to be covered by routine maintenance

are Intake Gates, Main Inlet valves (butterfly and/or spherical) and Draft Tube gates.
The following are the periodic inspection and checks for the preventive maintenance of
hydro-mechanical equipment.

6.3.5.1 Intake Gates

The maintenance of intake gates include (i) cleaning up, (ii) adjustment, (iii)
lubrication with recommended lubricants & methods, (iv) replacement of defective
parts, (v) repair of damaged parts, (vi) recoating of damaged coat on ropes, (vii)
recording details of all works carried out with date & time, and (viii) painting of gates
and hoisting arrangement. Following inspection and checks are recommended for
routine maintenance of intake gates:

(a) Daily inspection should be carried out by gate operator to ensure:

 Proper oiling and greasing whenever required;
 Tightening of loosened parts of tightening contacts in electrical system;
 Checking of ropes and hoisting arrangements;
 Checking general condition of gates and gate grooves wheels, etc.
(b) Periodic inspection (half-yearly or annual)
 Dismantle and check all components for any damage;
 Rectify damages or replace worn out irreparable components;
 All safety precautions, e.g., taking proper shut down, installing safety
tags, red flags, etc., must be taken, when any work is being done on
gates;
 Before taking up work on gates, stop log gates (duly inspected and
repaired) must be lowered in the groove meant for the same and plug all
leakage through them.
(c) Lubrication of gate parts
 Servogem EPI (IOC) or equivalent of other brand
- Rope drum shaft for all hoisting units (once a month)
- Plumber blocks for all hoisting units fitted with bush bearing
(once in two months).
- Coupling for transmission shaft ( once in two months)
- Plumber blocks for manual operation (once in three months).
 Servogem -3 (IOC) or equivalent of other brand
 Spherical roller bearings for gate wheels (once in two months).
 Compound –D (CAMAX Bharat Petroleum) or equivalent of other brand.
 Lifting ropes (once in six months)
 Servocoat 120 T (IOC) or equivalent of other brand.
 Gears and pinions for all hoisting units (once in two months –
Meshing faces only)
 Gears and pinions for manual operation (once in 3 months).
 Gears and pinions for all travel mechanism (once in two
months).
 Gears and pinions for position indicators (once in two months).
 Servosystem (320 IOC) or equivalent of other brand.
 WOM reducer for all hoisting units (once in two months).
Note: All brand name products such as lubricating oil etc., which have been mentioned
in the text on this page and elsewhere in the document are the products used in the
NPS power plants and cited for illustration only. However, it is up to the plant owners to
utilize other products best suited to them.

6.3.5.2 Main Inlet Valves (MIV)

The turbine may have either a butterfly or spherical valve. This valve is used
each time the unit is shut down. Valve seats, seals, operating links, bearings, bushings,
power source and hydraulic links are the main primary concern for maintenance. The
valve function should be verified periodically through test or normal frequent operation.

Butterfly Valves: Butterfly valves generally consist of a disc or lattice mounted on a

shaft that rotates in cylindrical body. Usually, the disc and lattice profile is contoured in
the flow direction to provide a smoothen hydraulic flow and balance forces on the valve.
The disc is oriented parallel to the flow to minimize any restriction when opened and at
right angle to the flow to provide full closer. Valve seals are on the circumference or in
contact portion of the valve body. These seals can be replaced or adjusted without
removing the disc from the valve. Valves have flanged connection and spool pieces to
facilitate dismantling. Sometime welded connections are preferred to save cost. The
maintenance procedures and frequencies for these valves are as follows:

Check operating system daily and ensure it is working smoothly;

Check for any leakage through joints daily;
Replace main seals in annual maintenance, if damaged;
Other seals may be replaced as and when heavy leakage is observed;
Overhaul operating system annually;
Replace gaskets in flanged connection during annual overhaul.

Spherical Valves: Spherical valves have a body shaped like hollow sphere with flanges
or other connection for mounting in a piping system. The rotor (shaped like ball) has a
cylindrical hole through its centre at right angles to support shafts located on each side
of valve. In open position with rotor opening parallel to the flow direction, the valve
offers and unrestricted flow with minimum disturbance to the flow path. To close the
valve, the valve rotor is turned to 90o from the axis of rotor opening. Spherical valve
has tendency to close for positions less than 50% opening which facilitates under
emergency closing. Movable seals reduce valve leakage when the valve is closed.
Mostly the valves have both upstream and downstream seal. The upstream seal is
maintenance seal or emergency seal, the downstream seal is working seal. When valve
is closed under full pressure, the upstream maintenance seal allows replacement or
maintenance of the working seal without dewatering the penstock. The upstream
maintenance seals have positive mechanical locking to prevent accidental opening. The
maintenance procedures and frequencies for these valves are as follows:
 Daily checks of operating system and remedial measures are must;
Annual inspection and overhauling of mechanical seal after dewatering
penstock is must;
Annual inspection and overhauling of operating seal is also essential; Annual
overhauling of operating mechanism to ensure smooth working throughout the
year is also done;
Annual overhauling of the valve rotor and other parts are also taken up as
required.

The following checks and attending are also essential during annual maintenance:

Checking and attending leakage from valve and dismantling joint;

Check and attending oil leakage from servomotor;
Checking and attending the setting of Limit Switches & Operation of the same;
Check and attending the leakage of distributing valve;
Check the correct working of the pressure gauges. Lubricate the parts, if
necessary;
Checking and attending for leakage in the piping;
Checking all the MIV system connection & union for tightness;
Checking all the MIV servo linkage during operation, look for backlash;
Cleaning of valve body, seal and solenoid valve;
Checking the actuating solenoids for operation of valve. Cleaning the contacts
and rollers;
Checking the operation of by-pass valve;
Checking for cracks, pitting and cavitations, etc. of MIV and Servomotor;
Inspection of rubber seals;
Checking trunions & bushes, bolts & nuts, etc;
Checking gland packing and lubrication;
Checking foundation bolts and nuts of valves and servomotor. Cleaning the
bolt, nuts etc.
Checking servomotor piston and its collars & its gland packing;
Checking hole of the servomotor cylinder;
Checking the pins and bushes of servomotor & its air valve;
Checking the operation & closing times of the MIV.

6.3.5.3 Draft Tube Gates

One, two or three bulk head gates are needed to close off the draft tube. These
are usually cable suspended gravity gates and designed for balanced pressure closure.
These are usually dropped to close or lifted to open through hoisting arrangement
having rope drums. The main problem with sealing is due to collection of debris at
bottom seal area. For withdrawal of gate, equalizing pressure across the gates is done
with by-pass line valve located within gates. When machines are running, these gates
and hoist remain available for maintenance. These should always remain in perfect
condition for use during emergencies for power station. During annual maintenance of
unit, these gates are required to be lowered so that dewatering of draft tube is
possible. As such, maintenance and overhaul of these gates are taken up before
starting annual maintenance of machine. Lubrication of operating mechanism, its
electrical system and coating all ropes meant for lifting are of main concern for
maintenance.

6.3.6 General Problems in Electrical Circuit and Checks

Problems could be in electrical circuit as well. Hence, the maintenance checks to avoid
general problems in electrical circuits should not be undermined. The following maintenance
checks / actions with respect to electrical circuits need to be carried out:

S. No. Problems Actions to be Taken

1 No supply at control panel in spite of Check fuses
turning on main switch
2 Incoming supply healthy but voltmeter is Check fuses voltmeter circuit.
not showing
3 Motor is running even after pressing stop - Immediately put-off main switch;
button - Check contact of motor control
contactor & push button contacts,
replace them if damaged;
- Reset O/L relay before starting again
4 O/L relay tripped - Check control fuse;
- If fuse ok, check control transformer
5 Gate is creeping down & restoration has Check position of toggle switch (it
failed indicating lamp is glowing but alarm should be in reset position)
is not ringing
6 Indication lamps are not glowing

6.4 REQUIREMENTS FOR EFFECTIVE OPERATION AND MAINTENANCE

The following are the basic requirements to ensure effective operation and
maintenance:

 Manpower planning and arrangement.

 Training program for operation & maintenance.
 Planning and arrangement of spare parts, consumables, tools and testing
equipment.
 Logging and reporting.
 Equipment labeling.

6.4.1 Manpower Planning and Arrangement

In order to ensure all structures and equipment are operated and maintained in
a safe and efficient manner, planning and management of manpower needs to be done
well in advance preferably during the pre-commissioning of the plant. The manpower
required will be based on following factors:

Type of plant.
 Number of shifts.
Location of the plant.

RoR type of plant demands more manpower than for dam type because of the spread
of hydraulic structures. Similarly, if the numbers of shifts are more there will be more
need of manpower. For remotely located plant there may be a need of additional staff
for the support services such as transport, maintenance of residences, drinking water
supply, etc. However, the manpower can be kept minimum by employing a
multidisciplinary force such as an engineer with experience in civil and electro-
mechanical work or technician with driving experience and by employing local labor
during requirement of additional work. The guiding factor is safety of equipment and
manpower. Similarly, the contractual work such as civil maintenance, welding and
fabrication, etc. may be awarded on annual basis to keep work force low.

In selecting manpower e.g. for a position of plant in-charge or plant manager a person
having basic degree in electrical with experience in civil and mechanical works is most
suitable while for testing engineer, he/she should be familiar with all equipment testing
to take decision in case of any fault on electrical equipment such as generator,
transformer and switchgear. For the technician, a technician level certificate holder with
hands on experience in electro-mechanical work such as diesel generating (DG) plant,
electrical installation, hydraulic equipment, electrical panel, PLC panels, cable work, etc.

Keeping n view that the private hydropower plants will be handed over to the GoN after
a designated period of Operation and Maintenance of the plant, the GoN staff to be
deployed for O & M need to be trained at least for a duration of one year before the
end of License Period.

6.4.2 Training Program for Operation & Maintenance

Each employee must receive training to meet the responsibilities of their position.
New or transferred employee is required to familiarize themselves with facility reference
documents, facility system, policies and procedures. The plant manager selects which
facility–specific or other training programs personnel must attend to be qualified to
operate or use the facility.

The plant manager may authorize training exemptions based on assessment of the
individual’s experience (Note that the exemptions must be documented). Annual
training (continuing type) to ensure the staff is proficient in the knowledge and skills
needed to perform their duties. Training must be provided sooner if there is a change in
job assignments, change to systems or processes, or a change in procedures. The
remedial type of training must be provided when there is a reason to suspect
deficiencies or inadequacies in the employee’s knowledge or skills.

The method of training could be:

On-the-job: The primary mode of training for the facility is through on-the-job
training. Training must be carefully supervised and controlled to avoid mistakes.
 Instructor-led: Classroom or in the field.
Computer–based: Online or other.
Required Reading: Assignments require signatures by the employee to indicate that
they have read and understood the document.

The contents of training should, in general, be safety, theory (electrical,

mechanical and operation principles), and knowing and understanding of operation
limits.

The knowledge and skills should be evaluated and the assessment methods must be
documented. The training program needs to be reviewed annually and
recommendations are to be made for any changes or improvements.

6.4.3 Planning and Arrangement of Spare Parts, Consumables, Tools and

Testing Equipment

For effective maintenance, it is necessary to list out all required ordinary and
special tools, spare parts, consumables and testing equipment along with assessment of
the quantity and arrange the same in a timely manner in advance so that time is not
lost in re-commissioning the plant after the shutdown. Ordinary tools and parts include
different type and sizes of screw drivers, pliers, spanners, hammers, etc., while the
special type of devices and parts is required during assembly or dismantling of
machines. For example, rotor lifting device and endless slings, pole turning device, shaft
lifting device, rotating device and slings for alignment, shaft extension pieces and so on.
These are not required for day to day maintenance; as such these should be properly
stored and secured. Necessary maintenance, if required, must be carried out on these
devices in time. Slings should be stored duly coated with preservatives as
recommended by the manufacturers.

6.5 Logging and Reporting

6.5.1 Logging

A station log needs to be maintained at each facility in the Control Room. The
station log contains chronological record of all operating and maintenance activities and
events which provides a reference for future use. Operation and maintenance personnel
use these information to evaluate present and past plant status. The station log may be
paper, electronic or a combination of both. The station log documents are following:
 Staff on duty
 Operations of waterway equipment including gates, valves and changes to
spillway gate positions.
 Communications involving plant operations, switching, Hot Line Orders,
clearances, special conditions, alarms and relay operations. All communications
with Transmission Operators shall also be logged.
  Water elevations and releases and operational changes affecting water
elevations and releases.
 Status of auxiliary equipment.
 Testing of equipment or gate controls.
 Act of vandalism or other security incidents.
 Requests and occurrence to change from normal operation during an emergency
or unusual conditions
 Communication network checks and emergency exercises conducted.
 The disabling and re-enabling of facility alarms.
 Unit start and stop times.
 Any equipment failures and malfunctions.
 Line outages.
 Breaker opening and closing.
 Callouts.
 Any change in unit status (available, unavailable, etc.)
 Status of all major equipment.
 Listing of personnel (visitors) arrival and departure.
The plant manager must review and initial the operating Log Book.

Shift turnover is critical part of the facility’s operation and provides oncoming operation
staff with an accurate picture of the overall status of the facility. Hence, the incoming
operation staff must review logs, turnover checklist (if used), SCADA displays, alarm
displays, disabled alarms, protective devices, and computer pages, and they must
receive verbal briefing from the on-duty operator prior to assuming responsibility for the
operation of the facility. A visual inspection of control boards including a test of the
annunciator windows will be completed to verify indication/annunciation light is
operational. During a shift turnover, at a minimum, the information on major equipment
status, alarm status, work in progress, hazardous energy control procedures, any
abnormal plant conditions, water release, power schedules and work schedule should
be exchanged. The operation staff, then, will sign into the log documenting that shift
turnover has been completed.

6.5.2 Reporting
With the passing of time along with growth of demand in electricity and due to
advancement in the technical development the interconnected power system are
becoming more and more complex. This requires increased emphasis on the analysis of
system performance to ensure achievement of the best reliability. One of the most
important requisites for such analysis is the availability of clear, concise and the
accurate reports on power system operation and maintenance (O & M) for review by
management at various levels. Specific details regarding preparation, issuance, and
distribution of the monthly O & M reports is described in the following paragraph.

A narrative report of power plant O & M activities shall be prepared and distributed
monthly by the power plant O & M office on each project that includes operating power
facilities. The report shall briefly describe all important non-routine events of a power
plant O & M nature that occurred during the month, such as date, time, duration of
major items of maintenance undertaken or accomplished new equipment or service
installation or connections, changes in system arrangement or interconnections with
adjacent utilities, major power interchanges between systems or water movements
scheduled or accomplished, new facility(ies) added, important personnel activities, etc.
The report shall be distributed to the concerned as specified by the system operating
authority/ regulating authority as applicable.

In addition to the above indicated monthly O & M report the following reporting are
required for record keeping for future reference.

Annual Outage Program,

Annual Availability Declaration,
Monthly Generation Outage Program,
Weekly Generation Outage Program,
Scheduled Outage, Request Form,
Forced/Maintenance Outage Request Form,
Monthly Availability Declaration on Hour to Hour Basis,
Monthly Availability Declaration on Hour to Hour Basis,
Weekly Availability Declaration,
Daily Availability Declaration,
Verbal Dispatch Instruction Confirmation,
Daily Generation Report Form,
Daily Generation Log Sheet,
Fault Registration Form,
Monthly Generation Performance Report Form,
Monthly Generation Report Form,
Monthly Outage and Reduced Output Report,
Maintenance Outage Report Form,
Loading Status and Scheduled Outages,
Forced Outages of Transmission Lines and System Failures, and
Transmission Line Shutdown Implementation Form.

In case any accident occurs, the accident hazard notice needs to be given as
earliest as possible to the chief electricity inspector appointed by GoN.

6.6 Equipment Labelling

In order to help ensure that the facility and the support personnel can identify,
instrumentation, controls and equipment, a well-established and maintained program
for labelling equipment is a must. A good labelling program that is understood and
maintained by O & M personnel enhances the effectiveness of work activities. Such a
program also helps to reduce errors by O & M personnel as errors can result from
incorrect identification of equipment and controls. Equipment labelling is required also
to comply with the safety regulations and for protecting from the health hazards.
At a minimum, the following items should be labelled:

 Emergency exits, fire alarms, fire protection, and fire extinguishers.

 Rescue and first aid equipment.
 SCADA displays.
 Circuit breakers, disconnects, and power panels.
 Annunciator panels
 Grounding switches
 Valves
 Piping systems.
 Major plant equipment
 Control switches
 Protective devices, including relays.
 Metering.

The labels are placed on, or as near as practical to, the controls or equipment being
labelled. Labels are oriented so that they are easy to read. The operation manager
should be responsible for ensuring that missing or damaged labels, once identified, are
promptly replaced and that newly installed equipment or new modifications to existing
equipment are properly labelled.

6.7 A Typical Format for Spare Parts List / Monthly Report of Power
Plant Operation and Maintenance / Typical Formats for Reporting
I) TYPICAL FORMAT FOR SPARE PARTS LIST

II) FORMAT FOR MONTHLY REPORT OF POWER PLANT OPERATION AND MAINTENANCE
III) ANNUAL OUTAGE PROGRAM

iv) ANNUAL AVAILABILITY DECLARATION

v) MONTHLY GENERATION OUTAGE PROGRAM

VI) WEEKLY GENERATION OUTAGE PROGRAM

VII) FORCED/ MAINTENANCE OUTAGE REQUEST FORM
VIII) SCHEDULED OUTAGE REQUEST FORM

IX) MONTHLY AVAILABILITY DECLARATION ON WEEKLY BASIS

X) MONTHLY AVAILABILITY DECLARATION ON HOUR TO HOUR BASIS
XI) WEEKLY/ DAILY AVAILABILITY DECLARATIONS

XII) VERBAL DISPATCH INSTRUCTION CONFIRMATION / DAILY GENERATION REPORT FORM

XIII) DAILY GENERATION LOG SHEET

XIV) FAULT REGISTRATION FORM

XV) MONTHLY GENERATOR PERFORMANCE REPORT FORM

XVI) MONTHLY GENERATION REPORT FORM

XVII) MONTHLY OUTAGE AND REDUCED OUTPUT REPORT

XVIII) MAINTENANCE OUTAGE REPORT FORM

XIX) LOADING STATUS AND SCHEDULED OUTAGES

XX) FORCED OUTAGES OF TRANSMISSION LINES AND SYSTEM FAILURES

XXI) TRANSMISSION LINE SHUTDOWN IMPLEMENTATION FORM
7 Power House Generator Room Ventilation
Ventilation of the generator is very important to reduce the heat in the room to
achieve the permissible operation temperature of 40℃. For this purpose I will suggest
to use the intake and exhaust fan system for the ventilation system with following
details.

7.1 Calculation of Heat Radiated by the Generator

1
𝐻𝑅𝐺 = 𝑃 ∗ (η − 1)

1
= 5500(0.94 − 1)

= 351 KW

= (351*56.9) Btu/min

=19972 Btu/min

Where,

HRG = Heat Radiated by Generator

P = Power of Generator

η = Efficiency of Generator at 0.85 power factor and 0.40 power utilization

7.2 Calculation of Air Flow Required for Ventilation

𝐻
𝑉𝑎𝑖𝑟 = (𝐷∗𝐶 )*F
𝑝 ∗𝑇

19972
=(0.071∗0.24∗50)*1.5

= 35161 cmf

Where

𝑉𝑎𝑖𝑟 = Ventilating Air (cfm)

H = Heat Radiation i.e. engine, generator, (Btu/min)

D = Density of Air at air temperature 38°C (100°F). (0.071 lb/ft3)
CP = Specific Heat of Air (0.24 Btu/LBS/°F)
T = Permissible temperature rise in generator room (°F)
F = Routing factor
7.3 Routing Factor
Routing factor is determined based on the ventilation type. Following are the
ventilation type with their cross ponding routing factor.

Fig: -Different Types of Ventilation type with their Routing Factor

7.4 Ventilation Fans

Except for special applications, natural draft ventilation is too bulky for practical
consideration. Adequate quantities of fresh air are best supplied by powered (fan-
assisted) ventilation systems.

As per the Structure of the power house it will be better to use intake and
exhaust fan system for the ventilation. As the air flow required is 35161 cmf per unit it
is better to use standard duty belt drive fan. Following are the details of fan.

Standard Duty Belt Drive Package

Blade Diameter Cmf range Qty (nos)
30 inch 9561 - 17704 3 (12000 cmf) / unit

7.5 Layout of Fans

As mentioned above three intakes fans per unit of cmf range 12000 cmf will be
used. Following is the layout.
Fig: - Lay out for intake and exhaust fans
 8 References

1. INSPECTION OF STEEL PENSTOCKS AND PRESSURE CONDUITS,

HYDROELECTRIC RESEARCH AND TECHNICAL SERVICES GROUP UNITED
STATES DEPARTMENT OF THE INTERIOR BUREAU OF RECLAMATION
DENVER, COLORADO.
2. INTEGRITY MANAGEMENT PROGRAMS FOR AGING INFRASTRUCTURES IN
HYDROELECTRIC GENERATING STATIONS, Jagannath Hiremagalur*, Charles
Ahlgren&, Steve J. White*, and Richard A. Mattson* &Chief Dam Safety
Engineer, Power Generation, Pacific Gas & Electric Company *Structural
Integrity Associates, Inc.
3. Optimization for Upgradation of Small Hydropower Plant in Nepal: A Case
Study of Sundarijal Hydropower Plant, Prahlad Raut1, 2, Rajendra Shrestha1,
Pashupati Raj Gautam2 1Department of Mechanical Engineering, Pulchowk
Campus, IOE, TU, Lalitpur, Nepal 2Nepal Electricity Authority, Kathmandu,
Nepal.
4. Guidelines for Operation and Maintenance of Hydropower Plants, Substation
s and Transmission Lines.
Government of Nepal Ministry of Energy DEPARTMENT OF ELECTRICITY DE
VELOPMENT Kathmandu, January 2017.
5. Design Guidelines for Water Conveyance System of Hydropower Projects,
DoED, Govt. of Nepal, August, 2006.
6. Proceeding of the Symposium on Electricity Generation in Nepal, the
Operational and Maintenance Aspects, April 27-29, 1993.
7. Operation and Maintenance of Hydropower Stations Planning and
Management – An Indian Perspective.
8. Black Start Studies, Prameesh Mohanan Electrical Engineer, Southern
Railway, july 2015.
9. Engine Room Ventilation CAT engine ventilation guide
10. https://www.grainger.com/category/belt-driven-exhaust-fans/exhaust-
fans/ventilation-equipment-and-supplies/hvac-and-refrigeration/ecatalog/N-
ylbZ1z13j7z