Guidelines For Operation and Maintenance of Small Hydropower Station

STANDARDS / MANUALS / GUIDELINES FOR
SMALL HYDRO DEVELOPMENT

SPONSOR:
MINISTRY OF NEW AND RENEWABLE ENERGY
GOVERNMENT OF INDIA

GUIDELINES FOR
OPERATION AND MAINTENANCE OF
SMALL HYDROPOWER STATION

LEADORGANIZATION:
ALTERNATEHYDROENERGYCENTRE
INDIANINSTITUTEOFTECHNOLOGY,ROORKEE
AHEC/MNRE/SHPStandards/E&MWorksGuidelinesforOperationandMaintenanceofSmallHydropowerStation
CONTENTS

ITEMS PAGE NO

SECTION-I GUIDELINES FOR OPERATION OF SMALL
HYDROPOWER STATION
1
1.0 Introduction 1
1.1 Civil & Hydraulic Structure 1
1.2 Power House 1
1.3 Switchyard 2
1.4 Other systems 2
2.0 Guidelines for Operation of Power Plant 2
2.1 Water Operation 2
2.2 Operation of Power Station 3
2.3 Guidelines for Preparing Operation Manual 10
2.4 Guidelines for Plant Reports and Records 11
2.5 Guidelines for Safety Manual 11
2.6 Guidelines for Disaster Management 12

SECTION-II GUIDELINES FOR MAINTENANCE OF SMALL
HYDROPOWER STATIONS

15
1.0 Introduction 15
2.0 Type of Maintenance 15
2.1 Reactive (Run to Failure) 15
2.2 Preventive Maintenance 15
2.3 Predictive Maintenance 16
2.4 Proactive Maintenance 16
2.5 Reliability Centered Maintenance (RCM) 16
3.0 Requirement of Effective Maintenance 16
4.0 Guidelines for Maintenance of Small Hydropower
Station

17
4.1 Preventive Maintenance of Hydro Turbine &
Auxiliaries
17
AHEC/MNRE/SHPStandards/E&MWorksGuidelinesforOperationandMaintenanceofSmallHydropowerStation
ITEMS PAGE NO

4.2 Preventive Maintenance of Hydro Generator 27
4.3 Preventive Maintenance of Power Transformers 43
4.4 Preventive Maintenance of Hydro-mechanical
Equipment
52
4.5 Procedures for Typical Maintenance Activities 55

SECTION-III GENERAL GUIDELINES 73
1.0 Guidelines for Taking over O&M of SHP 73
2.0 Guidelines for Manpower, Selection and Training 73
3.0 Essential T&P, Instruments ETC 75
4.0 Fire Protection & Fire Fighting 75
5.0 Safety Aspect of Running SHP 76
6.0 Guidelines for Documentation 78

SECTION I

GUIDELINES FOR OPERATION OF
SMALL HYDROPOWER STATION
AHEC/MNRE/SHP Standards/ E&M Works Guidelines for Operation and Maintenance of Small Hydropower Station 1

SECTION I

GUIDELINES FOR OPERATION OF SMALL HYDROPOWER
STATION

1.0 INTRODUCTION

Operation of Hydropower plant involves understanding of operation of hydraulic
features and equipments. All features may not be included in every plant and will
depend on type of plant water source, turbine & generator installed and power
evacuation arrangement and will generally consists of following:-

1.1 CIVIL & HYDRAULIC STRUCTURE

Lake/pond/river/canal as main water source
Dam/Diversion weir/Diversion barrage
Head regulator
Power channel/tunnel
Desilting arrangements
Fore Bay
Bye pass/Spillway
Trash racks
Intake Gates with Hoist
Siphon intake
Surge Tanks/Spilling pipes
Penstocks

1.2 POWER HOUSE

(i) Mechanical
Main inlet valve (Butterfly/Spherical valve)
Bye pass valve
Inlet bend and branching pipes
Drain valve
Pressure reducing valve for cooling water system
Cooling water system
Turbine and its auxiliaries
Draft tube
Draft tube gates
Governor, associated OPU and guide apparatus
Station auxiliaries such as:-
(i) EOT cranes/hoists
(ii) Station compressor
(iii) Drainage & Dewatering system
(iv) D.G. Set

(ii) Electrical
Hydro generator and auxiliaries

AVR & Excitation system
Generator protection/relay and control panel
A.C. auxiliary supply
D.C. control supply, batteries & battery charger
TG start up panel
Synchronizing panel
Generator transformer
Station transformer
Unit auxiliary transformer (if applicable)
Relay and control panel

1.3 SWITCHYARD

Switchyard structure
VCBs Isolators
CTs
PTs
LA
Lineside Isolator
Surge counters
Outgoing lines

1.4 OTHER SYSTEMS

Lighting system, emergency lighting
Station earthing, lightening protection
Communication system
Fire fighting and hydrant system
Safety tagging & safety interlocks

2.0 GUIDELINES FOR OPERATION OF POWER PLANT

Guidelines for operation of power plant shall have two elements:-

Water operation
Operation of Power Plant

2.1 WATER OPERATION

J ust like operation of Turbine Generator set or a transformer, efficient water operation
forms an important part of hydro power plant be it large storage plant or small run of
river plant. Water operation means operation of following systems of the hydro plant
in such a manner that efficiency of plant is maximum. It is generally reflected in
kWH/cumec.

2.1.1 Catchment Area

The area gives the run off into the lake/pond/river during rainy season. Run off rate
cubic metre/mm should be known to operator to adjust generation accordingly.

2.1.2 Lake/Storage/Pond

The operation of lake based plant means keeping the level such that during rainy
season the over flow chances are minimum. In case of diversion type plants it is
essential to keep the gates during flood conditions open to avoid flooding and lower
them only when rain is low or over. In such plant it is essential to check that there is
no leakage from the gates or stop log gates. If operator notes that the leakage is more,
he should pass on his observation to higher authorities to ensure corrective measures
in the interest of having more generation.

2.1.3 Run of River Type Plants

Availability of water is more important factor in operation of hydro power plants. It is
therefore, essential to generate continuously to its full capacity during monsoon
season. Failure of a machine during monsoon can cause a substantial generation loss.
All operation staff must, therefore, be very vigilant during this period. In lean season
diversion barrage gates/diversion weir gates are checked for leakage, corrective
measures are taken as soon as possible so that there may not be any generation loss on
this account.

2.1.4 Power Channel/Duct/Canal

The operation of open channel/duct is critical to water operation and efficiency of
plant. Depending upon the length, condition of lining, head on head regulator, time
required discharge to reach forebay and to the machine. As per this discharge guide
vane opening is calculated. Any time delay or change in opening will affect water
reaching the TG unit causing change in generation. The time taken by water to reach
the turbine will depend on many factors and only experience will make the operator
perfect.

2.1.5 Forebay

Forebay is a essential part of any water conductor system with open channel. It serves
the purpose of connecting penstocks with gates and acts as tank. It takes care of small
variation in generation, water supply and acts as desilting basin. The operation of
forebay is important during picking up load and at the time of tripping of machines.
Actual over flow, through bye pass, is always recorded to calculate water wasted
during over flow, specially during lean season.

2.2 OPERATION OF POWER STATION

The operation of power station requires that its staff is trained and well versed with all
necessary technical as well as basic trouble shooting knowledge. As a brief
description to bring out some details of operating a SHP, the following checks are to
be made before starting of machine:-

Shut down clearance
Water restriction, if any
Permission for ALDC

Permission from nearest grid substation
Proper working of
Communication system
AC Power
DC Power
Firefighting system
Drainage & dewatering system
H.S. lubrication system
L.P. & H.P. compressed air system
Protection system

2.2.1 Check List for Starting of Machine

The staff responsible for the operation should be well conversant with technical
details and importance of following:-
Intake gates bye pass gates & forebay
Inlet valves
Turbine
Generator
Generator Transformers
Switchyard
Synchronizing with grid
Closure of machine
Emergency closing of machine
Importance of log sheets

2.2.2 Mechanical

On Intake
Check bye pass gate are not mechanically locked and all valves are in okey
position
Check position of intake gate
Check position of stop log gates
Check filling line valve of penstock
Check supply to gates is O.K.
Inside P.S.
(i) Inlet valve:-
AC power for pump operation
HP compressed air
Locking pin position
Level and pressure in OPU
(ii) Others:-
(a) Check valves:
Check spiral drain valve is closed
Check D.T. drain valve is closed
Position of stainer valves ensure water flowing in cooling pipes
Gland seal valve open

Air seal valve closed
Top cover drain system okey
(b) Check levels:
Pressure accumulator (OPU)
Turbine Guide bearing
Lower Guide bearing
Upper Guide bearing
Thrust bearing
(c) Check pressures:
Spiral casing
OPU
Stator cooling water pressure
Thrust bearing UGB, LGB
Sealing water pressure
Servo motor Pr. Gauge
Air pressure (brakes)
(d) Check working of systems
Top cover drain
Oil leakage unit
Oil cooling unit
Oil pressure unit
Brakes
Position of CO
2
batteries
Guide vane lock on or off
Check jacking/dejacking of m/c
Check flow relays
Check emergency slide valve reset
Check working of ventilation system
D.C. System
Grid Power
DG Set power
Event logger
Disturbance logger

2.2.3 Electrical

Check list of Generator
Brake system
Cooling water for bearings
Generator fire fighting
AVR condition
DC supply for field flashing
Oil levels in bearings
IR values
J ack position
H.P. lubrication condition
Check earth link for bus duct


Check list for Transformers
Firefighting system
Transformer cooling oil pump position
Buccholz relay
Oil level in conservator
Colour of silica gel
IR of winding and core
BDV of oil

Check list for Switchyard
Compressed air in case of ABCB
SF
6
gas pressure in case of SF
6
breaker
Earthing switch position
Isolator position close
Breaker position off
Line isolator position

2.2.4 Operations

(i) Inlet Valve Opening
Put oil pumps on auto mode
Open compressed air valve
Open bye pass manual valve
Give opening command to bye pass auto valve
Check water pressure for equalizing
Give opening command to inlet valve
When inlet valve is fully open oil pumps must be stopped

(ii) Turbine Operation
Put oil pumps on auto mode
Open HP compressed air valve
Open LP compressed air valve
Open cooling water for bearings
Open shaft seal water
Put brake on auto mode
Release lock pin
Fix GV opening limit
Put machine on auto mode

(iii) Generator Operation
AVR on manual mode
Cooling water for transformer on
Oil circulation of transformer on
Keep fire fighting system alert
On D.C. supply for excitation flashing
At 30% of generator voltage D.C. supply from battery cuts
Now generator excitation supply get from excitation transformer

Start command initiated

(iv) Synchronization
(a) Synchronization checks
Line protection
PLCC
Give clearance for line back charging
Close line isolators
Close line breakers
Now circuit is charged upto switchyard from remote end
Start machine on auto mode

(b) Synchronization
Close field breaker
Now m/c will run at rated speed and rated voltage
Check line voltage & frequency
Check generator voltage & frequency
Reduce or increase generator voltage & frequency to match with line
voltage & frequency.
At equal line & generator voltage and frequency close generator
breaker.
Now generator is synchronized with grid.
Take minimum prescribed load immediately

(c) Checks after synchronizing and taking load
Unit control board supply is changed to unit Aux. Transformers.
Transformer Motor for Cooling Water Supply started.
All parameters in control room are matching and correct.
General check up of machine and other unit auxiliaries at all floors.

2.2.5 Checks at the Time of Shift Change Over (Machine Running on Load)

(i) Turbine & Governor

Check Temperature of following
- Thrust bearing
- Upper guide bearing
- Lower guide bearing
Check following in normal working condition
- Cooling water flow and pressure of all bearings at inlet & outlet
- Sealing water flow and pressure
- Stator cooling flow and pressure
- Grease pump
Check oil level in housings of all bearings
Check if, there is vibration or abnormal sound in OPU pumps
Check grease in the container of centralized grease lubrication system
Check working of following
- OPU pump 1 & 2
- OLU pump

- Drainage pump & Dewatering pumps
- Governor compressor
- General purpose compress
- Ejector system for top cover drains
- Cooling water strainers
Check sealing water pressure & air seal pressure
Check running and vibration of machine and ensure nothing is abnormal
Check working of top cover drainage system
Check water, oil and air flow indicators
Check physical appearance of various system such as man holes, valves,
indicators etc.
Check G.V. Servomotor stroke & R.B. angle is normal
Check general house keeping is in order and all panels, mountings on wall are
clean and in order.

(ii) Generator, AVR & Excitation System

Watch running and vibration of machine and ensure nothing is abnormal.
Check for any sparking from the brush of slip ring.
Check temperatures of winding & core. Ensure that these are with in limit.
Check that all instruments and indicators mounted on unit control board,
governor panel, AVR & excitation panel are in OK condition.
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 P.S.
Check all inlet exhaust fans are working.
Check all batteries are physically in good condition.
Check battery chargers are in normal working conditions.
Check for any abnormality, sound, chattering in bus duct, generator barrel,
neutral cubicle.
Check all AC supply boards installed in Power House are okey.
Check air conditioning plant is working satisfactorily.

(iii) Control room

Check that all parameters indicated on various panel are matching.
Check 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 facias & 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 out going lines.
Check grid voltage & frequency.

(iv) 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.

Check whether supply to various distribution boards are OK.

(v) DC Distribution Board, Battery Charger & Battery sets

Check D.C. voltage is correct.
Check D.C. supply is healthy by making momentarily float off. This would
ensure that batteries are connected with load.
Check both batteries are on float.
Check all the switches on DC board are in correct position.
Check that both chargers are functioning correctly.
Check all cells of battery bank are healthy. Their sp. Gravity and cell voltage
is correct.

(vi) Main Transformers

See that oil level is OK & there is no leakage from any where.
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 following checks for healthy condition of Mulsifyre system:
- Compressor
- Power
Oil level in conservator is normal.

(vii) Switchyard

Have general look at switchyard including bus bars, jumpers etc. Ensure that
there is no sparking any where and everything is in order.
Check compressed air system in case of ABCB, is OK.
Check SF
6
gas pressure in case of SF
6
breaker.
Check position of all breakers, isolators & line isolator and cast a look on all
CTs, PTs, LAs, Surge counters, wave traps and coupling capacitor and ensure
that everything is in order.

(viii) 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 instructions.
- Topping up of oil in bearings, OPU sump.
- Replacement of lamps, fuses etc.
- Cleaning of trash racks.
- Inspection of forebay, bye pass gates, intake gates.
- Any other work as assigned.

Work carried out during each shift shall be logged in daily in control room log
book.


2.3 GUIDE LINES FOR PREPARING OPERATION MANUAL

Every plant shall have an operation manual for guidance of operating staff. Generally
it should include following subjects:

General
General information about the project.
Salient features of the Project
Equipment data
Plant operation procedure
- Normal Start
(a) Prestart checks
(b) Starting procedure
Auto
Manual
- Synchronizing and taking load
- Normal shut down
- Emergency shut down
- Dead bus synchronizing
- Taking D.G. set in service
Problems during plant operation
Planned plant outage procedure
- Water conductor system outage
- Taking main transformer out for maintenance
- Taking turbine generator set out of work
- Plant outage for maintenance of machine
- Outage request form
- Plant outage instructions
- Procedure for operation personal for giving planned plant outage.
Essential Drawings (Enclosure)
- Plant layout
- Hydraulic layout
- Main single diagram
- Plan of different floors
- Transverse section thru unit
- Longitudinal section thru centre line of units
- Station earthing layout
- List of panels
- List of circuits
Operation of Auxiliaries and other system installed in P.S.
- Turbine Governor Oil Pressure Unit
- Cooling water system
- Drainage & Dewatering system
- AVR & excitation system
- Generator neutral grounding system
- Station compressors
- Station illumination & emergency lighting
- Station D.C. control system
- Generator fire extinguishing system
- EOT cranes

- Intake gates, bye pass gates, D.T. Gates
- MIV
Safety & Fire fighting
- General fire fighting
- Electrical safety
- First Aid
Duties of staff posted for operation of plant in each shift (Designation wise)
- Engineer-in-charge of Shift
- Technician (control room)
- Turbine operator
- Attendants/Oilers
- Intake Gate/Bye pass gate operator
Trouble shooting of various equipment in plant.

2.4 GUIDELINES FOR PLANT REPORTS AND RECORDS

A vast amount of information is generated by the power station on every aspect of
generation. Most of this data is generally compiled on daily basis at the Power Station
level and at HQ level for generation of Management Information Reports.

Generally following reports, logs, reading sheets are required to be prepared at
different levels of management structure:

Typical Plant Data Sheets:-

(ix) Hourly panel meter readings Control room
(x) Station event log book Control room
(xi) Station trouble/fault log book Control room
(xii) Energy meter readings Control room
(xiii) Daily generation report Control room
(xiv) Hydraulic data sheet Control room
(xv) Daily rainfall, lake level Control room
(xvi) Monthly generation & aux. consumption report Plant Manager
(xvii) Monthly water consumption & runoff report Plant Manager
(xviii) Occurrence and relay tripping report Plant Manager
(xix) Special event report (eg. Landslide, fire etc.) Plant Manager
(xx) Accident report (involving human being, animals) Plant Manager
(xxi) Quarterly safety & fire drill, training imparted at plant Plant Manager

2.5 GUIDELINES FOR SAFETY MANUAL

(i) Every power plant shall have safety manual, copies of which shall be given to
every employee. The safety manual shall contain:

Safety policy of the organization
Safety during work
Outage procedure with safety tags.

(ii) The management shall conduct safety training for operation and maintenance staff
on regular basis.

(iii)The safety equipment such as helmet, goggles, hand gloves, insulated T&P for
electrical works, earthing chains etc. shall be kept at the location where these can
easily be accessed.

(iv) The arrangement to supervise safety tags shall be made at each P.S. The list of
tags for every equipment outage must be finalized and given in safety manual.

(v) Guidelines for safety in working are to be given in detail in safety manual.

(vi) Fundamentals on Safety:

Prevention of accidents requires whole-hearted co-operation of all members of the
organization. A capable, mentally alert employee will avoid accidents. However
an unsafe person is a liability. He is danger to himself, his fellow workers and to
the equipment and organization.

Unsafe acts which may cause accidents:

- Operations an equipment without authority on warning.
- Operating or working without proper instructions.
- Making safety devices in operative.
- Using defective equipment or its improper use.
- Working nearby dangerous or live electrical equipment which
could conveniently be de-energised.

Unsafe conditions which may cause accidents:
- Ungrounded equipment.
- Defective material or equipment.
- Improper illumination.
- Non-standard design or construction.

Hence, accidents are the results of unsafe conditions or unsafe acts or
combination of both.

2.6 GUIDELINES FOR DISASTER MANAGEMENT

Disaster management is aimed at ensuring safety of people, protection of environment
protection of installation and restoration of generation.

(i) A task force consisting of O&M personnel of different discipline needs to be
constituted who will identify the following:

Source of disaster and steps to contain the same.
Isolate remaining plant and keep them in safe condition.
To organize safe shut down of Power Plant.
To organize all support services like fire fighting system etc.
Attend to all emergency maintenance jobs on top priority.
To apprise authorities on all safety related issues.
To record accident details.

To arrange for evacuation of man material from affected area.
Arrangement of ambulance and emergency first aid.

(ii) The disaster management plan for generating stations shall take care of the
following:

Emergency power supply system shall be made operational.
Back start procedure must be prepared needs to be reviewed from time to
time.
In case of fire, the unit/station needs to be emergency tripped through the
emergency push button.
Ensure immediate shut down affected or likely to be affected portion of
P.S., so that rest of the plant remains healthy.
Fire tenders need to be summoned immediately.
The fire extinguishing system needs to be automatically cut in and in case
of failure of auto system, the system should be manually started.
The earmarked hospital need to be informed of such emergency.

The units should be restarted as soon as the cause for disaster has been cleared
off.

(iii) Action Plan

For effective control and management of disaster an action plan and
organization shall be prepared by Power Station In-Charge alongwith
responsibilities. This shall consist of following factors:

Responsibility of employees about first information.
Responsibility of Emergency Management Manager (EMM) for
declaration of emergency (EMM to be nominated by Plant In-Charge).
Responsibilities of various teams constituted to deal with specific
emergency requirement.
Responsibility of EMM for All Clear signal after dibaster has been
cleared off

(iv) Essential Staff

In plants immediately affected or likely to be affected efforts will be made to
shut down and make other units safe. The plant supervisors and operators will
carry out this work without exposing them to any risk. The following staff will
also help them:

Attendants
First aiders
Persons responsible for emergency lighting
Persons responsible for transport
Persons working as runners, in case communication fails

Persons manning plant entrance, liason with police, Fire tenders, Call
for emergency vehicles, ambulance, to control traffic leaving P.H. to
turn away visitors and non-essential vehicles.

It is responsibility of EMM to identify such staff and form task force to
carry out above activities.

(v) Disaster Possibility in Hydro Power Stations

Disaster due to natural calamities such as floods, earthquake, wind
storms which may affect outdoor installations, land slides.
Areas prone to disaster on account of fire are cable galleries,
switchyard, switchgears.
Over speeding of turbines.
Failure of underground structures due to inadequate support or
geological reasons.
Following occurrence may cause flooding of P.S.

a) Failure of top cover studs.
b) Failure of Draft tube inspection window or near by liner plates.
c) Entry of water from down stream side windows of P.S. during
floods.
d) Failure of diversion dam gates opening during floods and entry
of water from upstream side in Dam Toe power station.

Power station staff should remain always alert for such emergent eventualities.
Power Station In-Charge should arrange drills, training for the staff at regular
interval specially before rainy season.

SECTION II

GUIDELINES FOR MAINTENANCE
OF SMALL HYDROPOWER


SECTION II

GUIDELINES FOR MAINTENANCE OF SMALL HYDRO POWER
STATIONS

1.0 INTRODUCTION

Experience of running hydropower station reveals that even after detailed project
planning/quality control measures taken at various stages from inception to commissioning
several unforeseen problems do take place during the operation and maintenance resulting in
forced outages/low generation and load shedding etc. causing misery to the consumers and
undesired set back to the overall economy. The main reasons which can be attributed to these
undesired phenomenon/events(during operation), are that the hydro power station equipments
is custom built in construction and tailor made at each discipline viz. design ,manufacturing,
erection, commissioning, operation and maintenance etc. The equipment cannot be fully
assembled or tested at works. Maintenance exercise at predetermined time interval are
therefore, planned to ensure the following objective:

1. Quality and reliable operation of equipment on long term basis through identified
periodic inspection /checking of components and subsequent replacement
/rectification parts, wherever required.
2. Maximum availability of equipment with least number of shut downs by ensuring that
the rate of deterioration of any component does not exceed the life expectancy of the
equipment at any stage. Periodic /planned shut downs should be arranged to avoid
long term forced shutdowns.
3. Eradiction /non-repetition of operational problems by timely analysis of the cause of
faults/problems and replacement of short term solutions by long lasting and
permanent ones.

2.0 TYPE OF MAINTENACE
2.1 REACTIVE (RUN TO FAILURE)

This is sometimes called crisis maintenance or hysterical maintenance. This has been
dominant form of maintenance for long time and its costs are relatively high because of
unplanned downtime damaged machinery and overtime expenditure. Run to failure should
be a very small part in a modern maintenance program. Planned maintenance is preferred
over this type so as to reduce downtime of machine and avoid uncalled for outages.

2.2 PREVENTIVE MAINTENANCE

Preventive maintenance is planned maintenance of plant & equipment. It is designed to
improve equipment life and avoid any unplanned maintenance activities. Preventive
maintenance is the inspection, replacement, repair of any piece of equipment or component
based on time and set parameters. It includes painting, lubrication, cleaning, adjusting and
minor component replacement to extend the life of equipment and facility. Its main purpose
is to minimize break down and excessive deterioration.


2.3 PREDICTIVE MAINTENANCE

This sort maintenance ensures ability to judge when a piece of equipment is going to fail and
replace the same before it does. Usually it requires some form of testing and analysis which
helps predict an eminent failure. Predictive maintenance can be used in conjunction with
preventive maintenance practices. In hydro power station there are many monitoring
systems, which can be used to predict problems and possible failures. These include
vibration monitoring, oil analysis, temperature, systems ampere readings resistance readings
of motors, efficiency in power generation out put, leakages of oil and water. All of these
things can be captured and tracked by computer system. The analysis of data can predict the
future.

2.4 PROACTIVE MAINTENANCE

Most recent innovative in maintenance is called proactive and it utilizes a technique called
root cause failure analysis. In this type of maintenance primary cause of failure is sought
and corrected.

2.5 RELIABILITY CENTERED MAINTENANCE (RCM)

This sort of maintenance is defined as a process used to determine the maintenance
requirements of any physical asset in its operating context. It is an on going process which
determine the mix of reactive preventive and proactive maintenance practices to provide
reliability at the minimum cost. It recognises that all equipments in facility are not of equal
importance for generation as well as plant safety. It recognizes that design and operation of
each equipment differs and therefore, possibility of failure also differs from equipment to
equipment. In this system diagnostic tools and measurements are used to assess when a
component is near failure and should be replaced. In this approach basic thrust is to eliminate
more costly unscheduled maintenance and to minimize preventive maintenance. In this
system unimportant maintenance activities are left to reactive maintenance approach.

3.0 REQUIREMENT OF EFFECTIVE MAINTENANCE

In addition to planning maintenance and allotting suitable time interval on the basis of water
supply availability following items also require close watch otherwise it may become difficult
to adhere to the schedules.

i) Man power planning and arrangement is most essential as without experienced /
skilled staff any maintenance programme may fall.
ii) Planning and arrangement of spares and consumable in advance so that time is not
lost I arrangement of the same after taking shut down.
iii) The maintenance engineers should have in his possession al the erection and
commissioning log sheet document to establish a record of installed clearances,
parameters, alignment results, test characteristics of al the power plant equipment.
These may be required at the time o diagnosis of the operational problems as well as
defined maintenance purpose.
iv) Log sheets of the previous maintenance exercise carried out on the machines. These
may be required to compare with the clearances/ settings/characteristics achieved
during present maintenance.

v) History registers of various machines duly recorded with all the abnormalities
observed on the machine and details of action taken to provide a guide line for future
maintenance exercise must be maintained at the power station.
vi) Logging of the performance characteristics of the power plant on daily basis recording
all the abnormalities and misbehaviors (if any) of the total plant observed during its
generation programme from one maintenance exercise to another.

4.0 GUIDELINES FOR MAINTENANCE OF SMALL HYDROPOWER STATIONS

In most of small hydro plants preventive maintenance approach is preferred over other
approaches. Following inspection checks are done in this type of maintenance:

Daily checks
Weekly checks
Monthly checks
Quarterly checks
Half yearly checks
Annual inspection and maintenance of components of plants
Capital Maintenance

4.1 PREVENTIVE MAINTENANCE OF HYDRO TURBINE & AUXILIARIES

4.1.1 Daily Checks

1. Foundation parts and Expansion J oints:
Checks for any leakage in draft tube manholes, spiral casing manhole, expansion
joint.

2. Vaccum Breaking Valve:/ Air Admission Valve
Checks the working of both vaccum breaking valve and see that there is no
abnormality in the springs, seats etc.

3. Water Seal and Air Seal:
i) Checks the position of water leakage of the water seal and see that there is no
excessive splashing and water level do not rise in top cover
ii) Note water pressure of water sealing /under sealing.

4. Turbine Guide Bearing:
i) Checks the oil level(stand still machine /running machine)
ii) Note the temp. of bearing and check that the temperature of oil and guide beaing pads
are within limits.
iii) Note the maximum and minimum temperature and compare with readings of the
previous day.
iv) Checks for any oil leakage from the bearing housing and check that oil is flowing
above the bearing pads.

5. Guide Apparatus:
Check any leakage from GV servomotor and its piping


6. Oil Leakage Unit:
i) Check any leakage from pipe line joints
ii) Check its satisfactory running on Auto.

7. Top Cover Drain System:
i) Main supply of ON for DPM.
ii) Vibration noise in the pump motor.
iii) Any leakage form the water piping
iv) Working and water pressure of the ejector.

8. Centralised Grease Lubrication System:
i) Check for any leakage from grease pipes, unions and nipples.
ii) Check grease container rand fill grease, if required.

9. Oil Header: (For Kaplan)
i) Check from perpex sheet manhole any splasing of oil from top and bottom bush.
ii) Check any oil leakage from the joints
iii) Note the pressure difference of opening and closing side of runner.

10. Oil Pressure System:
i) Check if there is any abnormal sound in the running of the motor and pump unit of
OPU.
ii) Check the oil level in pressure accumulator.
iii) Check any oil leakage from oil piping and its valve.
iv) Check for over heating of motor.
v) Note the timing of OPU pumps running and compare with previous day running
hours.

11. Mechanical Cabinet of Governor:
i) Pressure in transducer.
ii) Check any oil leakage from joints of piping.

4.1.2 Weekly Maintenance Checks

1. Greasing of guide vanes and servomotor with centralized grease lubrication system
and manually.
i) Oil in the gear box shall be checked.
ii) Check for any leakage
iii) Working of end pressure relay and solenoid valves, if defective, should be
reported.
2. Cleaning of OPU filters.
3. Cleaning of throttle filters in the governor mechanical cabinet.
4. Cleaning of governor compressor air filters and checking of oil levels.
5. Checking physically oil of OPU of the running machine, after taking sample through
the sampling cock, do the crackle test for detecting presence of water. Take remedial
measures.
6. Check oil level of all the bearings
7. Check wobbling of shaft at coupling flange and at oil header servo tube.


4.1.3 Monthly Maintenance Checks

All the checks covered in weekly maintenance as above are carried out monthly also. But
while carrying out these checks more attention is paid and short shutdowns, if required, for
rectification are taken.

4.1.4 Annual Inspection and Maintenance of Hydro Turbine

After successful running of plant for about one year few weeks are required to be allotted to
inspect rotating parts, control equipment and measuring instrument setc. And analyse cause
of change in the performance charactersitcs, if any. Modify / repair / replace (wherever
required) the worn out parts in order to prevent forced outages of machine at later date.

After every five years it is necessary to inspect 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 5 years operation.

The checks for annual and five yearly maintenance designed for a hydropower station are
enlisted below:

1. Foundation Parts:
i) Check condition of water path system. The damage due to cavitation and wear
to be rectified
ii) Check painting of spiral casing.
2. Runner:
i) Check the condition of the surfaces of the runner hub and the blades. The
damage due to cavitations & wear to be rectified by welding and grinding.
ii) Check the runner blade seals by pressurizing the system. Change seals if
necessary. No oil leakage is to be allowed (Kaplan only).
iii) Check the runner sealing for hermetic tightness, leakages of water in the
runner hub is not to be permitted (Kaplan only).
3. Guide Apparatus:
i) Check the presence of rubber sealing cords and the tightness of the rubber
sealing between the adjacent guide vanes in fully dosed position of guide
apparatus.
ii) Change oil in the regulating ring.
iii) Replace damaged shear pins.
iv) Check cup sealing of guide vane journals and replace, if necessary.
v) Check the bushes of guide vanes and change the worn out bushes of guide
vanes journals.
vi) Inspect the servomotor and change the seals, if these are worn out.
4. Guide Bearing:
i) Check the condition of rubbing surfaces of guide bearing. Clean the surface
and polish it with the help of chalk powder.
ii) Adjust the clearances of moving the segment with the help of adjusting bolts.
iii) Thorough cleaning of housing if necessary.
iv) Check all the RTDs and TSDs replace damaged one.


5. Shaft Gland Seal and Air Seal:
i) Check the condition of rubbing surface of sealing rings. In case found
damaged change the same.
ii) Check pipe lines and piping joints for any leakage if any, attend the same.
6. Emergency Slide Valve:
i) Check the functioning of emergency slide valve and the condition of inner
surfaces.
ii) Swift return of the valve in its original position after emergency operation
should also be checked.
7. Centralised Grease Lubrication System:
i) Check satisfactory working of CGLS system.
ii) Attend wherever fault is located.
8. OPU:
i) Check and attend leakage from any valve or flanged joints etc.
ii) Provide proper lubrication to the bearings of pump motor.
iii) Check filter and repair, if required.
iv) Clean oil sump, refill with centrifuged oil.
v) Check setting of the float relays for proper sequence of operation of pumps.
9. Oil Header
i) Measure clearances of upper and lower bushes, if found increased get the
bushes replaced.
ii) Clean the oil bath.
iii) Check the rubber cord fixed below the guide to check any oil dipping on the
exciter winding.
10. Oil Leakage Unit:
i) Check satisfactory working on Auto as well as manual.
ii) Clean the tank.
iii) Check the pipeline joints and valve for leakage, attend wherever necessary.
11. Oil Cooling Unit:
i) Check all the oil and water pipe lines for leakage and attend if necessary.
ii) Check satisfactory working of all cooling unit.
12. Governor Mechanical Cabinet:
i) Check filter and throttle if found damaged replace the same.
ii) Attend leakage of oil through pipe line joints and valves.
iii) Check auto rod setting, if found disturbed; set the same.
iv) Alignment of feed back wire rope pulleys.

4.1.5 Capital Maintenance of Hydro Turbine

Overhauling or capital maintenance of hydro set is usually recommended after about 10 years
of operation services. The whole unit is to be stripped off during capital maintenance and all
the defective/worn out parts/components repaired /replaced with new ones. Then the unit
recommissioned as per originally established commissioning practice of the power station.
After capital maintenance the unit are subjected to all periodic maintenance exercise outlined
above before it reach the next cycle of capital maintenance.

Following check are to be exercised during capital maintenance of a hydro set:

1. Turbine Bearing:

i) Desembly, inspection, cleaning, measurement of clearances, polishing of
guide pads, centering of shaft, reassembly, setting of clearances, filling of oil
sump with filtered water.
ii) Check the temperature sensing device, if necessary, replace with new ones.

2. Gland Seals and Isolating Air Inflated Seals:
Dessembly, inspection, cleaning and reassembly. Replacing of worn out rubber flaps
or carbon segments, if necessary.

3. Clean Water System:
Clean water pipes are dismantled, cleaned, reassembled with new gasket all the valves
are attended for any leakage etc.

4. Guide Vane Servomotor:
Dismentling for inspection and cleaning. Reassembling and replacing the seals with
new ones, if necessary.

5. Guide Vanes Bush Housing :
i) Removing, cleaning and inspecting for wear and tear replacing with new ones
if found necessary. Replace seals, if necessary.
ii) Guide vanes are reconditioned.

6. Governor:
i) Cleaning and checking OPU pumps. Replace bushes, bearings etc. if found
worn out. Also attend pump motors.
ii) Cleaning OPU sump and pressure accumulator and refill with filtered oil.
iii) Attend oil pipeline flanges and valves for leakages.
iv) Check setting of pressure switches installed for Auto operation for opu pumps.
v) Attend Governor Mechanical cabinet 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 be done.

7. Under Water Parts
i) Inspect condition of welded seams of penstock spiral crossing and draft tubes
rectify defects by welding and grinding. Penstock filling line valve should also
be checked and repaired.
ii) Cleaning and painting of penstock, spiral casing and draft tube liner.
iii) Overhauling of spiral drain valve and draft tube drain valve.

8. Runner
i) Dewatering of draft tube and fabrication of platform in the draft tube for
inspection of runner.
ii) If it is a Kaplan Runner test the same after applying full governor pressure for
leakage of oil.
iii) Replace blade seals if necessary.
iv) Inspect blades of the runner and make up profile of the blades by welding.
Due to erosion, abrasion and cavitations, material of the blade washes away
with passage of time. After weld repair heat treatment and dynamic balacing is
must before installation.

v) In case the runner is found to be irreparable arrange to replace the same with
new one.
vi) In case of Kaplan runner hydraulic test is also required to be done.

9. Turbine Auxiliaries
1. DPM

i) Inspect top cover drain system; overhaul the ejector and drainage pumps.
ii) Check pipe lines and valves. Replace gaskets and other parts, if necessary.

10 Oil Cooling Unit
i) Overhaul cooling pumps
ii) Attend all the valves and pipe line for leakage

11 Centralised Grease lubrication System
i) Overhaul greasing pump.
ii) Check whole greasing lines. Replace worn out valves and gaskets etc.
iii) Check all the nylon pipes connected with the guide vane bushes. Replace
damaged pipes.
iv) Check that all the guide vanes are receiving grease properly.

12 Oil Leakage Unit

i) Check the oil leakage unit overhauls the pumps.
ii) Clean tank and check that float is properly working.
iii) Checking all the pipe liens and valves for leakages.

4.1.6 Major Maintenance Problems of Hydro Turbines

Some of the major problems encountered in the hydro turbines are damage in runners due to
erosion, cracking and cavitation due pressure pulsation in draft tube, instability of operation
at partial gate opening. Failure of turbine bearings, leakages of water through of turbine guide
bearings, leakage of water through guide vane seals and turbine gland seals, these problems
are discussed in detailed in the following paras.

A. Runner

1. Erosion due to silt

The problem of erosion of turbine runners guide vanes and other under water parts has
assumed serious proportions especially in some of the run-of-river schemes, The rivers in the
northern region carry enormous silt loads especially during mansoon periods so much so that
the power stations has to be closed down to prevent serious damage to the turbines part and
water passage. Greater attention should, therefore, be paid to effective desilting arrangement
in such power station. Heavy damages have been observed on the runner labyrinth, seals,
guide vanes, inlet valve, shaft seals and draft tube cone. The wear due silt occurs so fast that
the unit has to be taken out for reconditioning every few years in some stations. The remedy
appears to lie in effective desilting arrangements and manufactures of turbine parts with
harder and erosion resistant material like stainless steel of popper grade and also design of
runner for such conditions.

At surface power stations with open channels following measures of desilting are taken:

i) Silt extruders have been provided near under sluice gates of the barrage.
ii) About half a kilometer downstream of the head regulator a silt ejector has been
constructed in the bed of the power channel
iii) In some projects desilting basin is constructed.
iv) Forebay is also used as desilting basing with flushing conduits

2. Cavitation & Cracking of Runner

The problem of cracking of runner and Pelton buckets in few power stations has been
reported. This can be due to following reasons:
i) Faulty design
ii) Poor metallurgy
iii) Metal fatigue

The cavitation phenomenon occurs due to the vaporization of flowing fluid in a zone of
excessive low pressure. Cavitation is inherent even in the best designed turbines and
cavitation damage occur under unfavourable operating conditions, limits of metal removal
have been specified beyond which cavitation becomes harmful and requires repair. To
minimize cavitation following steps are necessary:
i) Periodically (annually) inspect the runner and other turbine parts and take remedial
measures.
ii) Operate the machines as per guide lines given by manufacturers. The unit should not
be run below certain load to avoid cavitation pron zones.
iii) At design stage itself, ensuring proper submergence use of cavitation resistant
material and adoption of optimize runner profile based on mode tests, cavitation can
effectively controlled.
iv) As a result of draft tube pulsation and surges at no load or part gate opening excessive
nose, vibrations and cavitation is experienced. To minimize pulsation of draft tube
following measures must be taken:
-Air admission through air admission / vacuum braking valve installed at top cover.
-Provision of fins or flow splitter in draft tube to break the vortex flow.
-Provision of a byepass arrangement for releasing the pressure built up below the top
cover.
Normally the discharge side surface of buckets or blades, areas on the crown on the
throat ring and the tip of the blades and the upper portion of the draft tube liner are affected
by the action of cavitation. In rare cases, there may be pitting on the pressure faces of the
buckets or blades due to a unusual amount of over hung of the guide vanes improper design
or unusual operating conditions.

The power House authorities have over the years satisfactory expertise for repair and
welding of the runner at site, but it becomes a regular maintenance problem if the cracking
occurs too often.

3. Precaution in welding of runners

i) Surface should be prepared by chipping or grinding.
ii) To locate crack etc. die penetration test must be carried.

iii) Preheating of the blade to about 60 C is necessary.
iv) Avoid any localized excessive heating. It is achieved by welding for a short time in
any one particular area and then moving to a diametrically opposite area to continue
with the work.
v) The parent material about 70 to 75 mm. form the weld, should not be allowed to get
too hot to be touched with bare hand.
vi) Plenty of time should be allowed for the welded area to cool down since forced
cooling may cause distortion due to locked in stresses. Hot peening is also must.
vii) A close check should be made at least two to three times per day during the repair of
runner to runner chamber clearances.
viii) After welding all the welded areas should be properly ground to match with the
desired profiled.
ix) Die penetration tests should once again be carried out to ensure crack free welding.
Rectification, if necessary, should be done.

If extensive welding on the runner is required, it will be desirable to do static as ell dynamic
balancing of the rotating parts ad stress relieving before recommissioning to prevent problem
of cracking of blades and excessive vibrations in machines.

B. Turbine Guide Bearing

A number of turbine guide bearing designs are in use. These may be classified as follows:
i) Plain water cooled bearing.
ii) Bath type with circular cooling turbines.
iv) Bath type with cooling water tubes embedded in the pads.
v) Grease lubricated bearing.

In the case of plain water cooled bearings, either ferrobestos or rubber lined pads are used
against a welded shaft sleeve. The ferrobestos lined bearing have given considerable trouble
at one of the power station and these had to be replaced by rubber lined pads.

Small dia cooling pipes embedded in bearing pads have a tendency to clog especially at the
time of high silt contents resulting in water starvation. Complaints of excessive oil splashing
have been received about the rotating bath type bearing. 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.

A number of cases of turbine guide bearing failures have come to notice. These are:

i) Starvation of oil in the bath.
ii) Failure of cooling water due to clogging of pipe.
iii) Mal-functioning of instrument like RTDs, TSDs, oil level and flow relays etc.

To avoid failure of bearing due to cooling water tube a new design of turbine guide
bearing has been developed by M/s BHEL Hardwar. Two separate oil sumps are located in
the top cover in diametrically opposite locations. These sumps, through pipe lines are
connected to he oil bath of the bearing. The oil is circulated between sumps and the bath
Top cover being stationed just above the draft tube; separate cooling water arrangement for
bearing oil is not required. The bearing temperatures with this arrangement never go beyond
40C to 42 C.

C. Gland Seals

Normally two types of shaft gland seals are in use in different power stations:
i) Carbon or ferrobestos segment.
ii) Rubber flap type.

1. Carbon or Ferrobestos Segment Type

The seal segment s are housed in the stuffing box. Stuffing box being always in touch
with the shaft is subjected to excessive wear and tear. The overhauling of the stuffing 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. In general maintenance of the
seal 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 care
must be taken to ensure that the axial thickness of the new segments falls within the limit size
to 0.002 of the existing ring to which it is to be fitted.
All carbon segments and spacers are fitted to place and match marked on assembly.
Whenever any part is replaced it should be ensured that match marking after final assembly is
done. Whenever reassembly of the gland seal with existing gland ring or new ring is done it
is importance to ensure:
b) All carbon / ferrobestos segments are carefully examined for any chipping or damage.
c) All stainless steel facings are flat and square with the gland sleeve and there are not
steps at the facing joints.
d) Stainless steel facing and sleeve are completely free from grease.
e) Ensure proper bedding of segments with shaft sleeve.
f) All segment to segment and segment to stainless steel mating surfaces are perfect.
g) All garter springs are assembled to obtain even tension all around.
h) Alignment of segments in the lower assembly is carefully checked with a hard wood
peg for similar device before fitting retaining pins.

2. Rubber flap type

Maintenance of rubber flap type gland seal is comparatively simpler and easier. Only
precaution during assembly of rubber gland is jointing of the rubber seal in the proper way.

The quality of rubber used plays a very important role for satisfactory performance of the
rubber gland. In one of the recently commissioned power stations rubber gland seal used to
fail very frequently. The cause of frequent failure was discussed and analysed to be lying in
the quality of rubber. The problem after selection and use of proper quality of rubber is now
over.

D. Guide vane servomotor

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


E. Governor

Different types of governors are in use in different hydro power stations:
o Mechanical governor can be classified as follows
Fly ball type
Accelero technometric type
o Governor employing magnetic amplifier.
o Governor employing electro hydraulic amplifier.
o The 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 cleared. Filters should also be
cleaned, and after cleaning and reassembly governor parameters and
characteristics should be readjusted so that there is no hunting of the governor.

F. Governing Oil System

The oil sump should be well 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 cases oil retained its properties even up to 15 to 20 years of continuous use.

During annual overhauling OPU sump and pressure accumulator should be completely
emptied and cleaned. The strainers should be inspected and repaired of necessary. The OPU
pumps require maintenance when they develop excessive noise or vibration. This may be due
to some worn out bearing of the pump which would be replaced.

One more problem which has been faced in different power station is entry of water in the
governing oil system. From following two sources the water can enter in the governing oil
system.

i) From top cover, through oil leakage pumps which caters leakage of servo motor oil.
Its sump being located will below the level of servo motors in the top cover may not
be properly sealed, thus providing access to the top cover water which may ultimately
be pumped in to the OPU sump.
ii) In case of Kaplan turbine water may enter into the runner hub through rubber seal of
blades.
To eliminate first possibility the oil leakage unit delivery was isolated from the OPU
sump and connected to a separate tank.
But for the second possibility there is no way except replacing blade seals if excessive
water found in the Governor oil.

Daily check of the OPU sump oil sample and test of the same is necessary to keep
track of such possibilities.

G. Header

In Kaplan turbine the oil header is required to supply governing oil to the runner servomotor
and return oil to the OPU sump. Oil header has an oil guide connected with the rotating and

servo tube. The servo tube has ports to receive return oil to the pipes coming form OPU
sump. This tube is guided by three sets of bushes in the oil tube. Due to run out of the shaft
these bushes has to press the servo tube. Failure of these had been very frequent in one of the
power station.

Monitoring of wobbling of the servo tube with help of dial indicator may provide a guide line
and save the bushes from further wearing. Remedial measures to reduce run out of the servo
tube must be taken at this stage.

At the time of assembly of various parts of header proper match marking and dowelling is
essential so that reassembly may be correctly done.

4.2 PREVENTIVE MAINTENANCE OF HYDRO GENERATOR

Preventive maintenance ensures a long trouble free operation of the generator. Given in the
following table are the recommended daily, monthly, once in 3 months, half yearly & yearly
maintenance checks to be conducted on the generator. While it is appreciated that it is not always
possible to rightly follow this schedule due to generator loading constraints, the recommendation
given may be taken as a guide line and these may be altered slightly, based on the past experience.

Sl. No. Description Periodicity Remarks
1.00 Stator:
1.01 Temperature record on log sheet for core and
winding, hot and cold air temperature
Hourly
1.02 Visual inspection of the overhang parts of the
stator winding.
Once in 3
months

1.03 Checking the fixing of winding, condition of
winding joints with bus bars etc.
Once in 3
months

1.04 Clean the winding with dry & clean
compressed air (2 to 3 kg/cm
2
).
Once in 3
months
Cleaning to be done
such that the dust does
not collect in side
machine.
1.05 Check overhang parts of stator winding, bus
bars, inner periphery of stator core (if
possible), parts of stator winding in slots
(specially at sector joint) binding & spacers
between the winding bars/ bandage rings.
Yearly
1.06 Check looseness of overhang, busbars slot
wedges etc.
Yearly
1.07 Check the fixing of stator active iron with the
frame body in all possible places. If it is
necessary, tighten the studs of pressing
plates.
Yearly
1.08 Check pins & fixing of stator with
foundations.
Yearly
1.09 Check D.C. resistance, IR & PI value. Yearly Record to be
maintained
1.10 Check functioning of RTDs of stator. Yearly -do-
1.11 Blow the winding, active iron and bandage
rings etc. with dry & clean compressed air (2
Yearly

to 3 kg/cm
2
).
1.12 After cleaning apply Red-gel coat on the
overhang.
Yearly Not required during
600 hrs. inspection.
1.13 In case of excessive wetting of stator winding
during conditions such as flooding, drying of
winding by passing current is not allowed
initially as electrolysis of water may take
place. Which is harmful to the winding.
As per
requirement
External heating
arrangement is to be
provided till wetness
is removed
2.00 ROTOR:
2.01 Check rotor winding and insulation details of
current carrying leads.
Once in 3
months

2.02 Check the condition of interpolar connectins Once in 3
months

2.03 Check the condition of damper winding. Once in 3
months

2.04 Check the locking of pole wedges. If required
carryout additional wedging.
Yearly
2.05 Check locking of rim wedges Yearly In case the wedges are
loose contact
manufacturer before
attempting any
rectification.
2.06 Check the gaps of spider arms, brake track. Yearly
2.07 Check tightening & proper locking of all
fasteners.
Yearly
2.08 Clean rotor from dust by blowing
compressed air free from moisture (2 to 3
kg/cm
2
).
Yearly
2.09 Measure D.C. resistance and IR value of
rotor winding.
Yearly Keep a record
2.10 Check the pole coils for interturn fault. Yearly Not required during
600 hrs. inspection.
3.00 Slipring & Brush Rocker
3.01 Check sparking. Every shift
3.02 Check pitting & Grooving of slipring Monthly In case of excessive
grooving rectify by
grinding.
3.03 Check IR value of rotor through sliprings
before & after cleaning sliprings.
Once in 3
months
Keep a record
3.04 Clean the brush rocker, Brushes, sliprings
and the surrounding areas.
Monthly Special care be taken
to clear carbon dust
from V shaped
insulation pieces fitted
between sliprings.
3.05 Check brush wear & spring tension. Monthly Use a precision spring
balance for adjusting
spring tension. The
carbon brushes can be

used till it is not
possible to measure/
adjust spring tension.
3.06 Check for absence of oil or its vapours
slipring area.
Every shift. Oil leakages, if any, to
be removed.
3.07 Check distance of brush holder from slipring
and keep it as specified in the drawing.
Monthly
3.08 New brushes to be used after bedding the
brushes. The brush should not be too
tight/loose inside the holder.
While replacing
3.09 Ensure use of same & recommended grade of
carbon brushes on one machine.

3.10 Check all fasteners of sliprings, brush rocker
& current carrying lead.
Once in 3
months

3.11 Check carbon brushes for absence of
spittings and severe wear & tear.
Monthly In case the damage is
excessive, replace
complete set.
3.12 Inter change polarity of sliprings. Half yearly
3.13 Carryout thorough cleaning of slipring area.
Stop oil leakages in this area.
Half yearly
3.14 In case the original insulating enamel unit is
peeling off remove the balance enamel and
apply fresh enamel.
yearly While cleaning avoid
using insulating paint
removers.
3.15 Check wobbling at slip rings. At the time of
installation/
during major
overhauling

4.00 Thrust Bearing
4.01 Measurement of temperatures of T.B. Pad &
Oil by RTD & TSD and record on log sheet.
Hourly
4.02 Check & record reading of oil level relay. Once in a shift
4.03 Analysis of oil from oil bath. Half yearly Record to be kept.
4.04 Change of oil in T.B. oil bath When
centrifuging
doesnt help in
improving its
quality up to
acceptable
values.

4.05 Check level of oil from the gauge glass. Any
increase in level may be due to leakage of
water in the oil bath coolers.
Once in every
shift.
Unit should be
stopped in case of
leakage from cooling
tube, plugging of
cooling tubes upto
10% can be done
depending upon
bearing temperature.


4.06 Measures insulation resistance of T.B. disc. Yearly
4.07 Check calibration of the TSDs & RTDs of
thrust bearing.
Yearly
4.08 Check the working surface of thrust bearing
pads, scrapping, if required, should be carried
out with respect to T.B. disc after apply lard
(animal fat) on the pads & giving rotation to
the unit. Load sharing on T.B. pads and the
verticality of the unit is to be checked
thereafter.
Yearly
4.09 Check the condition of mirror surface of T.B.
Disc. Polishing of the surface can be done to
remove minor scratches.
During capital
maintenance
This will require
partial dismantling of
unit.
4.10 Clean all inner surfaces of oil bath from dust,
wash them with Kerosene and dry with clean
cloth.
Once in Two
years.
Oil bath is to be
finally flushed with
fresh turbine oil; to be
discarded after use.
4.11 Check the condition of weld seam of oil bath
& oil pipe lines for leakages visually.
Yearly
4.12 Check the condition of insulation of RTD
leads.
Yearly
4.13 Check if excessive foaming is taking place
on oil through gauge glass. This is normally
due to mixing of water leaking from oil
coolers. If oil level is not rising, the oil may
need a defoment. Oil sample to be checked.
As required Watch carefully for
rise in water level to
confirm leakage and
attend accordingly.
4.14 Check if any insulating segment over T.B.
Disc is displaced.
During capital
maintenance

4.15 Check (in case of problem) the intactness of
spherical surface of thrust bolt.
As per
requirement.

4.16 In case of uneven wear of pad, check that the
pad eccentricity is correct.
As per
requirement.

4.17 Check for proper seating of pads As required
4.18 Change rubber seals & woolen felts

As required
5.00 GUIDE BEARINGS

5.01 Measurement of temperatures of G.B. pads,
oil by RTD & TSD & record on log sheets
Hourly
5.02 Check & note reading of level relay Once in every
shift

5.03 Analysis of oil from oil bath Once in 3
months
Record to be kept.
5.04 Change of oil in T.B. oil bath When
centrifuging
doesnt help in
improving its
quality up to


acceptable
values
5.05 Measures insulation resistance of G.B. pads. Yearly
5.06 Check calibration of TSDs & RTDs of of
G.B.
Yearly
5.07 Prior to removal of pads, measure and record
guide bearing clearances.
As per
requirement
To be readjusted if
required, during
reinstallation
5.08 Check each pad for:
i) Absence of scratch marks. Scrapping to
be done with respect to the journal, if
required
ii) Heavy damage on babbit surface of pads
full set be replaced from spares. The
spares set tot be scrapped with respect to
its respective journal surface by giving
rotation to the unit.
Yearly
5.09 Check the centering of the unit vis--vis the
labyrinth/runner chamber of turbine.
Yearly as per
requirement

5.10 Check the friction surface of the bearing
journal. Carryout its polishing, if necessary.
Yearly
5.11 Wash pads & journal with aviation petrol and
then carryout assembly of the guide bearing.
Yearly
5.12 Check the condition of welding seems of oil
bath & leakages from them and oil pipe liens.
Yearly
5.13 Clean all inner surfaces of oil bath from dust,
wash them with Kerosene and dry with clean
cloth.
Once in two
years
Oil bath is to be
finally flushed with
fresh turbine oil; to be
discarded after use.
5.14 Change rubber seals and woolen felts. As required
5.15 Check operation of the level relay and its
calibrations.
Yearly
5.16 Check welding of pad support block with oil
bath.
Yearly
5.17 Check looseness of pad and pad support
bolts.
Yearly
5.18 Check condition of pad insulation Yearly
5.19 Check looseness of bolts holding Z clamps
(in wedge type construction of guide
bearings.

Yearly
6.00 AIR/OIL COOLERS

6.01 Check water boxes for clogging by opening
them. In case of clogging clean tubes water
boxes with wire/ nylon brush. Remove all
dirt etc & finally clean with fresh water &
Yearly This checking may be
done frequently if
clogging is more.

dry.
6.02 Check the gasket between oil cooler & oil
bath & between air cooler & stator frame.
Gaskets to be replaced if required.
Yearly
6.03 When the shutdown exceeds 10 days, water
from coolers is to be drained and the coolers
kept dry.
As required
6.04 Coolers are to be immediately attended to as
given above at 6.03.
On flooding of
the unit.
This is to safe guard
failure on subsequent
commissioning of the
unit.
6.05 Normally upto 10% of the cooling tubes of
coolers can be plugged, if required.
As required Temperature of the
bearing pads/ stator
winding to be taken in
view while plugging
tubes of the coolers.
7.00 UPPER BRACKET / LOWER BRACKET

7.01 External inspection & tightening of the lock
nuts in the radial jacks, if required.
Once in 3
months

7.02 Check fixing of the generator cover plate Once in 3
months

7.03 Check all fasteners of Upper and lower air
baffles.
Once in 3
months

7.04 Check the value of air gap between air
baffles and rotor.
Yearly These gaps are to be
compared with
original values during
erection and
maintained as such, if
required.
7.05 Clean the brackets of dirt & dust. Yearly Cleaning can be done
more often if possible.
7.06 Check fastening between upper bracket &
stator and foundation plates.
Yearly
7.07 Check foundation bolts tightening for stator
& lower bracket.
Yearly
7.08 Check all fasteners for locking / tightness Yearly
8.00 Brake pipe line
8.01 Record air pressure available at brake panel. Every shift Record on log sheet
8.02 Check thickness of brake pad As required Record to be
maintained along with
number of braking in
the period with Air
pressure used for
braking.

8.03 Measure:
i) Time for unit to come braking speed
During first
spinning / yearly
Record be kept. In
case if this time has

from rated speed after signaling the unit
to stop.
increased abnormal
then look for
increased guide vanes
clearances. Presence
of oil on brake track
or reduction in air
pressure, defective
gauge etc.
8.04 Check if excessive brake dust is generated
and find its cause.
Yearly Clean the affected
areas periodically as
required
8.05 During jacking operation lifting of the rotor
is to be limited to the specified value (7.0
mm)
During jacking Limit switch to be
suitably mounted to
check the rotor lift.
8.06 Keep the unit on jacks which are
mechanically locked during each shut-down
of the unit
As required
8.07 After each jacking operation ensure cleaning
of pipe with air under pressure as provided in
the system.
As required
8.08 Check no oil leaks from return line during
jacking operation
As required
8.09 Check function of the braking system on
manual & auto and the operation of the limit
switches of brake. Check leakage through
pipelines during braking / jacking.
Yearly Record be maintained.
In case of any
problem brake panel
& brakes are to be
checked & rectified as
required.
8.10 Check all fasteners of brakes and brake pipe
lines & gaskets wherever provided.
Yearly
8.11 Check the condition of brake track and its
holding with the rotor.
Yearly
8.12 Open brake cum jack assembly. Clean the
inner surface of dust with Kerosene &
reassemble.

Yearly Replace the gasket, if
required.
9.00 GENERAL

9.01 External examination of parts of generator
which are accessible.
Once in each
shift

9.02 External inspection of air coolers, oil coolers,
pipe lines, sealing & control etc. for leakages.
Once in each
shift

9.03 Ensure cleanliness of all external accessible
parts of the generator & wipe with clean &
dry cloth.
Once in each
shift

9.04 Check wobbling of the shaft at turbine
generator flange/ TGB.
Daily
9.05 Blow with compressed air the internal Monthly

surface of the generator.
9.06 External inspection of current carrying leads
PMG, Bus Bars, Terminal Blocks, Panels
edc.
Monthly To be cleaned if
necessary
9.07 Check the condition of lighting inside the
barrel
Monthly
9.08 Check the recordings of lighting inside
original results.
Daily Reasons for variance
to be investigated
9.09 Check for proper cleaning of sliprings. As per
requirements

9.10 Check the vibrations at TGB, UGB & LBG
predetermined points.
Yearly
9.11 Check connections of current carrying leads
& cables. Tighten the bolts, if required, after
removing the insulation.
Yearly
9.12 Check the calibration of Electrical measuring
instruments i.e. voltmeter, ammeter, Active/
Reactive Power meter. Frequency meter, P.F.
meter for Stator output, Voltmeter &
Ammeter in Field winding circuit, energy
meter etc.
Yearly
9.13 Check the Sensitivity & Stability of
Generator Electrical Protection scheme.
Yearly
9.14 Check the working of Fire Extinguishing
(CO
2
) system without actually releasing the
CO
2
) gas on manual and on auto operation as
per the instructions provided in O&M manual
of the Fire Extinguishing System provided by
its supplier.
Yearly
9.15 Check the characteristics of Static Excitation
system in both auto & manual mode and
sensitivity of various limits.
As specified in
its O&M
manual.

10.00 OIL PIPE LINE/ EXTERNAL OIL
COOLING SYSTEM (If applicable)

10.01 Check oil pressure at the pump across the
filter & point of entry to the bearing.
Every shift Record is to be
maintained.
10.02 Check the operation of the electrical contact
pressure gauge.
Monthly
10.03 Check temperature of bearings of the Pump-
motor set.
Daily This temp. is not to
exceed the specified
limits. In case temp. is
excessive check if
lubricating grease is
filled as required.
10.04 Check conditions of gland packing of the
pump and see that air is not being sucked
from here into the system.
Monthly These are holes in
pipes which feed oil
in between the pads.
10.05 Completely clean the oil tank & T.B. oil bath Yearly

10.06 Clean the oil pipe line after disconnecting it Yearly
10.07 Check the operation of the valves of the pipe
line.
Yearly
10.08 Check the Operation of D.C. pump motor set
(if provided)
Monthly
10.09 Remove sludge from oil tank. Monthly
10.10 Check the temperature of cold & hot oil. Hourly Keep record in the log
sheet.
10.11 Check the air ventilation cock of the oil tank
are open during operation of the unit.
During start of
the unit/ during
each shift.

10.12 Check pipe line for leakage of oil. Once in each
shift.

10.13 Check oil sample for acidity, viscosity,
moisture content, foreing material & sludge.
Formations.
Once in 3
months
Separate oil sample
from each bearing
should be sent for
chemical analysis &
record to be kept.
10.14 Clean holes for oil entry into the T.B.
housing
Yearly

All the above checks and some more checks are again tabulated for daily, weekly, monthly
and annual checks and maintenance.

4.2.1 Daily Checks

Sl.
No.
Assembly Item Check Point Method Remark & Remedial
Measures
1. Stator Core Core Noise Abnormal
noise around
stator
Periodic
listening
Checking for core
looseness especially at
frame joints
If abnormal add
additional paramax
paper in core joints
2. Wound Stator Stator core and
coils
Core &
winding temp.
Temp.
scanners
Check cooled air &
cooling system
3. Guide & thrust
bear
Bear pads Bear. Temp. R.T.Ds. Abnormal Vibrations,
Balancing of rotor,
dirty oil coolers,
cooling water flow
contaminated oil,
bearing clearances
4. Bear oil Oil level Level gauge Visual High- Due to Water
Leakage
Low- Leakage of Oil
From Housing
5. Air Coolers Cooler tubes Water leakage Visual Plug the leaking tubes
6. Collector Brushes Sparking, Mix
of C-Dust/ Oil
Visual Cleaning
7. Brake & J ack Air Pr. Pr. Gauge Pr. Gauge Check for leakage,
pipeline, joints
8. D.C. Exciter Commutator
brush gear
Commutation Visual


4.2.2 Weekly / Monthly Checks

Sl.
No.
Measures
Weekly
1. Collector ring Cleaning Accumulation
of Dirt
Visual Clean compare, IR
value
2. Brushes Sparking,
Chattering
wear &
clearance
Smoothen collector
surface clean adjust
brush (5 to 8 mm for
1000 R-hour)
3. Brake Lining Air leakage,
excessive wear
Visual Attend leakages
More than 4 to 5 mm
per 50 OP
Reduce application,
speed & PR.
Check air PR, Clean
Track, Change Lining
4. Brake Track Clean liners &
Oil Sludge/
Moisture Trap
Visual Clean Drain Trap &
Clean Brake Track
5. Dc. Exciter Commutator
Brush Gear
Commutation Visual Brushes are not sticking
in their boxes, rough or
high spot on
commutator smooth
surface.
Monthly
1. Stator core Back of core Visual Adjust core packing of
jack screws, insert
paramax paper
2. Field wind Field coil top Visual Feeler
Gauge Visual
Clean Comp. Air
3. DC Exciter Commutator,
Brush Gear,
Air Filter
Visual Replace brushes, clean
com., Risers, clean with
detergent sol. Dry.


4.2.3 Annual Inspection & Maintenance

Sl.
No.
Measures
1. Stator (i) Frame J oint bolt
tightness &
Dowel Pins
Hammering Retighten, if Necessary
(ii) Core Tightness of
Core
Check Tightness of
core specially at the top
& bottom most
packets. Any local
looseness between
punchings can be filled
up with asbestos of
paramax paper glued
with epoxy varnish &
core bolts retightened.
After repairs spray the
top & bottom three
packets (both from I.D.
& O.D.) with loctite
290 Marketed By M/s
Fit Tite Chemicals Ltd.
Core Duct Contamination Visual Clean with Dry
compressed air
Stator
winding
Cleanliness &
general
condition
Visual Clean the end windings
Measure IR
values after
cleaning
Dryout if IR Value is
low
2. Field winding Field coil &
rotor
General
condition of
coil, Pole &
cleanliness
Visual Clean the field coil
with compressed air
Check the coil joints
for any cracks
overheating etc.
Field coil &
rotor leads
Inter turn faults Measure
impedance of
field coils by
applying 60 to
100 V AC, 50
Hz supply
If impedance of some
coils is very low (say
less than 40%) they
must be checked for
possible inter-turn
faults.
3. Brushgear and
Sliprings
Brushes &
Sliprings
General
Conditions &
Cleanliness
Visual The slipring is running
out, Correct it, any
groves etc to be
removed by oil stone
for excessive sparking


Sl.
No.
Measures
4. DC exciter Core &
Winding
Accumulation
of dust
Visual For cleaning the exciter
Note: For cleaning stator ducts, stator winding, field coils, rotor leads, brushgear, PMG and
DC Exciter, Use cleaning agents as recommended by manufacturer
5. Bearings Top &
Bottom
Guide
Bearing
Pads
Clearance Feeler Gauge Check guide bearing
pad clearance. If pad
clearance have to be
reset the shaft must be
centered first.
Examine the condition
of guide pads and any
slight scouring marks
can be attended by
water emery paper
(GR-400)
6. Air coolers Coolers
tubes
Clean inside and
outside of air cooler
tubes
Checks for any tube
leakage by pressurizing
to a pressure slightly
more than maximum
expected working
pressure.
7. Oil coolers Coolers
tubes
Clean inside & outside
of oil
Check for any tube
leakage by pressurizing
to a pressure slightly
more than maximum
expected working
pressure.
8. HS Lub.
System
HS Lub
Motor HP
Hose
Assembly
Inspect bearing &
Grease, if necessary
check the condition of
the hoses & if
necessary replace them.
9. PMG Air gap
winding
General
condition &
cleanliness
Check air gap
Clean the stator & field
windings check the
open circuit voltage
and if less than 100 V
remagnetise
10. Shaft runout &
centering &
rotor level
Readjustment, if
necessary
11. Water flow
relays, visual
Impact, clean water
passages, if necessary

Sl.
No.
Measures
flow indicators
& flow meters
to remove silt etc.
12. Oil level
indicator
Clean rod probe
13. Braking &
J acking system
Combinat
ory unit
and air
supply
pipe line,

Brake
track
fixing

Brake
limit
switch

Clean the filter element
and bowl of filter,
similarly clean the
bowl of lubricator also,
cessation of oil
dripping through that
sight glass is an
indication that cleaning
is done

Tightness of Dog
clamps

Proper Operation &
Cleaning
14. Thrust & top
guide bearing
Bearing

Oil vapour
seal of top
bearing
Bearing
insulation
Vapour seal
insulation

IR value

IR value
Check IR value of
bearing
Insulation & replae
insulation if damaged.
Check IR value of
vapour seal insulation
and replace, if
damaged
15. Electrical
Connections
Pole to pole
connections

Brushgear
connection
RTD
terminal
heater
terminal
connection
Electrical
J oints
Tightness Tighten all electrical
joints

Tighten all electrical
joints.
16. Brushgear Cleaning Insulated parts Visual Clean the insulated
parts by compressed air
17. Rotor
assembly
Tightening
of fasteners
Looseness of
fasteners
Visual Tighten all the
approachable fasters on
rotor assembly
including tightening
pole and rim keys &
lock all of them.

Sl.
No.
Measures
18. Rotor Shaft
vibration

Bracket
vibration
Slipring and
coupling

Vibration
Dial gauge

Balancing
equipment
Check for run out at
slipring and turbine
coupling and readjust if
found more than the
specified value.
Rebalance if necessary
19. Rotor pole Damper
system

structure
Interconnection
between poles

Supporting
structure for
proper
tightness

Insulation
provide on
supporting
Visual

By tapping
By shaking

Visual
Tighten and lock
properly if supporting
structure found loose.

Rectify if found
damaged.
20. Top shaft Current
carrying
leads
Tightness of
clamps General
condition
Visual Repair insulation if
found damaged
21. Generator
Auxiliaries
Check for
proper
operation
Clean that these are in
good working
condition
22. Cooling water
valves
Check for
proper
operation
Clean & replace glands
where needed.
23. Over speed
device
Plunger &
contact
mechanism
Proper operation

4.2.4 Capital Maintenance of Hydrogenerator

Dismantling:
- Decouple generator shaft and turbine shaft after recording guide bearing clearances air gaps
between stator & rotor air gaps of main, pilot exciter & PMG etc if mounted on shaft.
- Dismantling 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
plat. Rotor rim to be supported by block and jacks all around the circumference.
- All stator air coolers are to be dismantled and kept for testing and repair.
- Braking & jacking units to be dismantled
- All cares are to be taken during dismantling to ensure safety of all components, fastners, pins
etc.
- Prior arrangement of proper T&P, special T&P, slings, D-shackles etc, is also necessary.

Maintenance of Stator:
- Stator Frame

Check all joints, tightness of bolts and location pins etc. Retighten if necessary.

- Stator core winding
Stator tightness of core specially at the top and bottom most packets.
Any local looseness between punchings can be filled up with paramax paper glued
with epoxy varnish & core bolt retightened.
After repair spray top and bottom three packets with loctite-290.
Clean core duct with dry compressed air
Clean the ends of winding.
Measure IR value of winding after through cleaning; Dry out if IR is low.
Carryout Electronic Core Imperfection detection test also to ensure healthyness of
core.
After rectifying all defect and thorough cleaning the inner bore and overhang portion
of winding is to be spray painted. Paint used should be specified insulating paint.

- Maintenance of 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 turn fault. Measure impedance of coils by
applying 60 to 100 VAC, 50 C/s If impedance 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. 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 damaged 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.
After rectification of all defects and thorough cleaning, spray point the rotor with
insulating red gel paint.
Keep the rotor covered with asbestos cloth to prevent deposit of dust and fire safety.
All safety precautions for external damage, fire etc are to be taken in the service.

- Maintenance of brush gears and slip rings
Check if there are any grooves, roughness high points use oil stone for rectification
Check brush gear connections clean all the insulated parts with dry compressed air.

- Maintenance of Bearing
Guide bearings
Check condition of Housing
Check condition of Pads, if required, bedding is to be done
In case babbit material found damaged or thinned, rebabbit of pads with proper grade
of white metal.
Check insulation of pads, if found damaged replace the same. Check IR value
Check all RTDs & TSDs
- Thrust Bearing
Check condition of pads, if found some damage to babbit material, get rebabbiting
done
Bedding of pads 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 vapour seal also and replace, if found damaged
Check condition of housing, pivot points of thrust bearing.
Check all pressure gauges, level indicator.
Check all RTDs & TSDs
- Maintenance of Air Coolers
Clean inside and outside of air cooler tubes
Check for any tube leakage by pressurizing to a pressure slightly more than max.
expected working pressure
If more than 10% tubes are leaking change full set of tubes otherwise change only
leaking tubes
After repair paint the body of coolers.
- Maintenance of Oil Coolers
Clean inside and outside of cooling tubes
Check for any tube leakage by pressurizing to a pressure slightly more than
maximum expected working
Replace full set of tubes if more than 10% of total tubes are leaking.
- Maintenance of H.S. Lub system
Inspect bearing and grease, if necessary
Check the condition of hoses, if necessary replace
Check for any leakages and take remedial measures.
Check pressure gauges etc.
- Maintenance of Flow relays, visual flow indicators and flow meter:
Inspect, clean water passages remove silt.
All defective meters are to be replace.
- Braking and jacking system:
Check brake units and clean inside outside of the unit
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
- General checks
Check condition of current carrying leads.
Check all water & oil valves for their proper working
Check general operational healthiness of all auxiliaries
Check proper working of overspeed device.

4.3 PREVENTIVE MAINTENANCE OF POWER TRANSFORMERS

The maintenance of transformer is an ongoing process and stress should be on preventive
maintenance rather than acting when a fault occurs. A schedule of maintenance activities is drawn
and tabulated below. This is applicable to Main, Auxiliary, stator & distribution transformers.


S.
No.
Item to be
inspected
Inspection Procedure Action required if
unsatisfactory condition
indicated
Applicable
UATS, SSTS and
distribution
transformers
when ticked
Applicable for
transformers
1 2 3 4 5
A Hourly
1. Ambient
temperature
Take air temperature
near the transformer
for air cooler
transformers. Take
water temperature at
the inlet to the cooler
for water cooled
transformers.

2. Winding
temperature
indicator reading
relation
Check for
abnormalities in to
ambient temperature
and load.
If the temperature indicated
is more than envisaged as
per loading condition, check:
i) That radiator valves or
cooler circuit valves are
all open.
ii) Fans operate at set value
of temperatures.
iii) Fans/oil pumps are in
circuit
iv) Winding CT connection
and C.T. ratio adopted.
v) Check calibration of OTI
and WTI.

3. Oil temperature
indicator reading
-do-

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/
Shunt reactor
humming and
general
vibration.
Check for any
abnormality in sound.
- Tighten any looseness in
external parts. If
abnormal sound still
persists, complete
checking be done.

B. Daily -
1. Oil level in
transformer /
shunt reactor
Check oil level from
oil gauge
- Top up if found low.
Examine transformer/
shunt reactor for leaks.
- Tighten gasket joint at
the leak point.

2. Oil level in
diverter switch
the gauge glass.
- If oil leakage found,
check sealing gasket
between diverter switch


S.
No.
Item to be
inspected
indicated
Applicable
UATS, SSTS and
distribution
transformers
when ticked
Applicable for
transformers
1 2 3 4 5
and transformer/ reactor
tank. Top up oil.
3. Oil level in
bushings
the oil gauge of the
bushings in which oil
remains separate from
the tank oil.
- If low, top up oil.
Examine bushing for any
oil leakage.

4. Pipe work and
accessories for
leakage
Check for oil leaks - If leakages are observed,
tighten evenly the gasket
joints. Replace O ring
or washer suitably.
Replace gasket if
needed.

5. Relief vent
diaphragm
Check for any crack - Replace if cracked /
broken. If broken, ensure
from other protections
provided that there is no
fault inside the
transformer / reactor.

6. Fans/ oil pump
running
Check that fans / oil
pump are running as
required.
- Check connections. If
found defective correct
them.

7. Oil & cooling
water flow.
Check oil and water
flow indicators.
- Check opening of valves
if restricted flow
observed.

C. Weekly
1. Leakage of
water into cooler
Check by opening the
end covers of the
cooler.
- Plug the tube leaking.
2. Operating
sequence of oil
pump and the
cooler
Change over from one
cooler to the other.
- Ensure proper change
over.

3. Operation of
anti-
condensation
heater in
marshalling box
and OLTC
motor drive
panel.

Check anti-
condensation heaters
are working.
- Set them right if not
working


S.
No.
Item to be
inspected
indicated
Applicable
UATS, SSTS and
distribution
transformers
when ticked
Applicable for
transformers
1 2 3 4 5
D. Monthly
1. Dehydrating
breather
i) Check colour of
silica gel

ii) Check oil level in
the oil cup and
contamination of
oil visually.

iii) Check that air
passages are free.
- If more than half of
silica gel has turned
pink, change by spare
charge. The old charge
may be reactivated for
use again.
- Add oil, if required to
maintain oil level.
Replace oil if
contaminated.

- Ensure air passages are
free.

2. Maximum
pointer of OTI
and WTI
Record the maximum
oil and winding
temperature readings
reached during the
month.
- Check whether the
readings are within
permissible limits.

- Reset maximum pointer
of OTI and WTI.

3. Operation of
fans
In mixed cooling in
ONAN/ ONAF, if
temperature of oil has
been less than the fan
control setting
temperatures, operate
the fans manually to
check their running.
- Ensure smooth running
of fans.

E. Quarterly
1. Bushings Visual inspection for
cracks and dirt
deposits.
- Clean dirt deposits. If
cracks observed, cracked
bushing should be
rectified / replaced.

2. Cooler fan
bearing and
control, pumps
Check contacts,
manual control
- Lubricate bearings.
Replace worn out
contacts. Clean fans and
adjust controls.

3. External earth
connections
Check all external
connections for
discoloration or hot
joints.
- Tighten them if loose.

S.
No.
Item to be
inspected
indicated
Applicable
UATS, SSTS and
distribution
transformers
when ticked
Applicable for
transformers
1 2 3 4 5
4. OLTC Examine contacts,
Check step by step
mechanism operation,
end position limit
switches and brakes.
Check that wiring is
intact and all terminals
are tight.
- Replace all the worn out
and burnt contacts. Set
limit switches in
position. Clean / replace
brake shoe lining.
Lubricate all bearing and
coupling points suitably.
Tighten terminals if
found loose.

5. Marshalling box Check wiring and that
terminals are tight.
- Tighten them if found
loose.

6. Oil in
transformer
Check for dielectric
strength and moisture
content
- Take suitable action to
restore quality of oil

7. Oil in diverter
switch
Check for dielectric
strength and moisture
content.
-do-
8. Insulation
resistance
Measure IR value
between windings and
to earth.
- Compare with previous
values. The comparison
should be done with
those values where
transformer/ reactor is
connected externally to
the line and bus ducts. If
the values are low,
measure IR values after
isolating it.

9. Oil bag sealing
arrangement
where provided.
Check presence of oil
outside the oil bag in
the conservator.
- If oil is present check
leakage in the oil bag by
applying air pressure.

F. Half Yearly
1. Alarm, trip and
protection
circuits
Check operation of
alarm / trip contacts of
each protection by
actual initiation and
also check display and
annunciation on the
panel.
- In case of faulty
operation, check contacts
and wiring circuits.

2. Oil in bushings Check BDV and
moisture content of oil.
- If values are low, filter oil
or replace with fresh oil.

3. Vibration level
of tank walls for
shunt reactors.
Measure vibration
level.
values.


S.
No.
Item to be
inspected
indicated
Applicable
UATS, SSTS and
distribution
transformers
when ticked
Applicable for
transformers
1 2 3 4 5
G. Yearly
1. Oil in
transformer
shunt/ reactor
i) Complete testing of
oil.

ii) DGA of oil.

- Filter to restore quality
or replace if the values
have reached discarding
limit.

2. Oil and winding
temperature
indicators.
i) Calibrate and also
check differential
between WTI and
OTI by feeding
current to the WTI
pocket heating
element.
ii) Check oil in the
pockets.
- Adjust if found reading
incorrectly.

- Replenish, if required.

3. Magnetic oil
level gauge and
prismatic level
indicator
i) Check oil level in
conservator by dip
stick method.
ii) Clean the oil gauge
glass.
- If oil level indication is
not correct check the
float.
- Replace glass if cracked.

4. Buchhloz Relay Mechanical inspection
i) Close valve
between buchholz
and conservator
and lower oil level.
ii) Check the
movement of floats
for rise and fall.
iii) Check tightness of
mercury switches.
iv) Check the
operation of alarm
and trip contacts by
air injection.
v) Clean cable entry
terminal box.
- Buchholz contacts
should operate when oil
level comes below
buchholz relay level.

- Make the movement
smooth.

- Tighten clamps if loose.
- Check contacts if
abnormality found.

- To be sealed to avoid
ingress of moisture.

5. Fan motors Check IR value of
motor winding, noise
and vibration of fans.
Dry out if found low. Check
balancing of fans.

6. Tanks and
accessories
Check painting and
surface finish.
Mechanical inspection
of all accessories.
Touch up / re-paint, if
required. Replace any
component found damaged.


S.
No.
Item to be
inspected
indicated
Applicable
UATS, SSTS and
distribution
transformers
when ticked
Applicable for
transformers
1 2 3 4 5
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 i) Diverter switch
servicing
ii) Check the contacts
of diverter switch
for burning or
pitting marks.

- Draw out diverter, clean
& tighten contacts.
- Recondition/ replace, if
required.

10. Bushing top
connectors and
arcing horns
i) Check contact
joints.
ii) Clean arcing horns
and check gap.
- Retighten.
- Adjust arcing horn gap

11. Air bag sealing
arrangement
where provided.
i) Check healthiness
of air bag.
- Clean, if required.
12. Cable boxes, if
provided
Check for sealing
arrangement for filling
holes. Examine
compound for cracks.
- Replace gaskets, if
leaking.
- Replace compound, if
necessary.

13. Lightening
arrestors
i) Examine for cracks
and dirt deposits.
ii) Measure IR value
of each stack of las.
- Clean or replace.

- In case IR value is poor,
replace.

14. Off circuit tap
switch
i) Move from
minimum to
maximum tap
position & return to
minimum position.
ii) Check resistance
measurement at
each tap.
- Compare resistance
values with previous
results. If resistance is
high, tap switch contacts
to be attended to.

15. Condenser
bushing
Measure power factor/
capacitance
measurement.
- Dryout bushing if values
are abnormal and replace
oil if required.

16. Electrical tests Carry out
i) Resistance
measurement at all
taps for
transformers with
off circuit tap
values. Incase of
abnormality investigate
causes.


S.
No.
Item to be
inspected
indicated
Applicable
UATS, SSTS and
distribution
transformers
when ticked
Applicable for
transformers
1 2 3 4 5
switch and at
maximum,
minimum and
normal taps for
transformers with
OLTC
ii) Magnetising current
at 415 volts.
iii) IR values after
isolating the
transformer.
iv) Turn ratio.
17. Oil coolers Clean oil coolers.
Check for leaky tubes.
- Flush cooler tubes
Repair leaky tubes. If
more than 10% tubes
leaking, replace the total
tube nest.

H. 5 yearly for
UATS and
SSTS and
Distribution
Transformers
& 7-10 yearly
for other
Transformer/
Shunt Reactors
-
1. Transformer
core and
windings
i) Wash by hosing
down with clean
dry oil.

- See following paras a &
b.

I 20 Yearly
1. Life assessment
tests
DP and Furan content
measurement
See following para c.

Note:

(a) 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
etc. at regular intervals. This can be done while the transformer is in position. Close all valves
connecting the cooler circuit/ radiators to 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.
(b) Whenever 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 work for which
the transformer was opened, do the following also:
(i) Tighten all coil clamping screws to remove looseness from the windings, if any.
(ii) Tighten all nuts and bolts whether metallic or made of insulating material on
mechanical and electrical joints.
(iii) Tighten core yoke bolts, core-clamping screws etc.

(c) Under the normal operating condition transformer has an useful life of about 25-30 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 worth while to know well in advance the remanent 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 remanent life in a
transformer, the action can be planned in conjunction with life assessment studies on
generating unit.
As these are comparatively new studies, the data are still being built and one should go by the
re-commendation of the Test Laboratory. However the following figures may serve as
guidelines.

Degree of Furan content
Polymerization ppm (mg/kg)
New transformer 800-950 Negligible
Nearing end of life 150-200 10

AHEC/MNRE/SHPStandards/E&MWorksGuidelinesforOperationandMaintenanceofSmallHydropowerStation S2
4.4 PREVANTIVE MAINTENANCE OF HYDROMECHANICAL EQUIPMENT

4.4.1 Maintenance of Intake Gates

The maintenance work shall included

Cleaning up
Adjustment
Lubrication with recommended lubricants & methods
Replacement of Defective parts
Repair of damaged parts
Recoating of damaged coat on ropes
Recording details of all work carried out with date & time.

Inspection and checks

Daily inspection should be carried out by gate operator to ensure:
Proper oiling and greasing wherever required
Tightening of loosened parts tightening contacts in electrical system
Check of ropes and hoisting arrangement.
Checking general condition of gates and gate grooves wheels etc.
Periodic inspection (half yearly or annual)
Dissemble and check all components for any damage.
Rectify damages or replace worn out irreparable components.
All safety precautions eg taking proper shut down installing safety tags, red flags etc.
are must, when any work is being on gates.
Before taking up work on gates, stop log gates must be lowered in the groove meant
for the same and plug all leakages through these.

Lubrication of gate parts:
Servogem EPI (IOC) or (equivalent of other brand)
- Rope drum shaft for all hoisting unit (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 2 months)
Compound D (Bharat camax) or (equivalent of other brand)
- Lifting ropes (once in six months)
Servocoat 120 T (IOC) or (equivalent of other brand)
- Gears & Pinions for all hoisting units (once in 2 months) (Meshing
faces only)
- Gears & Pinions for manual operation (once in 3 months)
- Gears & Pinions for all travel mechanism (once in 2 months)
- Gears & 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)

AHEC/MNRE/SHPStandards/E&MWorksGuidelinesforOperationandMaintenanceofSmallHydropowerStation SS
Problem in electrical circuit and checks

No supply at control panel inspite of turning on main switch check fuses.
Incoming supply healthy but volt meter not showing check fuses of voltmeter circuit
Motor is running even after pressing stop push button
Immediately put main switch off
Check contacts of motor control contactor & push button contacts. If damaged replace
these
Reset O/L relay before starting again
O/L relay tripped
Check control fuse
If fuse OK check control transformer
Gate is creeping down & restoration has failed indicating lamp is glowing but alarm
not ringing
Check position to toggle switch (it should be in reset position)
Indication of lamps are not glowing.
Check by pressing lamp test push button replace bulbs, if found fused.

4.4.2 MAINTENANCE OF MAIN INLET VALVES

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 maintenance concern.

The valve function should be verified periodically through test or normal frequent
operation.

Butterfly valves (head upto 120 m)

Butter valves generally consists 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
smooth 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 closure
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 connections and spool pieces to facilitate dismantling. Sometime
welded connection are preferred to save cost

Maintenance procedure

- Check operating system daily and ensure it is working smoothly
- Check for any leakage through connection daily
- Replace seals in annual maintenance
- Overhaul operating system annually
- Replace gaskets in flanged connection during overhaul

Spherical valves (for heads more than 120 m)

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 an unrestricted flow with minimum disturbance to the
flow path. To close the valve, the valve rotor is turned to 90
o
from the axis of rotor opening.

Spherical valve has tendency to close for positions less than 50% opening which
facilitates emergency closing.

Moveable seals reduce valve leakage when the valve is closed. Mostly valves have
both upstream and downstream seal. The upstream seal is maintenance seal or emergency
seal, the down stream seal is working seal.

When valve is closed under full pressure, the upstream maintenance seal allows
replacement or maintenance of the working seal with out dewatering the penstock. The
upstream maintenance seals have positive mechanical locking to prevent accidental opening.

Daily checks of operating system and remedial measure are must.

Annual inspection and overhauling of mechanical seal after dewatering penstock is
must.
Annual inspection and over hauling of operating seal is also essential.
Annual overhauling of operating mechanism to ensure smoth working through out
year is also done.
Annual overhauling of the valve rotor and other parts are also taken up as required.

Following Checks are also Essential

Checking and attending leakages from Valve & dismantling joint.
Checking and attending oil leakages from Servomotor
Checking the operation of operating valves.
Checking and attending the setting of Limit Switches & Operation of the same
Checking and attending leakages of distributing valve
Checking the correct working of the pressure gauges. Lubricate the parts if necessary.
Checking and attending for leakages in the piping.
Checking all the MIV System connections & Union for tightness
Checking all the MIV servo linkage during operation, looking for backlash
Cleaning of valve body, seal & solenoid valve
Checking the actuating solenoids for operation of valve. Cleaning the contacts and
rollers.
Checking the operation of bypass valve
Checking for cracks, pitting and cavitation etc. of MIV and Servomotor
Inspection of Rubber Seals
Checking trunions & bushes, bolts & nuts etc.
Checking gland packings and lubrication
AHEC/MNRE/SHPStandards/E&MWorksGuidelinesforOperationandMaintenanceofSmallHydropowerStation 55
Checking foundation bolts and nuts of valves & servomotor. Cleaning the bolts and
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 diapharms in the opening & closing circuit. Checking the opening &
closing times of the MIV.

4.4.3 MAINTENANCE OF 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 debris in bottom seal area. For withdrawal of
gate/ equalizing pressure across the gates is done with byepass line valve located with in gate.

When machine are running these gates and hoist remains available for maintenance.
These should always remain in perfect condition for use during emergencies of power station.

During annual maintenance of the 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.

4.5 PROCEDURES FOR TYPICAL MAINTENANCE ACTIVITIES
Fig 1 to 4, 10, 12 to 14 have been taken from Hydropower Stations: Generating Equipment and its
installation by AN Goncharov
4.5.1 Reassembly of Vertical Hydro Unit

Sequence and Checks

Lower all guide vanes.
Trial assembly of Turbine runner for checking clearance between runner & runner
chamber (Kaplan) or static labyrinths & rotating labyrinths (Francis).
After setting above clearances take out runner & shaft assy. to service by.
Assemble runner, runner shaft and top cover and lower the complete assembly in pit.
Again check clearances between runner and runner chamber. Also check free
movement of guide vanes. Check top and bottom clearances of all guide vanes and
set.
Lower all the guide apparatus components in the pit and carry out installation &
setting.
Lower bottom bracket with brake, set elevation, centering and tighten with
foundation.
Lower rotor with brake track in pit.
Carry out fitting & setting of Thrust bearing (and other guide bearings).

Check rotor level, verticality of shaft and centering of shaft, correction of inclination
of shaft to be done at this stage itself (Alignment of generator).
Couple Exciter shaft and assemble exciters, PMG, Oil header (Kaplan) etc. carry out
centering and setting.
Couple Turbine and Generator shaft properly as per procedure with help of torque
spanners. Ensure elongation of shaft bolts as per procedure.
Checking unit alignment and taking corrective action by providing shims or
scrapping.
Carry out load sharing of thrust pads.
After completing assembly of machine and rotating the machine at no load check
balancing of rotor as per procedure. Balancing of the machine by adding calculated
weight on rotor spider and at proper angle, is done.
Check vibrations of machine at no load, part load and full load, rectify defects if any.

4.5.2 Checking Concentricity of Labyrinth Seals

The upper and lower labyrinth rings must be concentric with the shaft to within 10%
of the gap on one side of the labyrinth seals. This is checked with a special device mounted
on the shaft (Fig. 1)

Fig 1: Device of checking concentricity of labyrinth-seal rings:
1)Testing device; 2) support with roller; 3) indicators [Goncharov]

4.5.3 Balancing of Runner

For balancing of runner a balancing device, 1, a steel plate 2, a sphere 3 will be
required (Fig. 2). The centre of gravity of runner must always be below centre of gravity of
sphere so that during balancing runner remains in stable position. Following steps are taken
to balance the runner.

Fig 2: Balancing of Runner [Goncharov]

Calculation of displacement of centre of gravity of runner (h)

The runner is placed on the device having horizontal steel plate-2 and sphere in
such a way that its centre of gravity lies well below the support point
A small weight is then placed on the lower band. This cause runner to resume a
new equilibrium position. The runner is thus titled. Equilibrium condition in this
case is equal to the moments acting on runner:

PR =Ga +G (1)

P =weight applied in kg
R =radius at which wt. is placed
a =displacement of centre gravity of runner = h.b/R
=coefficient of rolling friction (0.001 to 0.0015)
Thus =h=
(PR-u)R
u.b

To find centre of gravity of runner a weight is placed on lower band such that it is
sufficient for shifting the centre of gravity 1 to 2 mm. If magnitude h is more it
can be adjusted with the help of adjusting screws. The following optimum value of
h are recommended.

Runner wt. (Tons) 50 100 200
Height h (mm) 40 to 60 40 to 60 40 to 60

Procedure of Balancing

Now four levels are placed on the upper runner band
Different weights placed on the lighter side of lower band until the face of upper
band is horizontal. It is the balanced position of runner.
The sensitivity of balancing device is also checked by minimum weight P
min
whose
value is determined as explained above. The runner is then balanced by adjusting
earlier placed weight. The face of upper band should be horizontal.
The horizontal position of runner should also be checked. The clearance between
runner band and the stand must permit oscillation during balancing.
Any possible inbalance of runner (due to inertia and friction between the
supporting parts of balancing device) is determined after runner has been brought
into equilibrium. This is done by placing weights at six to eight points of the band
circumference which cause the runner to assume equal inclinations. The magnitude
of the residual imbalance is equal to half of max and min weights needed for this.
The weight for this imbalance should be placed where the maximum weight is
placed.
The balance weight should be reliably fixed on the runner in such a way that it is
protected from the action of flow. Best location for this is on the top of runner
beneath protective casing. The weight must be recalculated since the radius of
location has been changed.
Balancing must again be checked after weights have been fixed.
Balancing is checked if minimum weight placed successively at two diametrically
opposite points tilt the runner by equal angle.

4.5.4 Checking Concentricity of Kaplan Runner

Fig 3: Checking concentricity of peripheral edges of runner blades;
1) Plumb line; 2) boom; 3) cable; 4) frame; 5) rollers [Goncharov]

It is advisable to check the concentricity of the peripheral edges of the blades after
their assembly in service bay. This is done with a special device (Fig. 3) mounted at the top
of the servomotor piston rod. The check is performed by measuring the clearance between a
plumb line and the peripheral edges of the blades.

4.5.5 Hydraulic Testing of Runner (Kaplan) in Service Bay

Fig 4: Testing of Runner [Goncharov]

The correct assembly of the blade-actuating mechanism and the tightness of the
flanged joints of the runner and of its blade seals are checked after assembly. The tightness of
the runner is checked by hydraulic tests, while the correct assembly of the blade-actuating
mechanism is verified by rotating the blades.

The runner is hydraulically tested before the hub extension is fitted. This makes it
possible to check the tightness of the joint between hub body and hub bottom. Servomotor
cylinder cover (2) is placed on hub (1) before the test. A temporary cover is used if the
permanent cylinder cover is integral with the shaft flange. The openings in the cylinder over
for the connection with the shaft are blanked off with plugs (3). The gap between piston rod
and cylinder cover is closed with seal (4). Temporary connecting piece (5) with two unions is
placed on the piston rod. One union is connected to the opening in the rod and oil is delivered
through this opening into the servomotor cylinder beneath the piston. The second union is
connected to the opening in the rod, delivering oil into the cylinder above the piston. The
other ends of these unions are connected to pump (7) via hoses (6) (Fig. 4).

The hub is filled with oil through a plug in the bottom and pipe (8). The air escapes
through valves fitted on top and bottom of the servomotor cylinder. Oil delivery to the hub is
stopped when oil flows from these valves. Oil is then delivered through pipe (9) by pump
(10). The oil pressure is thus raised to a level which usually corresponds to three times the
height of the oil column from the runner hub to the oil supply head.

The runner must remain under the test pressure for 24 hours at a runner and oil
temperature of not less than 10
o
C. During testing, the blades are successively set to their no-
load, half-load, and full-load positions, and held in each position for 8 hours. No oil should
leak through the fixed joints of the runner. The maximum permissible oil leakage per day
through the seal of each blade is as follows:

Runner diameter, m . 3.0 5.0 7.2 9.3
Oil leakage per day, 1.. 0.10 0.15 0.18 0.20
AHEC/MNRE/SHPStandards/E&MWorksGuidelinesforOperationandMaintenanceofSmallHydropowerStation 6u

The blades are set to the no-load position by the oil pressure acting on the bottom of
the servomotor piston. Pressure on the top of this piston causes the blades to move into the
full-load position. This pressure is created by a pump. The smoothness of blade actuation is
tested at the same time, as are the blade travel and setting angle.

4.5.6 Centering and Alignment of Vertical Hydro Generator

Alignment of rotor during installation is ensuring rubbing surface of thrust
bearings and the shaft mirror disc face are perpendicular to rotor centre.
The procedure for rotor centering is as follows.
- First centering of turbine shaft is checked since its flange and
centre line from reference bases centering of the generator rotor
- The generator is then provisionally centered relative to turbine
shaft.
- Then perpendicularity of rubbing surfaces of thrust bearing and
shaft flange face to the generator shaft centre line is checked.
- Then final alignment generator and turbine is done.

I. Procedure for alignment of unit
- Set elevation of thrust bearing
- Carry out rotational check of gen. shaft
- Calculate maximum throw and direction
- Minimize throw by scrapping insulated surface of mirror disc.
- Couple generator shaft with turbine shaft
- Again check elevation & level of thrust bearing
- Carry out rotational checks
- Find out run out at LGB & coupling flange
- If throw is still more again carry out scrapping of insulated surface of mirror
discs. Again check by rotation method and repeat till throw is with in limit
- Check throw and its direction at TGB
- Minimize throw by providing shim between coupling flange
- Check throw at LGB, coupling flange and TGB, ensure these are with in limit.
This is necessary to establish unit axis.
- Check verticality of shaft with respect to duly leveled thrust bearing at correct
elevation.

II. Coupling of Shafts

A. Before coupling of generator shaft and turbine it is to be checked that following
requirements are met:

Sl.
No.
Type of Deviation Allowable Deviation
in mm
1. Shift of Gen. shaft axis with turbine
shaft axis
0.01 mm
2. Non parallelity of mating surfaces of
both flanges at shaft dia.
Upto 600 mm
Upto 1000 mm
Upto 1500 mm

0.020
0.025
0.030
B. Coupling

Force of tightening of all bolts should be identical
Elongation of bolts, required to ensure proper tightening
Soundness of flange connection is checked by feeler gauge of 0.03 mm
thickness

III. Setting Elevation of Thrust Bearing

Elevation of upper bracket should be such that the runner is at desired level
Allowance for deflection of upper bracket due to weight of rotating parts and initial
thrust should be taken into account.
Mount thrust bearing on upper bracket
Check perpendicularity of thrust collar with shaft
Set elevation of bearing, by providing shims under flexible support

Fig 5: Position of Dial Indicators

IV. Rotational Checks

Arrangement to turn rotor by 360
o
in steps of 45
o
smoothly
In machines having high pressure lubrication of TH.B. It is possible to rotate machine
manually.
In other machine mechanical arrangement is made and rotation is done with the help
of EOT crane. For lubrication of thrust pads in such case is ensured by using
Molybdenum-di-Sulfide Grease (Molysulf Grease)
Mount dial Gauges at UGB, LGB, Flange & TGB to find out run out (Fig 5)
Throw and its direction is calculated by resultant method (Table 1 & Fig 6)

V. Shimming of Scrapping

Amount of Scrapping or Shim Thickness (Fig 7 & 8)

t =
Mux.csuItunt thow x dumctc
2 x c]]cctc Icngth

a. For correcting gen. shaft
(i) T =amount of scrapping
(ii) Max. throw at coupling flange for correcting gen. shaft
(iii) Eff. Length =distance between insulated surface or mirror disc and coupling
flange
(iv) Diameter =Dia of thrust bearing mirror disc.

b. For correcting turbine shaft
(i) Max throw at TGB
(ii) Eff. Length =Between Flange and TGB (Dial Gauge Locations)
(iii) Diameter =Dia. of coupling flange

Shimming or scrapping to be done at coupling shaft joint

VI. Checking Verticality of Shaft (Fig 9)

Four piano wires with dash posts are placed as shown in the figure. Precession stick
micrometer is used to measure a
1
, b
1
, c
1
, d
1
and a
2
, b
2
, c
2
, d
2
. The whole procedure of
calculation of deviation is given with the figure its self. If the deviation is less than 0.05 mm/
m of shaft length, them verticality is taken to be normal otherwise corrective measure has to
be taken.
AHEC/MNRE/SHPStandards/E&MWorksGuidelinesforOperationandMaintenanceofSmallHydropowerStation 6S
Table 1

RESULTANT METHOD OF ALIGNMENT
(ACTUAL EXAMPLE OF UNIT-I OF A POWER STATION)
(VECTORIAL RESULTANT AT FIG. 6)

Position
of Dial
Gauge
Upstream Side Dial Gauge Down Stream Side Dial Gauge
No. of
Point
at
Shaft
UGB
a
LGB
c
Flange
e
TGB
g

c-a

c-a

g-a
UGB
b
LGB
d
Flange
f
TGB
h

d-b

f-b

h-b
No. of
Point
at
Shaft
0
0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2
45
0
1 +
D
i
a
l

G
a
u
g
e

w
a
s

n
o
t

f
i
x
e
d

32 46
D
i
a
l

G
a
u
g
e

w
a
s

n
o
t

f
i
x
e
d
31.5 45.5 0
D
i
a
l

G
a
u
g
e

w
a
s

n
o
t

f
i
x
e
d

+1 +1
D
i
a
l

G
a
u
g
e

w
a
s

n
o
t

f
i
x
e
d

+1 +1 3
90
0
2 0 40 85 40 85 +3 +3 +30 +26 4
135
0
3 0 40 86 40 86 +6 +13 +31 +6 +24 5
180
0
4 0 30 65 30 65 +7 +28 +71 +21 +64 6
225
0
5 +1 8 22 9 23 +7 +41 +80 +34 +73 7
270
0
6 +15 +26 +15 +26 +7 +30 +76 +23 +69 8
315
0
7 0 +6 +17 +6 +17 +3 +18 +51 +15 +48 1
360
0
8 1 +4 +14 +5 +15 +1 6 1 7 2 2

Note: (a) The readings of upstream side dial gauges are not acceptable as closing error is more.
(b) Unit-II side readings are fine because (i) closing error is negligible (ii) curve plotted along X-Y axis is nearer to sine curve (iii)
these are confirmed in subsequent rotation also. Further calculations and correction is based on these.

Fig 6: Resultant Method of Throw Calculation

Fig 7: Calculation of Shims Between Flanges

Fig 8: Illustrative Example of Scrapping


Fig 9: checking Verticality of Generator Shaft

4.5.7 Load Sharing of the Thrust Bearing

There must be uniform distribution of load between all thrust pads. Over loading of
any pad may cause destruction of babbit material and failure of thrust bearing. The load is
equalized after the generator shaft wobble has been eliminated or after the turbine and
generator shaft has been connected and the unit has been aligned.

Uniform distribution of load is achieved by tightening supporting screws against the
elastic plates beneath the shoes carrying rotor weight. This is done by striking the spanner
with sledge hammer.

The load distribution is adjusted in this manner by first checking that all supporting
screws are tightened equally. The position of locking device of each support screw is then
marked with the vertical lines on it and on the thrust bearing housing or on the support stand.


Fig 10: Load Sharing of Thrust Pad [Goncharov]

A sledge hammer of approximately 8 kg weight is than used to strike hard once or
twice the end of 600 to 700 mm long spanner placed on the head of supporting screw
considered. The process is carried out on all shoes with the same force. The position of all
pads are measured after each round with a slide caliper and distances between the lines on the
locking devices and on thrust bearing housing are recorded. This tightening process is
repeated several times until distances between the lines are increased equally by hammer
blows on all supporting screws. Another round of tightening the screws is then performed
with lighter sledge hammer. Adjustment is considered completed if the distance between the
line have not changed in one round.

The load can be adjusted by using a dial indicator also as shown in Fig 10.

The support screws must be locked after completion of this activity

4.5.8 Dynamic Balancing of Low Speed Hydro Generator

A sensitive dial gauge (0.002 mm) is fixed as shown in Fig. 11.
A suitable bracket, which is firm and rigid, will be required to fix dial gauge.
Four runs of machine at full speed will be required to find out magnitude of weight
and position of correction
- First run
Run to rated speed and note total deflection of the pointer on dial (the reading
is proportional to the unbalance force). Make two marks on rotor A & B at
O
o
and 180
o
respectively
- Second run
Put a calibration weight (Wc) at O
o
and run upto full speed and note the dial
gauge reading (the calibration weight must be sufficient to produce and
appreciable difference in the reading compared to the first run reading).
- Third run
Remove weight from O
o
position and put at 180
o
position and run upto full
speed. Note reading of dial gauge.


Fig 11: Checking Balancing of Generator

Draw to some scale a line OA to represent reading of first run.
Extend OA to C such that OA =AC
With centre O and radius equal to second run reading to the earlier
scale draw an arc.
With centre C and radius equal to third run reading to same scale
draw an arc to cut earlier arc at point B. J oin AB.

Balance weight W =w
c
x
0A
AB

The angle of this weight is to be put with reference to 0
o
position and is
given by angle 0AB.

Whether this angle is to be measured in the direction of rotation or
opposite to the direction of rotation is done by trial. The position which
gives minimum vibration is the required position. This is done by
Fourth run. For fourth run calculated weight at calculated angle is put
and machine run at full speed if dial gauge reading is almost zero, the
weight and direction is corrected otherwise the weight is required to be
put in the opposite direction.

o
4.5.9 Alignment of Horizontal Generating Set

Adjustment of Turbine Shaft

The centre line of turbine bearing with respect to longitudinal axis of generator is
checked by stretching a horizontal wire through spiral casing and along bearing centre
line. Correct position of wire inside spiral casing is checked with inside micrometer.
Bearing housings are centered with respect to longitudinal axis of generator by an end
gauge which is inserted into the bores of bearing shell
Ensure clearenses of guide vanes at both ends are uniform and are between 0.2 to 0.6
mm. Feeler gauge is used to check these. These can be adjusted by tightening bolts.
When distributor is closed there should be no clearance in guide vanes.
Measure clearance with feeler gauge between shaft and the lower bearing shell to
ensure correct position of rotating parts of turbine.
If there is no clearance, it indicates that the shaft is resting on both bearings.
The horizontal position of shaft is checked by placing a level successively on both
bearing journals. Then turn the level by 180
o
and place in the same position as before
and check level. Arithmetic mean of two measurements should be taken, if two
differ (more than one division). If difference is more investigate reasons and take
remedial measure,
The permissible inclination in shaft is 0.04 to 0.06 mm per m length of shaft.
The permissible inclination in transverse direction is 0.1 mm / m of shaft length. This
should also be checked with level.
The radial clearance between runner and the cover plates which should not exceed 2.5
to 3.0 mm. these should be uniform.
The gaps in labyrinth seals should be with in 0.5 to 0.6 mm.
The axial gaps in labyrinth seals should also be measured and these should be within
0.2 to 0.3 mm. These are measured by pushing the rotating parts to extreme positions.
All the clearances and gaps are measured again after turning the rotating parts through
180
o
and 360
o
. These should be with in permissible limit.
1 mm thick lead wire of 30 to 50 mm length is used to measure clearance between
turbine shaft and the upper bearing shell. Length of this wire are placed across the
shaft in two sections beneath the shell which is then tightened well. The thickness of
flattened wire thus indicate the clearance on top of the shaft which should be 0.2% of
shaft dia.
The lateral clearance between the shaft and the lower shell are checked at a depth 10
to 12 mm below the plane in which bearing is split. These should be half of clearance
between shaft and upper bearing shell.
The adjusted shaft of turbine will be reference base for alignment of generator shaft.

Preliminary alignment of generator shaft

Alignment consists

(i) Removal of misalignment of turbine shaft and generator shafts (Fig 12)
(ii) Making generator shaft horizontal
(iii) Making centerlines of generator and turbine shaft coincide
(iv) Alignment is carried out relative to half couplings of turbine and generator shafts
(v) Wobbling at half coupling should not be more than 0.2 mm

Procedure for preliminary alignment:

The turbine and generator shafts are forced to their outer most position after the
generator is assembled and clearance between half coupling is ensured. This clearance
should be 5 to 6 mm (or as designed)
A straight edge is pressed against the turbine or generator shaft along generator axis in
four diametrically opposite positions. Clearance if any is checked and equalized. For
this shims are provided beneath foundation fame.
By measuring clearances between faces of half coupling at four points, alignment of
shafts at joint is checked.
The position of generator is first checked in vertical plane than in horizontal
Misalignment is corrected by placing shims under foundation frame
After this foundation bolts are tightened and locked

Fig 12: Misalignment of turbine and generator shafts [Goncharov]

Procedure for final alignment

Check positions of half coupling
Measure clearances between half couplings in the initial position and after turning
through 90
o
, 180
o
, 270
o
& 360
o

The position of half coupling should be same of initial position and after rotation by
360
o

For radial displacement of half couplings is measured by mounting a dial indicator on
a bracket fixed at turbine half coupling (Fig 13)

Fig 13: Aligning Horizontal Generator with Turbine [Goncharov]
Determine alignment and inclination of generator axis first in vertical, then in

horizontal plane. Record measurement in following table.

Site of
measurements
Clearance b between half-coupling ends,
mm
Distances a to generatrices of
half-couplings, mm
Positions of rotating parts of generating set
0
0
90
0
180
0
270
0
360
0
Mean
Clear-
ance
0
0
90
0
180
0
270
0
360
0
Top a
1
;b
1
+ + + + + + + +
Bottom a
3
;b
3
+ + + + + + +
Right a
2
;b
2
+ + + + + + +
Left a
4
;b
4
+ + + + + + +
Note: The plus sign indicates that measurements were carried out at this point.

Compute displacements of generator rotor, for ensuring correct position
Move generator rotor in correct position and check axis.
Check position of stator
All measurements of clearances and displacement should be recorded viewing from
generator side.
Magnitude a are measured in one position and after turning rotating parts by 90
o
,
180
o
, 270
o
& 360
o

End clearance b is measured at four points in order to eliminate the effects of axial
displacement of the rotor. The mean clearance is then calculated for each position of
generator rotor (Fig 13)
The measurements are satisfactory if both [(a
1
+a
3
)-(a
2
+a
4
)] and [(b
1
+b
3
)-(b
2
+b
4
)]
are with in 0.02 mm.
All measurements are repeated till good set is achieved.
Permissible deviations in alignment of horizontal hydro generating unit are given in
following table.

Rotational speed of
generating set, rpm
Permissible skewness and
eccentricity, mm
Up to 500 0.15
Up to 750 0.10
Up to 1500 0.08

If, after alignment radial and end clearances at diametrically opposite point are with in
limit as shown in table, the alignment is taken as adequate other wise repeat alignment
procedure and compute more accurately.
Computing eccentricity of generator shaft with respect to turbine shaft (measurement
a) and its direction and computing inclination and its direction (measurement b) is
done as explained below: (Fig 14)
(i) Displacement of generator shaft axis due to eccentricity relative to turbine
shaft:
Horizontal plane h
x
=(a
2
-a
4
) / 2
Vertical plane h
y
=(a
1
-a
3
) / 2


Fig 14: Determining Displacements of Generator Bearings [Goncharov]

The displacement of bearings due to inclination of shaft are given by difference
between end clearances. They depend on the location of bearings and dia of coupling
D
c
.

(a) Front bearing in horizontal plan
k
x1
=(b
2
-b
4
) l
1
/Dc
k
x2
=(b
2
-b
4
) l
2
/Dc

(b) Front bearing in vertical plane

K
y1
=(b
1
-b
3
) l
1
/Dc
k
y2
=(b
1
-b
3
) l
2
/Dc

Correct position of the generator rotor can be obtained by moving its bearings by
following distances:

(a) Front bearing horizontal plane

A
x1
=(a
2
-a
4
) / 2 +(b
2
-b
4
) l
1
/ Dc
A
x2
=(a
2
-a
4
) / 2 +(b
2
-b
4
) l
1
/ Dc

(b) Front bearing vertical plane

A
y1
=(a
1
-a
3
) / 2 +(b
1
-b
3
) l
1
/ Dc
A
t2
=(a
1
-a
3
) / 2 +(b
1
-b
3
) l
2
/ Dc

The rotor must be moved up and to the right if the computed displacement is positive
The rotor must be moved down and to left if the computed displacement is negative
The air gaps of generator are checked after completing alignment. These should be
equal all around the circumference
The turbine and generator half coupling are connected after completing alignment of
generator shaft

SECTION III

GENERAL GUIDELINES

SECTION-III

GENERAL GUIDE LINES

1.0 GUIDELINES FOR TAKING OVER O&M OF SHP

The O&M of the plant shall be taken over from agency executing the project after due
diligence and checking on following conditions. A report shall be prepared and both handing
over and taking over party shall sign it. Following are the guide lines:

1.1 Operating condition of E&M equipment shall be monitored for 72 hrs continuous
running for full load condition and results, observations are noted. If any defect is
found, it shall be noted and corrected. This shall include turbine, generator,
auxiliaries, control metering and relay panels, HT and LT switchgear, main and
auxiliary transformer and switchyard equipments.

1.2 All civil building and structures such as water carrier system, lake diversion weir,
channel, pipe line, forebay, tailrace, draft tube, etc shall be monitored during load test
and observations and defects noted. However all civil structures under water shall be
inspected on draining, if possible. Leakages, cracks on wall, and operation of main
gates shall be noted.

1.3 All the area of the plant shall be cleaned and all rooms checked for unwanted material
stored in it. Such material shall be taken out of building and stored in closed out door
yard.

1.4 All the spares of the E&M equipment shall be listed and their condition checked for
use during replacement. These shall include gate, valve, turbine, generator
transformers, breakers, panels, AVR and governor spares.

1.5 All the tools and instruments ordered for the plant shall be listed and their condition
checked.

1.6 Documents: Following documents shall be insisted upon:

All plant and equipment drawings with as executed status.
All commissioning reports duly signed. This shall include generator, turbine,
auxiliaries, transformers and breakers, DC station battery, battery charger
Cable schedule and termination drawing, panel wiring drawing.
Suppliers manuals including erection and trouble shooting manual.
Relay test report and relay setting duly signed by manager/ resident engineer.

2.0 GUIDELINE FOR MANPOWER, SELECTION AND TRAINING

2.1 Man power required for the operating and maintenance of SHP shall be based on
following factors:

Type of plant such as ROR, dam based or canal based. The manpower for the ROR
plant is more because of the spread of hydraulic structures, the water channel and its
equipment.
The number of shifts/ hours the plant is going to work e.g. one shift or three shift. A
plant with 3 shift working will need more staff than a single shift.
Location of the plant, a remotely located plant will need additional staff for the
support services such as transport, maintenance of residences etc.

This may increase the strength of the remotely located ROR plant. However the
manpower can be kept minimum by employing a multidisciplinary force such as an
engineer with experience in civil and electromechanical work. Or technician with
driving experience etc. The guiding factor is safety of equipment and manpower.

Other method is to employ local labor, during requirement of additional work such as
rainy season where inspection of water channel is needed or during annual maintenance
work. It will benefit the plant, if these persons are given proper on job training.

2.2 SELECTION

Man power required for operation and maintenance shall be selected before
commercial operation of the plant.

The operation staff shall be selected well in advance preferably during the pre-
commissioning and commissioning of the plant.
The experience of the persons shall be in hydro generating plant, DG plant of a co-
generation plant. An experience on large electrical substation with DG set may be
accepted.
Plant incharge having basic degree/ diploma in electrical with experience in civil and
mechanical works is most suitable.
Testing engineer is most important for any generating plant. He should be
experienced engineer familiar with all equipment testing to take decision in case of
any fault on electrical equipment such as generator, transformer and switchgear. This
being a specialized job it may be difficult to get such persons and to hold them as
such can be engaged by group of plants or among the IPPS in the area.
For the technician an ITI certificate with hands on experience in electro-mechanical
work such as DG plant, electrical installation, hydraulic equipment, electrical panel,
PLC panels cabling work etc.
Contractual work such as civil maintenance, welding and fabrication, etc may be
awarded on annual basis to keep work force low.

2.3 TRAINING OF OPERATION STAFF

The operation staff shall be given training by Sr. Experienced personal and also on
simulator, if available. The training shall be in the area of SHP operation, maintenance, safety
and fire fighting. A training period of three month is necessary for small hydropower plant.

On completion of training the trainee shall be assessed for his skills and capability on
actual work in the plant where they will be working.
On placing them on operation duty they shall be periodically assessed for their
performance in actual operation such as start of units etc.

3.0 ESSENTIAL T&P, INSTRUMENTS ETC

(i) Ordinary tools, instruments
For effective maintenance it is necessary to list out all required ordinary T&P as
also assess quantity and arrange the same otherwise it may become difficult even
for a skilled and capable technicians to carryout the require maintenance job.
Ordinary T&P includes different type & sizes of screw drivers, pliers, spanners
hammers etc.

(ii) Special T&P
Such type of T&P 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 manufactures.

4.0 FIRE PROTECTION & FIRE FIGHTING

It is necessary to install necessary hydrant points fire extinguishers at different
locations of the power station as per recommendations of district fire officer.

Periodic drill of use of different types of fire extinguishers is must so that staff on
duty in the power plant could operate these in case of emergencies.

First aid boxes as per recommendation of Factory Rules must be kept in the PS and
these should be inspected periodically by station incharge. Timely recoupment of consumed
items must be ensured by shift incharge.

Shift incharge should also ensure timely refilling of fire extinguishers installed in the
powerhouse. He must periodically check working of hydrant points.

Smoking inside power station should be prohibited. Throwing match sticks and other
burning stuff may some time create fire in the power station.

Additional fire extinguishers must be kept during maintenance specially when
activities like, welding, brazing etc. are going on.

Asbestos cloth must be used to cover electrical parts during such maintenance
activities.

In power stations normally following types of fire extinguishers are used:
o Soda acid type
o Dry chemical type foam type (chemical foam)
o CO
2
cylinders
o Fire hydrants
o Sand and water buckets

5.0 SAFETY ASPECT OF RUNNING SHP

It is said that 90% of accidents are avoidable. Out of these 20% are due to faulty
conditions and 20% due to faulty behavior and 60% due to both.

Accidents cause human suffering and loss of production to the organization. Safety
measures are therefore, essential. Success of safety measures depends on safety mindedness
of the management supervisions and workers. Some of the methods to improve safety
consciousness are given below:

Prompt investigations pin pointing cause of accident and remedial measures
Use of personal protective equipment such as helmet, goggles, gloves safety belts etc.
Arousing safety consciousness through the use of posters, films, journal, safety talks,
safety competition etc.

General Safety Precautions in SHP

All voltage level, even low shall be considered dangerous even though the voltage
may not be high to cause shock.
All electrical circuit to be treated live and no work should be carried out with out
proper shut down and ensuring that it is
(i) De-energised (ii) Insolated from all sources
(iii) Effectively connected with ground

Fundamental on Safety

Prevention of accidents require whole hearted cooperation of all members of
organization. A capable, mentally alert employee will avoid accident.

Unsafe acts which may cause accidents are as follows:

- Operation of an equipment with out authority or warning.
- Operating without proper instructions
- Making safety device inactive
- Working nearby dangerous or live electrical equipment which could conveniently be
denergised
- Using defective T&P or equipment or its improper use.

Unsafe conditions which may cause accidents are as follows:

- Unground equipment
- Defective material or equipment
- Improper illumination
- Non standard design and construction

Accidents are, therefore, results of unsafe acts or unsafe conditions or combination of
both.


Safety Precautions and Practices in Operating and Maintenance

No unsafe operation will ever be permitted. Feedback regarding unsafe operation/
condition should be taken into consideration with proper spirit and review should be
made to avoid accidents.
Interlocks should not be by-passed unless it is very essential. Written permissions
should be obtained from the superintendent/ incharge of the station. Extra precaution
should be taken by all the parties during such cases.
Equipment are designed for certain operating conditions, it should be operated within
prescribed operations limits. Overstressing of the equipment should be for minimum
possible time with minimum percentage of overloading. This will avoid damage to the
equipment.
Operation and Maintenance staff should be familiar with the station layout and
operations limits of different equipment such as breakers, transformers, isolators CTs,
PTs, etc. A person should be allowed to operate or take over the equipment only after
he has acquired adequate knowledge of the equipment.
Operation should be carried out as per Operations Instructions. This will help in
carrying out operations safely and maintaining uniformity. In case of any
modifications/ change in the layout operating instructions should be reviewed.
Booklets/ manufacturers instructions for different equipment should be available and
should be referred to before taking out equipment for maintenance.
It is the responsibility of the supervisor to interpret correctly and explain safety rules
and regulations to all the persons concerned and ensure that they thoroughly
understand the same.
Breach of safety rules should be suitably dealt with.
Only authorized persons shall be allowed to carryout operation and maintenance.
Supervisor shall guard against the use of defective safety appliances, tools, and
materials.
In case of any emergency, in which quick action is necessary, in order to safe guard
personals or property, only authorized persons will take necessary action. Under no
circumstances attempt shall be made to carryout operations which are not safe.
All persons must use the standard protective equipment intended for the job.
All protective equipment should be periodically tested.
Metal ladders should not be used in switchyard.
Adequate number of first aid and fire fighting equipment shall be maintained.
First aid and artificial respiration chart shall be exhibited. Every person shall be
familiar with the same.
Every person shall be familiar and should know how to operate fire fighting
equipment, so that fire can be extinguished promptly thus minimizing damage.
In the event of the fire on electrical installation, the affected part shall be immediately
switched off and isolated from all the sources.
Use HRC fuses only with proper capacity.
While opening isolator confirm that it is not carrying load current. Similarly isolator
should not be closed on load.
Underrated circuit breakers should not be used to clear the fault.
No breaker should be operated beyond stipulated operating duty.
While working on the breaker, its operating mechanism should be de-energized such
as discharging spring, releasing air pressure etc.
Transformer should be discharged and grounded from all sides (windings). Neutral
grounding of the transformer should not be treated as grounding.
Current transformer secondary should never to be left open circuited.
After cutting out capacitor bank, it should be allowed to discharge through discharge
PT for about 10 minutes. The bank should be grounded with hot stick before
commencing the work.
ASKAREL compound used in capacitor bank as a dielectric is very toxic and harmful.
Hence, should be handled with great care.
Apparatus, frame work and other non-current carrying metal parts associated with
power system are to be effectively grounded.
Lighting arresters shall be grounded independently.
Isolating switches provided for Generators and synchronous condensers and other
rotating machines should never be opened when connected to any voltage source even
when the machine is carrying no load.
The areas should be cordoned off indicating location of work on the particular
equipment.
Use of safety tags must be ensured while allowing shut down for maintenance on
some part/ equipment.

6.0 GUIDELINES FOR DOCUMENTATION

Documentation

Documentation at all levels of work done is necessity for any references and analysis
of data/information in future as and when required.

Roll of operation staff is very important in registering all valid information operating
parameters such as temperature, vibrations pressure, generation, voltage current etc. in the
operation log books and shift registers.

Every event should clearly mention frequency, voltage, MVAR, MW, MWH at the
instant with other necessary data e.g. alarms, annunciations temperatures, forebay
levels/reservoir levels, inflows etc. as may be necessary from case to case.

Any tripping event should be clearly noted with relevant details, such as relay
operation details, disturbance recorders and event logger print outs. Restoration activities
after every tripping should be reported with details of preventive action taken or to be taken
based on certain conditions. This information should be presented in prescribed format,
should be checked on daily basis by Engineer concerned who will check and authenticate the
same for future use.

For maintenance also similar registers are maintained giving details of maintenance
activities at different frequencies such as daily, monthly, annual etc. or break down
maintenance.

Results of test and measurements carried out during maintenance should be tabulated
in standard formats and this should include the commissioning and acceptable values are
applicable for proper comparison and planning remedial action.

The log books and log sheets normally maintained in SHPs are given in annexed
table:-

Operating Condition Record Sheets

Type Description of Log Purpose/used for Location/authority
1. Log Books Very important station record of events.
Helps during even analysis by others.

a. Control Room Shift
Log Book
Record of events date and time wise and
sequential in case of operation carried out.
This will also record any instructions
given or taken from. Left side of the page
to record specific equipment operated and
right side events such as tripping, set
synchronizing, taking over shift with
signature switchyard operations etc.
Control Room Shift
Charge Engineer
b. Turbine Room Shift
Log Book
All turbine and its Aux. operation and
events, same as 1.a above.
Turbine operator
2. Log Sheets Gives station equipment load condition.
Helps in assessing during event analysis.

a. Control Room Meter
Reading
Hourly readings of all panel metes,
transformer auxiliaries, generator and
transformer temperature, and general
condition of equipment. Ambient temp.
Control room / assistant
shift engineer / shift
engineer.
b. Control room energy
meter log sheet.

Hourly KWH meter, import export
meter.
Aux. consumption meter.
Control room / shift
charge engineer.
c. Turbine room log
sheet
Hourly readings of bearing temperature,
aux. in service, pumps running, cooling
water pressure, compressor air pr, etc.
turbine water head/pressure and other
quantities as per manufacturer.
Turbine operator
3. Defect cum
Equipment Record
Books
Equipment defects noticed by operation
and action taken by maintenance dept.
Corrections to be
recorded by maintenance
engineer.
a. Defect log book
electrical
Record of electrical equipment defects
noticed during shift needing attention of
maintenance dept.
Control room/ Shift
charge/ assistant shift
engineer. Equipment
under their scope.
b. Defect log book
Hydraulic
Record of equipment defects on Hydraulic
equipment noticed during shift needing
attention of maintenance dept.
Turbine room/ shift
charge/ assistant shift
engineer. Equipment
under his scope.
4. Monthly
Generation record
register.
Keeps monthly total of unit generation,
aux. consumption, running hours, shut
down hours, outages, forced and
Control room shift
charge engineer.
Type Description of Log Purpose/used for Location/authority

emergency outages, maximum equipment
temperatures during month, water utilized,
rainfall, lake contents etc., plant load
factor, availability factor etc. the data is
important in studying plant performance
over years.
5. Daily report book
(duplicate)
For sending daily short summary to main
office of important events in plant. Shall
give rainfall, lake condition, water
utilized, water rate, generation, outages,
tripping of lines etc., and any other
operation related information. DC battery
related voltage. Over loading of units etc.
Control room Resident
engineer/ manager
operation/ shift charge
engineer.
6. Station water
consumption
report. Monthly
(duplicate)
For mainly Hydro power plant, keeps
records of daily/ monthly water discharge
for generation, leakage, wind and
evaporation losses for storage dams,
meteorological and atmospheric data, at
lake and at power house.
Control room. Resident
engineer/ manager
operations. Head works
engineer.
7. Station occurrence
record.
Record of all tripping, loss of time, and
cause of tripping, relay action etc.
Shift charge engineer,
manager operation.
8. Relay setting
register.
Record of all relay equipment relay setting
giving normal condition and during outage
of transformer or line, record of all
instructions for revision. This is an
extremely important register shall be
available for reference at all times.
Manager operation/
Resident engineer
9. Station operation
manual
Manual giving all step by step operation
procedure for outages etc. Giving all
equipment data and equipment operating
parameter. Guidelines for emergency
operation, black start procedure, starting
and stopping of units, lake discharge and
other hydraulic data, all mechanical
installation operating procedure and
drawings, station interlocking drawings
Resident engineer,
manager operations.
10. Station safety
manual
Safety procedure for giving outages, and
tagging procedure. Use of tools, cranes,
compressor, pumps etc. instructions giving
use of fire protections and fighting
equipment. First Aid instructions.
Resident engineer
manager operation,
medical officer. Safety
officer if appointed
separately.
11. Disaster
management
instruction
Gives details of instructions to be followed
by shift staff during any disaster. It further
gives details of how to act and tackle the
disaster.
Resident engineer/ shift
incharge

Some sample formats of log book and reports are also enclosed to provide a guide line
to create formats for the power station under considerations:
(NAME OF POWER STATION)

DAILY GENERATION/ TRANSMISSION REPORT FOR

GENERATION (MU) Monthly cum1 (MU) =_______. Yearly cum1 (MU)=__________
Unit
No.
Daily R/ Hours
Hr: Min
OUTAGES HOURS (Hr: Min) Available
Hr: Min
Deemed
Gen (MU) Planned Forced Misc.
Unit 1
Unit 2
Unit 3
.
Total

TRANSMISSION (MU) Monthly Cum1 (MU)=_______ Yearly cum1 (MU)=_________
LINE-I LINE-II LINE-III
EXPORT
IMPORT

STATION DATA MW MVAR BUS/VOLT,
KV
FREQ,
Hz
AUX.
CONSUMPTION
AVERAGE
LOAD MW
MAXIMUM
MINIMUM
TOTAL, INFLOW
Cumecs
WATER UTILIZED, Cumecs SPILLAGE, Cumecs
MAX RESERVOIR
LEVEL, M
MIN
RESERVOIR
LEVEL, M
MIN INTAKE
LEVEL, M
MAX TRW LEVEL, M SILT, (PPM

WEATHER

OUTAGE DETAILS COMMUNICATION STATUS: PLCC/P&T /
LDST/WIRELESS
OK/AS PER
REMAKRS
UNIT/
LINE
OUTAGE
TYPE
PO/FOR/MISC
TRIPPING/
OUTAGE TIME
Hr : Min
RESTORED
AT Hr: Min
TOTAL
OUTAGE
TIME
Hr: Min
Energy
Loss MU
(If Any)
REASONS

TRIPPING DETAILS NIL / AS PER TRIPPING REPORT

REASONS FOR LESS GENERATION / REMAKRS:

[SHIFT INCHARGE]

HOURLY STATION DATA REPORT FOR

Time
kV
BUSEND UNIT -1
GENERATION
UNIT -2
GENERATION
UNIT -3
GENERATION
. TOTAL
GENERATION
VOLTAGE
Hz
FREQ.
MW
MVAR MW MVAR MW MVAR MW MVAR MW
1:00
2:00
3:00
4:00
5:00
6:00
7:00
8:00
9:00
10:00
11:00
12:00
13:00
14:00
15:00
16:00
17:00
18:00
19:00
20:00
21:00
22:00
23:00
24:00

OPERATION
PARAMETERS
NORMAL
VALUE
MAX TEMP.,
O
C at Hrs.
O
C Hrs.
O
C Hrs.
O
C Hrs
O
C
STATOR WINDING
THRUST BEARING
TURBINE GUIDE BEARING
UPPER GUIDE BEARING
ANY ABNORMAL
OPERATION PARAMETER
NOTED

[SHIFT INCHARGE]
NAME & DESIGNATION

DAILY TRIPPING REPORT FOR ______________ REPORT NO. (STATION)/TRIP/

Sl
No
Name of
Line/ Unit
Time
Hr : Min
Details of
tripping
Replay operated along with
Alarm and Flags
Remarks
Power
Station end
Grid Station
end

COPY OF EVENT LOGGER/ DISTURBANCE RECORDER PRINTOUT ENCLOSED
YES/NO

Specify reason if not attached_____________________

[Shift Incharge]
Name/ Designation


GENERATION REPORT

FOR THE MONTH OF _______________

DATE UNIT-1 UNIT-2 UNIT-3 TOTAL DEEMED
MU MU MU MU GENERATION (MU)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Total

INCHARGE [OPERATIONS]
NAME / DESIGNATION

M/C AVAILABILITY REPORT FOR THE MONTH OF

Unit GENERATION
(MU)
TOTAL
TIME
(Hrs:
Min)
RUNNING
TIME
(Hrs: Min)
PLANNED
OUTAGE

(Hrs: Min)
FORCED
OUTAGE
DUE TO
BREAK
DOWN
OF M/S
(Hrs:
Min)
MISCELLANEOUS OUTAGE DUE TO AVAILABILITY
IN HRS
(D+G+H+I)
%
AVAILABILITY
(J/C)*100
HIGH
PPM
(Hrs:Min)
LESS
AVAIL.
OF
WATER
TRANSMISSION
CONSTRAINTS
ETC.
A B C D E F G H I J K
1

2

3

PLANNED OUTAGE : Outage planned in advance for annual maintenance, periodical/ routine maintenance/ checking, inspection.
Any outage planned in advance because of abnormal operating parameters i.e. high temp, oil level failure
of shaft seal etc. should come under forced outage and not in planned outage.
FORCED OUTAGE : Outage due to tripping caused by abnormal operating parameters like high temp. / oil level etc, stopping/
closure of units for inspection / investigation /rectification of abnormal operating parameters/ behavior
condition.
MISCELLANEOUS OUTAGE : Outages due to reasons beyond control of generating stations or for which generating stations are not
responsible like tripping of units due to failure of grid, line problems, etc. backing down due to grid
constraints/ requirements, closure of units due to high ppm, less availability of water etc. outage for less
than 15 minutes due to tripping and resynchronization should also come under miscellaneous outage.

ABSTRACT OF OUTAGES FOR THE MONTH OF

UNIT NO.___________________

Sl
No
FORM TO TOTAL
TIME
Hr:Min
ENERGY
LOSS
(MU)
Reasons
DATE
dd/mm/yy
TIME
Hr:Min
DATE
dd/mm/yy
TIME
Hr:Min
PLANNED OUTAGE

FORCED OUTAGE

MISCELLANEOUS
OUTAGE

NAME/ DESIGNATION

MONTHLY TRIPPING REPORT

FOR THE MONTH OF ____________________

Sl.
No.
Name of
Units/ Line
Type of Tripping Tripping Report
No. & Date
Comments / Remarks
(if any)

NAME / DESIGNATION


DEEMED GENERATION REPORT FOR THE MONTH OF

Sl.
No
Unit
No.
DATE
dd/mm/yy
CONSTRAINTS/
BACKING DOWN
CODE
TIME BACKING
DOWN
PERIOD (t)
Hr
CAPACITY
BACKED
DOWN
B, IN MW
ENERGY
LOSS
E
LOSS
(MU)
TOTAL
GENERATION
LOSSDURING
THE DAY
G
LOSS
(MU)
SPILLAGE
ENERGY
DURING
THE DAY

G
SPILLAGE
(MU)
DEEMED
GENERATION
G
DEEMED
(MU)
FROM
Hr:MIN
TO
Hr:Min

NAME/ DESIGNATION


STATISTICAL ANALYSIS TRIPPINGS

POWER
STATION
LEGEND CLARIFICATION FROM THE
STTION
A B C D E F G H I J K L M N O P Q R S T U V W

LEGEND DESCRIPTION OF PROTECTION NO. OF OCCURRENCE
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.
q.
r.
s.
t.
u.
v.
w.
Approved:
Issued:
(POWER STATION)
ANNUAL MAINTENANCE SCHEDULE
(FOR THE YEAR )

UNIT/ EQUIPMENT FEEDER BAY/:

SL.
NO.
DETAILS OF EQUIPMENT TYPE OF ACTIVITY PERIOD
FROM TO

SIGNATURE
ISSUED BY POWER STATION


(POWER STATION)
MONTHLY MAINTENANCE REPORT
(FOR THE MONTH)

UNIT/EQUIPMENT/FEEDER BAY/:

SL
NO
DETAILS OF
EQUIPMENT
MAINTENANCE
PLANNED
DATE OF
COMPLETION AS
PER SCHEDULE
STATUS AT THE
END OF THE
MONTH
REASON FOR
DEVIATION IF
ANY
ACTION PLAN
IF ACTIVITY
NOT
COMPLETED IN
TIME

SIGNATURE
ISSUED BY POWERSTATION
Engineer (O&M)

Head (O&M
(POWER STATION)
BREAK DOWN STATUS

UNIT/ EQUIPMENT/ FEEDER BAY/:

DATE & TIME OF BREAKDOWN:

DATE & TIME OF RESTORATION:

BREAKDOWN BRIEF ACTION TAKEN FOR
RESTORATION
PREVENTIVE ACTION TO
AVOID RECURRENCE

SIGNATURE / DATE
ISSUED BY STATION

Approved:
Issued:


OUTAGE REPORT

SL
NO
NAME OF
EQUIPMETN
OF THE
UNIT/
FEEDER
STARTING RESTORATION TOTAL
OUTAGES
TIME
(Hrs:Min)
REASONS GENERATION
LOSS IN MU
ACTION
TAKEN FOR
RESTORATION
PREVENTIVE
ACTION TO
AVOID
RECURRENCE
DATE TIME
(Hrs:Min)
DATE TIME
(Hrs:Min)

ACTION TAKEN BY STATION:

[SHIFT INCHARGE]
NAME/ DESIGNATION

Guidelines For Operation and Maintenance of Small Hydropower Station

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Guidelines For Operation and Maintenance of Small Hydropower Station

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What are the guidelines provided for operation of small hydropower stations?

What are the guidelines provided for operation of small hydropower stations?

What are the different types of maintenance discussed for small hydropower stations?

What are the different types of maintenance discussed for small hydropower stations?

STANDARDS / MANUALS / GUIDELINES FOR

SMALL HYDRO DEVELOPMENT

4.4 PREVANTIVE MAINTENANCE OF HYDROMECHANICAL EQUIPMENT

Problem in electrical circuit and checks

Spherical valves (for heads more than 120 m)

4.5.5 Hydraulic Testing of Runner (Kaplan) in Service Bay

IV. Rotational Checks

4.5.9 Alignment of Horizontal Generating Set

Determine alignment and inclination of generator axis first in vertical, then in

o Sand and water buckets

Type Description of Log Purpose/used for Location/authority

(NAME OF POWER STATION)

(NAME OF POWER STATION)

(NAME OF POWER STATION)

(NAME OF POWER STATION)

(NAME OF POWER STATION)

(NAME OF POWER STATION)

MONTHLY TRIPPING REPORT

(NAME OF POWER STATION)

STATISTICAL ANALYSIS TRIPPINGS

(NAME OF POWER STATION)

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