Chapter-10

Repair and maintenance of Electromechanical components

10.1

Importance of maintenance:

The importance of maintenance depends upon the type of electrical machine or equipment. It can be
summarized follows:

- Due to lack of maintenance, any machine or equipment may be failed. This results in losses and
requires skilled manpower.

-If maintenance of electrical machine and equipment is properly organize, it will reduce the fault
occurrence and hence increases the life of machines.

- It machine is poorly maintained or totally negated, it may breakdown the machine totally and
sometimes replacement of parts are required which may increase maintenance cost and requires more
care.

- A good maintenance program provide for a planned shout down during the period of inactivity (or less
usage). This ensures continuity of operation and chance of breakdown of machine is reduces.

- Such program helps to detect the problems in early stages. So, the chance of extensive damaged is
reduced.

Routine Inspection

Definition:
Routine inspection involves regular, systematic checks of equipment or systems to ensure they are
operating correctly and to identify any potential issues before they escalate into major problems.

Purpose:

 Detect Early Signs of Issues: Identify wear, damage, or abnormal conditions (e.g., unusual
noises, vibrations, leaks).

 Ensure Operational Integrity: Verify that equipment is functioning as expected and within the
required parameters.

 Compliance and Safety: Ensure that the equipment or system complies with safety standards
and regulations.

Activities Involved:

 Visual inspections (e.g., checking for leaks, wear, or damage).

 Monitoring of operating conditions (e.g., temperature, pressure, vibration levels).

 Testing of safety devices and control systems.

  Recording observations and findings.

Routine Maintenance

Definition:
Routine maintenance refers to the regular tasks performed to keep equipment or systems in good
working condition and prevent potential failures or breakdowns.

Purpose:

 Preventive Action: Proactively address wear and tear to avoid unexpected downtime or costly
repairs.

 Longevity: Extend the lifespan of the equipment or system by keeping it in optimal condition.

 Efficiency: Ensure that the system operates at peak efficiency, reducing energy consumption and
operational costs.

Activities Involved:

 Lubricating moving parts.

 Cleaning filters, fans, or other components.

 Replacing worn-out parts (e.g., bearings, seals).

 Testing and calibrating systems (e.g., control systems, safety devices).

 Performing minor repairs or adjustments.

Summary:

 Routine Inspection is about observing and identifying potential problems.

 Routine Maintenance is about taking action to prevent those problems from occurring.

Both are essential for ensuring the reliability, efficiency, and safety of any equipment or system.

Routine inspection and maintenance of hydro turbines and their auxiliaries

1. Routine Inspection

Daily:

 Visual Inspection:

o Check for any visible leaks or unusual noises.

o Inspect the turbine casing, penstock, and other visible components for any signs of
wear, cracks, or corrosion.

o Ensure that all safety devices, alarms, and protective relays are functioning properly.

 Operational Checks:
 o Monitor the turbine's operating parameters such as speed, vibration, and temperature.

o Check oil levels and pressures in the lubrication system.

o Verify that cooling water is flowing correctly and that temperatures are within
acceptable limits.

Weekly:

 Mechanical Inspection:

o Inspect the turbine bearings for excessive wear or abnormal temperature readings.

o Check the alignment of the turbine shaft.

 Electrical Inspection:

o Inspect the condition of the generator brushes and slip rings.

o Check the insulation resistance of the generator windings.

Monthly:

 Detailed Inspection:

o Perform a thorough inspection of the wicket gates and guide vanes for any signs of wear
or damage.

o Inspect the runner blades for cavitation, cracks, or other defects.

 Control System:

o Test the functionality of the control and automation systems, including the governor,
exciters, and protection relays.

Quarterly:

 Hydraulic Systems:

o Inspect the hydraulic pressure system for leaks or pressure drops.

o Check the condition of hydraulic seals and hoses.

 Cooling Systems:

o Inspect and clean cooling water filters and strainers.

o Test the cooling water flow rates and check for any blockages.

2. Routine Maintenance

Daily/Weekly:

 Lubrication:

o Regularly lubricate all moving parts according to the manufacturer's specifications.

 o Check and top up oil levels in gearboxes, bearings, and other components.

Monthly:

 Cleaning:

o Clean the turbine and generator area to prevent dust accumulation.

o Clean air filters, cooling fins, and other components as needed.

Quarterly/Semi-Annually:

 Bearing Maintenance:

o Change the lubrication oil and grease in bearings according to the schedule.

o Inspect and replace any worn-out bearings.

 Hydraulic System:

o Replace hydraulic oil and filters if needed.

o Inspect and maintain the hydraulic actuators and pumps.

Annually:

 Comprehensive Inspection:

o Perform a complete disassembly and inspection of the turbine if necessary.

o Inspect and refurbish or replace any worn or damaged components.

o Rebalance the turbine runner and perform alignment checks.

 Electrical System:

o Test the generator’s insulation resistance and perform a high-potential (Hi-Pot) test.

o Inspect and clean the generator windings, and check for any insulation degradation.

 Protection System:

o Calibrate and test all protection relays and safety devices.

3. Documentation and Record Keeping

 Inspection Logs:

o Maintain detailed records of all inspections, including dates, findings, and corrective
actions taken.

10.2
Annual Inspection
Definition: Annual inspection is a thorough, detailed examination of equipment or
systems conducted once a year. This inspection goes beyond routine checks,
aiming to assess the overall condition, identify any hidden issues, and evaluate
the need for major repairs or replacements.
Annual Maintenance
Definition: Annual maintenance involves a series of more significant maintenance
tasks that are typically carried out once a year. This maintenance goes beyond
routine upkeep and often includes repairs, replacements, and upgrades that
ensure the long-term reliability of the equipment.
Annual Inspection of a Hydro Turbine
1. Visual and Structural Inspection:
 Turbine Runner and Blades:
o Inspect the turbine runner and blades for cracks, cavitation, erosion,
or any other damage.
o Use non-destructive testing methods like ultrasonic or dye penetrant
testing to detect internal flaws.
 Wicket Gates and Guide Vanes:
o Check for wear, corrosion, and proper alignment.
o Ensure smooth operation and check for any signs of leakage or
obstruction.
 Penstock and Inlet Valves:
o Inspect for signs of corrosion, sediment buildup, or any structural
damage.
o Ensure that inlet valves are functioning correctly without any leaks.
 Casing and Foundation:
o Check the turbine casing for cracks, corrosion, or any other damage.
o Inspect the foundation for any signs of settlement or cracks.
2. Mechanical System Inspection:
 Bearings:
o Inspect and test the turbine and generator bearings for wear and
tear.
o Measure the bearing clearances and temperatures during operation
to ensure they are within specified limits.
 Shaft Alignment:
o Check the alignment of the turbine shaft with the generator to
prevent excessive wear and vibration.
 Seals and Gaskets:
o Inspect all seals and gaskets for leaks or degradation, replacing them
if necessary.
 Cooling System:
o Inspect the cooling system components, including heat exchangers,
cooling water pumps, and filters, for any blockages or leaks.
3. Electrical System Inspection:
 Generator Windings:
o Perform insulation resistance testing (Megger test) on the generator
windings to detect any insulation breakdown.
o Conduct a partial discharge test to identify any early signs of
insulation deterioration.
 Control and Protection Systems:
o Test and calibrate all protective relays, governor systems, and control
units.
o Check the functioning of the excitation system and AVR (Automatic
Voltage Regulator).
 Brushes and Slip Rings:
 o Inspect the brushes and slip rings for wear and ensure proper contact
and alignment.
4. Hydraulic System Inspection:
 Hydraulic Oil Quality:
o Test the hydraulic oil for contamination, viscosity, and other quality
parameters. Replace the oil if necessary.
 Hydraulic Pumps and Actuators:
o Inspect the hydraulic pumps, actuators, and associated piping for
leaks, pressure loss, or wear.
 Pressure Testing:
o Conduct pressure tests on the hydraulic system to ensure it operates
within the specified range.
Annual Maintenance of a Hydro Turbine
1. Component Replacement and Repairs:
 Bearings and Seals:
o Replace or refurbish worn bearings, seals, and gaskets to prevent
leaks and ensure smooth operation.
 Lubrication:
o Drain and replace the lubrication oil in the bearings and other
moving parts.
o Ensure that all moving components are properly lubricated according
to manufacturer specifications.
 Runner and Blades:
o Repair or replace damaged runner blades if cracks, cavitation, or
significant wear are detected.
 Wicket Gates and Guide Vanes:
 o Repair or replace any worn or damaged parts and ensure proper
operation and alignment.
2. Cleaning and Debris Removal:
 Water Passage Cleaning:
o Clean the water intake, penstock, and other water passages to
remove sediment, debris, and other obstructions.
 Cooling System Cleaning:
o Clean the heat exchangers, cooling fins, and other components of the
cooling system to ensure efficient heat dissipation.
3. Calibration and Testing:
 Control Systems Calibration:
o Calibrate the turbine’s control systems, including the governor, to
ensure precise control of speed and load.
 Protection Relay Testing:
o Test and calibrate all protection relays to ensure they respond
correctly to faults and abnormal conditions.
 Performance Testing:
o Conduct a full-load performance test to measure the turbine’s
efficiency and identify any areas needing improvement.
4. Alignment and Balancing:
 Shaft Alignment:
o Re-align the turbine shaft with the generator to reduce wear and
vibration.
 Runner Balancing:
o Perform dynamic balancing of the turbine runner to minimize
vibrations and ensure smooth operation.
5. Safety Checks:
  Emergency Shutdown Systems:
o Test the emergency shutdown systems to ensure they function
correctly in case of a fault.
 Fire Suppression System:
o Inspect and test the fire suppression systems to ensure they are
operational and meet safety standards.
Documentation and Reporting
 Inspection and Maintenance Records:
o Document all findings from the inspection, including measurements,
test results, and any anomalies detected.
 Maintenance Logs:
o Record all maintenance activities, including parts replaced, repairs
conducted, and adjustments made.
 Reporting:
o Provide a detailed report summarizing the condition of the turbine,
maintenance performed, and any recommendations for further
action.
10.3
Capital maintenance in a hydroelectric power plant refers to significant,
planned maintenance activities that involve major repairs,
replacements, or upgrades of essential equipment and infrastructure.
-Unlike routine maintenance, which focuses on day-to-day upkeep,
capital maintenance is aimed at ensuring the long-term reliability,
efficiency, and safety of the hydroelectric facility. It often involves
substantial investments and can require extended plant downtime.
Key Aspects of Capital Maintenance in Hydro Plants
1. Major Overhauls:
 o Turbine Overhaul: Involves disassembling the turbine to inspect,
repair, or replace critical components such as the runner, bearings,
and seals. This process is essential for restoring the turbine’s
efficiency and preventing failures.
o Generator Rewind: The generator’s stator and rotor windings may
be rewound to restore insulation integrity, improve electrical
performance, and extend the life of the generator.
2. Replacement of Aging Equipment:
o Penstock Replacement: If the penstock (the large pipe that delivers
water to the turbine) shows signs of severe corrosion, leaks, or
structural issues, it may need to be replaced or relined.
o Transformer and Switchgear Replacement: Aging transformers and
switchgear that no longer meet performance standards or safety
requirements are replaced to improve reliability and safety.
3. Upgrades to Improve Efficiency:
o Turbine and Generator Upgrades: Replacing or upgrading
components to more modern, efficient designs can increase the
power output and overall efficiency of the plant.
o Control System Upgrades: Modernizing control systems with digital
technology can enhance automation, improve response times, and
provide better data for monitoring and optimization.
4. Infrastructure Rehabilitation:
o Dam and Spillway Repairs: Major structural repairs to the dam or
spillways to address issues like concrete degradation, seepage, or
structural weakness are vital for ensuring the safety and longevity of
the hydro facility.
o Civil Works Maintenance: This includes reinforcing or repairing
intake structures, tailraces, and other civil infrastructure to ensure
they can continue to function properly.
5. Safety and Environmental Compliance:
 o Safety System Enhancements: Upgrading or replacing fire
suppression systems, emergency shutdown mechanisms, and worker
safety equipment to meet current safety standards.
o Environmental Improvements: Implementing measures such as fish
ladders or water quality monitoring systems to comply with
environmental regulations and minimize the plant's impact on the
local ecosystem.
Purpose and Benefits of Capital Maintenance
 Extended Equipment Life: By replacing or refurbishing critical components,
capital maintenance helps extend the operational life of the plant, delaying
the need for new construction or major capital investments.
 Increased Reliability: Addressing wear, tear, and potential failure points
reduces the likelihood of unexpected breakdowns and unplanned outages.
 Improved Efficiency: Upgrades and refurbishments can lead to more
efficient operation, which can increase energy production and reduce
operational costs.
 Compliance with Regulations: Ensuring that the plant meets current safety,
environmental, and operational standards, which is crucial for legal and
operational viability.
 Enhanced Safety: Reducing the risks associated with aging infrastructure
and outdated systems, thereby protecting workers and the surrounding
environment.

10.4
Common Materials Handling Equipment in a Powerhouse
1. Overhead Cranes:
o Bridge Cranes: These are heavy-duty cranes used to lift and move
large and heavy components such as turbine parts, generators, and
 other equipment within the powerhouse. They are mounted on
overhead rails and can travel the length of the powerhouse.

o Gantry Cranes: Similar to bridge cranes but supported by legs that

move on rails on the floor, gantry cranes are often used in areas
where overhead space is limited or where a bridge crane is not
feasible.

2. Hoists:
o Electric Hoists: Used for lifting and lowering heavy objects, electric
hoists are often attached to overhead cranes or other support
structures. They provide precise control over heavy components
during maintenance or installation.

o Manual Chain Hoists: These are smaller, portable hoists operated by

hand. They are used for lifting lighter loads and in situations where
power is not available.

3. Forklifts:
o Industrial Forklifts: Used for
moving materials, components,
and equipment around the
powerhouse. Forklifts can
handle a variety of tasks, such
as transporting pallets, crates, and other heavy items.
 o Telescopic Forklifts: These forklifts have an extendable boom,
allowing them to reach higher areas, making them useful for tasks
such as stacking heavy equipment or reaching elevated workspaces.

4. Conveyor Systems:
o Belt Conveyors: These are used for moving bulk materials, such as
coal (in thermal power plants) or other resources, from one location
to another within the powerhouse.
 o Roller Conveyors: Often used
to move heavy items, such as
machinery components,
across short distances. They
allow for easy manual or
powered movement of items.

5. Trolleys and Carts:

o Hand Trolleys: Used for moving smaller components or tools within
the powerhouse. They are portable and can be easily maneuvered in
tight spaces.
 o Heavy-Duty Carts: Used for transporting heavier equipment or
multiple items at once. They often have reinforced structures and
heavy-duty wheels for handling substantial loads.

6. Hydraulic Lifting Equipment:

o Hydraulic Jacks: Used for lifting heavy machinery or parts during
maintenance or installation. They provide stable and controlled
lifting, crucial for precision work.
 o Hydraulic Lifting Tables: These are used to lift and position heavy
components to a desired height, making assembly, maintenance, or
inspection tasks easier

7. Pneumatic Tools:
o Pneumatic Wrenches: These are commonly used for tightening or
loosening bolts and nuts on large machinery. They are essential for
quick and efficient assembly or disassembly.

o Pneumatic Lifting Bags: These are inflatable bags used to lift or

stabilize heavy objects in tight or uneven spaces. They provide a
versatile lifting solution in situations where traditional jacks or hoists
cannot be used.
8. Rigging Equipment:
o Slings and Shackles: Used for securing loads during lifting operations.
They are crucial for ensuring safety when moving large or awkwardly
shaped components.

o Turnbuckles and Rigging Screws: These are used to adjust the

tension in ropes or cables during lifting and moving operations,
ensuring that loads are secure and balanced.
9. Mobile Cranes:
o Truck-Mounted Cranes: These cranes are mounted on trucks and are
used for lifting and moving equipment within or around the
powerhouse, especially in outdoor areas.

o Crawler Cranes: These are mobile cranes with tracks instead of

wheels, providing stability on rough terrain. They are used for lifting
heavy loads in areas where other cranes might not have access.

10.Automated Guided Vehicles (AGVs):

o Robotic Transporters: In some modern powerhouses, AGVs are used
to transport materials, tools, and components autonomously. They
can be programmed to follow specific routes and schedules,
increasing efficiency.
Safety Considerations
 Load Capacity: Always ensure that the materials handling equipment is
used within its specified load capacity to prevent accidents.
 Training: Operators of cranes, forklifts, and other heavy equipment should
be adequately trained and certified to handle the equipment safely.
 Maintenance: Regular inspection and maintenance of materials handling
equipment are crucial to ensure they operate safely and effectively.
 Ergonomics: Equipment should be used in a manner that minimizes strain
and injury to workers, such as by providing appropriate lifting tools and
devices.