standards / manuals / guidelines for small hydro development - AHEC

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SECTION – IIGUIDELINES FOR MAINTENANCE OF SMALL HYDRO POWERSTATIONS1.0 INTRODUCTIONExperience of running hydropower station reveals that even after detailed projectplanning/quality control measures taken at various stages from inception to commissioningseveral unforeseen problems do take place during the operation and maintenance resulting inforced outages/low generation and load shedding etc. causing misery to the consumers andundesired set back to the overall economy. The main reasons which can be attributed to theseundesired phenomenon/events(during operation), are that the hydro power station equipmentsis custom built in construction and tailor made at each discipline viz. design ,manufacturing,erection, commissioning, operation and maintenance etc. The equipment cannot be fullyassembled or tested at works. Maintenance exercise at predetermined time interval aretherefore, planned to ensure the following objective:1. Quality and reliable operation of equipment on long term basis through identifiedperiodic inspection /checking of components and subsequent replacement/rectification parts, wherever required.2. Maximum availability of equipment with least number of shut downs by ensuring thatthe rate of deterioration of any component does not exceed the life expectancy of theequipment at any stage. Periodic /planned shut downs should be arranged to avoidlong term forced shutdowns.3. Eradiction /non-repetition of operational problems by timely analysis of the cause offaults/problems and replacement of short term solutions by long lasting andpermanent ones.2.0 TYPE OF MAINTENACE2.1 REACTIVE (RUN TO FAILURE)This is sometimes called crisis maintenance or hysterical maintenance. This has beendominant form of maintenance for long time and its costs are relatively high because ofunplanned downtime damaged machinery and overtime expenditure. Run to failure shouldbe a very small part in a modern maintenance program. Planned maintenance is preferredover this type so as to reduce downtime of machine and avoid uncalled for outages.2.2 PREVENTIVE MAINTENANCEPreventive maintenance is planned maintenance of plant & equipment. It is designed toimprove equipment life and avoid any unplanned maintenance activities. Preventivemaintenance is the inspection, replacement, repair of any piece of equipment or componentbased on time and set parameters. It includes painting, lubrication, cleaning, adjusting andminor component replacement to extend the life of equipment and facility. Its main purposeis to minimize break down and excessive deterioration.AHEC/MNRE/SHP Standards/ E&M Works – Guidelines for Operation and Maintenance of Small Hydropower Station 15
2.3 PREDICTIVE MAINTENANCEThis sort maintenance ensures ability to judge when a piece of equipment is going to fail andreplace the same before it does. Usually it requires some form of testing and analysis whichhelps predict an eminent failure. Predictive maintenance can be used in conjunction withpreventive maintenance practices. In hydro power station there are many monitoringsystems, which can be used to predict problems and possible failures. These includevibration monitoring, oil analysis, temperature, systems ampere readings resistance readingsof motors, efficiency in power generation out put, leakages of oil and water. All of thesethings can be captured and tracked by computer system. The analysis of data can predict thefuture.2.4 PROACTIVE MAINTENANCEMost 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 soughtand corrected.2.5 RELIABILITY CENTERED MAINTENANCE (RCM)This sort of maintenance is defined as “a process used to determine the maintenancerequirements of any physical asset in its operating context”. It is an on going process whichdetermine the mix of reactive preventive and proactive maintenance practices to providereliability at the minimum cost. It recognises that all equipments in facility are not of equalimportance for generation as well as plant safety. It recognizes that design and operation ofeach equipment differs and therefore, possibility of failure also differs from equipment toequipment. In this system diagnostic tools and measurements are used to assess when acomponent is near failure and should be replaced. In this approach basic thrust is to eliminatemore costly unscheduled maintenance and to minimize preventive maintenance. In thissystem unimportant maintenance activities are left to reactive maintenance approach.3.0 REQUIREMENT OF EFFECTIVE MAINTENANCEIn addition to planning maintenance and allotting suitable time interval on the basis of watersupply availability following items also require close watch otherwise it may become difficultto 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 notlost I arrangement of the same after taking shut down.iii) The maintenance engineers should have in his possession al the erection andcommissioning 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 asdefined maintenance purpose.iv) Log sheets of the previous maintenance exercise carried out on the machines. Thesemay be required to compare with the clearances/ settings/characteristics achievedduring present maintenance.AHEC/MNRE/SHP Standards/ E&M Works – Guidelines for Operation and Maintenance of Small Hydropower Station 16
Page 1 and 2: STANDARDS / MANUALS / GUIDELINES FO
Page 3 and 4: ITEMSPAGE NO4.2 Preventive Maintena
Page 5 and 6: SECTION - IGUIDELINES FOR OPERATION
Page 7 and 8: 2.1.2 Lake/Storage/PondThe operatio
Page 9 and 10: 2.2.3 Electrical• Air seal valve
Page 11 and 12: • Start command initiated(iv)Sync
Page 13 and 14: ‣ Check whether supply to various
Page 15 and 16: - Intake gates, bye pass gates, D.T
Page 17 and 18: • To arrange for evacuation of ma
Page 19: SECTION - IIGUIDELINES FOR MAINTENA
Page 23 and 24: 6. Oil Leakage Unit:i) Check any le
Page 25 and 26: 5. Shaft Gland Seal and Air Seal:i)
Page 27 and 28: v) In case the runner is found to b
Page 29 and 30: iii) Preheating of the blade to abo
Page 31 and 32: E. GovernorDifferent types of gover
Page 33 and 34: Sl. No. Description Periodicity Rem
Page 41 and 42: 4.2.1 Daily ChecksSl.No.Assembly It
Page 43 and 44: 4.2.3 Annual Inspection & Maintenan
Page 45 and 46: Sl.No.Assembly Item Check Point Met
Page 47 and 48: • Check all joints, tightness of
Page 49 and 50: S.No.Item to beinspectedInspection
Page 57 and 58: 4.4 PREVANTIVE MAINTENANCE OF HYDRO
Page 59 and 60: Spherical valves (for heads more th
Page 61 and 62: • Check rotor level, verticality
Page 63 and 64: • Any possible inbalance of runne
Page 65 and 66: The blades are set to the no-load p
Page 67 and 68: IV.Rotational Checks‣ Arrangement
Page 69 and 70: Fig 6: Resultant Method of Throw Ca
Page 71 and 72:
Fig 9: checking Verticality of Gene
Page 73 and 74:
oFig 11: Checking Balancing of Gene
Page 75 and 76:
Procedure for preliminary alignment
Page 77 and 78:
Fig 14: Determining Displacements o
Page 79 and 80:
SECTION-IIIGENERAL GUIDE LINES1.0 G
Page 81 and 82:
• On placing them on operation du
Page 83 and 84:
Safety Precautions and Practices in
Page 85 and 86:
Results of test and measurements ca
Page 87 and 88:
(NAME OF POWER STATION)DAILY GENERA
Page 89 and 90:
(NAME OF POWER STATION)DAILY TRIPPI
Page 91 and 92:
UnitGENERATION(MU)TOTALTIME(Hrs:Min
Page 93 and 94:
MONTHLY TRIPPING REPORTFOR THE MONT
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AHEC/MNRE/SHP Standards/ E&M Works
Page 97 and 98:
(POWER STATION)ANNUAL MAINTENANCE S
Page 99 and 100:
UNIT/ EQUIPMENT/ FEEDER BAY/:DATE &
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standards / manuals / guidelines for small hydro development - AHEC

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