standards / manuals / guidelines for small hydro development - AHEC

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i) Desembly, inspection, cleaning, measurement of clearances, polishing ofguide pads, centering of shaft, reassembly, setting of clearances, filling of oilsump 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 flapsor carbon segments, if necessary.3. Clean Water System:Clean water pipes are dismantled, cleaned, reassembled with new gasket all the valvesare attended for any leakage etc.4. Guide Vane Servomotor:Dismentling for inspection and cleaning. Reassembling and replacing the seals withnew ones, if necessary.5. Guide Vanes Bush Housing :i) Removing, cleaning and inspecting for wear and tear replacing with new onesif found necessary. Replace seals, if necessary.ii) Guide vanes are reconditioned.6. Governor:i) Cleaning and checking OPU pumps. Replace bushes, bearings etc. if foundworn 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 andpilot slide valves. Set Auto rod as per designs Alpha Beta setting may also bechecked in case of Kaplan turbine.vi) Check electrical circuit. Tightening of all the connections should be done.7. Under Water Partsi) Inspect condition of welded seams of penstock spiral crossing and draft tubesrectify defects by welding and grinding. Penstock filling line valve should alsobe 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. Runneri) Dewatering of draft tube and fabrication of platform in the draft tube forinspection of runner.ii) If it is a Kaplan Runner test the same after applying full governor pressure forleakage of oil.iii)iv)Replace blade seals if necessary.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 awaywith passage of time. After weld repair heat treatment and dynamic balacing ismust before installation.AHEC/MNRE/SHP Standards/ E&M Works – Guidelines for Operation and Maintenance of Small Hydropower Station 21
v) In case the runner is found to be irreparable arrange to replace the same withnew one.vi) In case of Kaplan runner hydraulic test is also required to be done.9. Turbine Auxiliaries1. DPMi) 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 Uniti) Overhaul cooling pumpsii) Attend all the valves and pipe line for leakage11 Centralised Grease lubrication Systemi) 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. Replacedamaged pipes.iv) Check that all the guide vanes are receiving grease properly.12 Oil Leakage Uniti) 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 TurbinesSome of the major problems encountered in the hydro turbines are damage in runners due toerosion, cracking and cavitation due pressure pulsation in draft tube, instability of operationat partial gate opening. Failure of turbine bearings, leakages of water through of turbine guidebearings, leakage of water through guide vane seals and turbine gland seals, these problemsare discussed in detailed in the following paras.A. Runner1. Erosion due to siltThe problem of erosion of turbine runners guide vanes and other under water parts hasassumed serious proportions especially in some of the run-of-river schemes, The rivers in thenorthern region carry enormous silt loads especially during mansoon periods so much so thatthe power stations has to be closed down to prevent serious damage to the turbines part andwater passage. Greater attention should, therefore, be paid to effective desilting arrangementin 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 thatthe unit has to be taken out for reconditioning every few years in some stations. The remedyappears to lie in effective desilting arrangements and manufactures of turbine parts withharder and erosion resistant material like stainless steel of popper grade and also design ofrunner for such conditions.AHEC/MNRE/SHP Standards/ E&M Works – Guidelines for Operation and Maintenance of Small Hydropower Station 22
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 and 20: SECTION - IIGUIDELINES FOR MAINTENA
Page 21 and 22: 2.3 PREDICTIVE MAINTENANCEThis sort
Page 23 and 24: 6. Oil Leakage Unit:i) Check any le
Page 25: 5. Shaft Gland Seal and Air Seal:i)
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
Page 95 and 96:
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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