standards / manuals / guidelines for small hydro development - AHEC

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Sl. No. Description Periodicity Remarksacceptablevalues5.05 Measures insulation resistance of G.B. pads. Yearly5.06 Check calibration of TSD’s & RTDs of of YearlyG.B.5.07 Prior to removal of pads, measure and recordguide bearing clearances.5.08 Check each pad for:i) Absence of scratch marks. Scrapping tobe done with respect to the journal, ifrequiredii) Heavy damage on babbit surface of pads– full set be replaced from spares. Thespares set tot be scrapped with respect toit’s respective journal surface by givingrotation to the unit.5.09 Check the centering of the unit vis-à-vis thelabyrinth/runner chamber of turbine.5.10 Check the friction surface of the bearingjournal. Carryout its polishing, if necessary.5.11 Wash pads & journal with aviation petrol andthen carryout assembly of the guide bearing.5.12 Check the condition of welding seems of oilbath & leakages from them and oil pipe liens.5.13 Clean all inner surfaces of oil bath from dust,wash them with Kerosene and dry with cleancloth.AsrequirementYearlyperYearly as perrequirementYearlyYearlyYearlyOnce in twoyears5.14 Change rubber seals and woolen felts. As required5.15 Check operation of the level relay and its Yearlycalibrations.5.16 Check welding of pad support block with oil Yearlybath.5.17 Check looseness of pad and pad support Yearlybolts.5.18 Check condition of pad insulation Yearly5.19 Check looseness of bolts holding ‘Z’ clamps(in wedge type construction of guidebearings.YearlyTo be readjusted ifrequired, duringreinstallationOil bath is to befinally flushed withfresh turbine oil; to bediscarded after use.6.00 AIR/OIL COOLERS6.01 Check water boxes for clogging by openingthem. In case of clogging clean tubes waterboxes with wire/ nylon brush. Remove alldirt etc & finally clean with fresh water &YearlyThis checking may bedone frequently ifclogging is more.AHEC/MNRE/SHP Standards/ E&M Works – Guidelines for Operation and Maintenance of Small Hydropower Station 31
Sl. No. Description Periodicity Remarksdry.6.02 Check the gasket between oil cooler & oil Yearlybath & between air cooler & stator frame.Gaskets to be replaced if required.6.03 When the shutdown exceeds 10 days, water As requiredfrom coolers is to be drained and the coolerskept dry.6.04 Coolers are to be immediately attended to as On flooding of This is to safe guardgiven above at 6.03.the unit. failure on subsequentcommissioning of the6.05 Normally upto 10% of the cooling tubes ofcoolers can be plugged, if required.7.00 UPPER BRACKET / LOWER BRACKETAs requiredunit.Temperature of thebearing pads/ statorwinding to be taken inview while pluggingtubes of the coolers.7.01 External inspection & tightening of the lock Once in 3nuts in the radial jacks, if required.months7.02 Check fixing of the generator cover plate Once in 3months7.03 Check all fasteners of Upper and lower air Once in 3baffles.months7.04 Check the value of air gap between air YearlyThese gaps are to bebaffles and rotor.compared withoriginal values duringerection andmaintained as such, ifrequired.7.05 Clean the brackets of dirt & dust. Yearly Cleaning can be donemore often if possible.7.06 Check fastening between upper bracket & Yearlystator and foundation plates.7.07 Check foundation bolts tightening for stator Yearly& lower bracket.7.08 Check all fasteners for locking / tightness Yearly8.00 Brake pipe line8.01 Record air pressure available at brake panel. Every shift Record on log sheet8.02 Check thickness of brake pad As required Record to bemaintained along withnumber of braking inthe period with Airpressure used forbraking.8.03 Measure:i) Time for unit to come braking speedDuring firstspinning / yearlyRecord be kept. Incase if this time hasAHEC/MNRE/SHP Standards/ E&M Works – Guidelines for Operation and Maintenance of Small Hydropower Station 32
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 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 35: Sl. No. Description Periodicity Rem
Page 39 and 40: 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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