standards / manuals / guidelines for small hydro development - AHEC

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• Type of plant such as ROR, dam based or canal based. The manpower for the RORplant is more because of the spread of hydraulic structures, the water channel and itsequipment.• The number of shifts/ hours the plant is going to work e.g. one shift or three shift. Aplant 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 thesupport services such as transport, maintenance of residences etc.This may increase the strength of the remotely located ROR plant. However themanpower can be kept minimum by employing a multidisciplinary force such as anengineer with experience in civil and electromechanical work. Or technician withdriving experience etc. The guiding factor is safety of equipment and manpower.Other method is to employ local labor, during requirement of additional work such asrainy season where inspection of water channel is needed or during annual maintenancework. It will benefit the plant, if these persons are given proper on job training.2.2 SELECTIONMan power required for operation and maintenance shall be selected beforecommercial operation of the plant.• The operation staff shall be selected well in advance preferably during the precommissioningand commissioning of the plant.• The experience of the persons shall be in hydro generating plant, DG plant of a cogenerationplant. An experience on large electrical substation with DG set may beaccepted.• Plant incharge having basic degree/ diploma in electrical with experience in civil andmechanical works is most suitable.• Testing engineer is most important for any generating plant. He should beexperienced engineer familiar with all equipment testing to take decision in case ofany fault on electrical equipment such as generator, transformer and switchgear. Thisbeing a specialized job it may be difficult to get such persons and to hold them assuch 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-mechanicalwork 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 beawarded on annual basis to keep work force low.2.3 TRAINING OF OPERATION STAFFThe operation staff shall be given training by Sr. Experienced personal and also onsimulator, if available. The training shall be in the area of SHP operation, maintenance, safetyand 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 onactual work in the plant where they will be working.AHEC/MNRE/SHP Standards/ E&M Works – Guidelines for Operation and Maintenance of Small Hydropower Station 74
• On placing them on operation duty they shall be periodically assessed for theirperformance in actual operation such as start of units etc.3.0 ESSENTIAL T&P, INSTRUMENTS ETC(i)(ii)Ordinary tools, instrumentsFor effective maintenance it is necessary to list out all required ordinary T&P asalso assess quantity and arrange the same otherwise it may become difficult evenfor a skilled and capable technicians to carryout the require maintenance job.Ordinary T&P includes different type & sizes of screw drivers, pliers, spannershammers etc.Special T&PSuch type of T&P is required during assembly or dismantling of machines. Forexample, rotor lifting device and endless slings, pole turning device, shaft liftingdevice, 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 beproperly stored and secured. Necessary maintenance, if required, must be carriedout on these devices in time. Slings should be stored duly coated withpreservatives as recommended by the manufactures.4.0 FIRE PROTECTION & FIRE FIGHTINGIt is necessary to install necessary hydrant points fire extinguishers at differentlocations 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 onduty 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 andthese should be inspected periodically by station incharge. Timely recoupment of consumeditems must be ensured by shift incharge.Shift incharge should also ensure timely refilling of fire extinguishers installed in thepowerhouse. He must periodically check working of hydrant points.Smoking inside power station should be prohibited. Throwing match sticks and otherburning stuff may some time create fire in the power station.Additional fire extinguishers must be kept during maintenance specially whenactivities like, welding, brazing etc. are going on.Asbestos cloth must be used to cover electrical parts during such maintenanceactivities.In power stations normally following types of fire extinguishers are used:o Soda acid typeo Dry chemical type foam type (chemical foam)o CO 2 cylinderso Fire hydrantsAHEC/MNRE/SHP Standards/ E&M Works – Guidelines for Operation and Maintenance of Small Hydropower Station 75
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STANDARDS / MANUALS / GUIDELINES FO
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ITEMSPAGE NO4.2 Preventive Maintena
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SECTION - IGUIDELINES FOR OPERATION
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2.1.2 Lake/Storage/PondThe operatio
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2.2.3 Electrical• Air seal valve
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• Start command initiated(iv)Sync
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‣ Check whether supply to various
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- Intake gates, bye pass gates, D.T
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• To arrange for evacuation of ma
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SECTION - IIGUIDELINES FOR MAINTENA
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2.3 PREDICTIVE MAINTENANCEThis sort
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6. Oil Leakage Unit:i) Check any le
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5. Shaft Gland Seal and Air Seal:i)
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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: SECTION-IIIGENERAL GUIDE LINES1.0 G
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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