New Bong Escape Hydropower Plant

1st Hydel IPP of Pakistan

Laraib Energy Limited

Submitted by
Iqra Aziz
Date: 08/10/2015

Mirpur University of Science & Technology

 Abbreviations

LEL Laraib Energy Limited

PPA Power Purchase Agreement

HSE Health, Safety and Environment

PPE’S Personal Protective Equipment

PSM Process Safety Management)

PHA Process Hazard Analysis

O&M Operation and Maintenance

EPA Environmental Protection Agency

 Acknowledgement
First of all I would like to thank Laraib Energy Limited to give me an opportunity to follow my
internship at Laraib and TNB Remaco Pakistan. I experienced great things here.

I would like to thanks my mentor Sir Asif for providing me with all the information and materials
regarding Mechanical portion. He coached me during my internship by giving me feedback and
tips how to handle and approach situations in monthly and annually maintenance.

I would like to pay a special thanks to Sir Mustafa Umar Riaz who is the senior operation manager
in Laraib for his efforts to provide me with this opportunity. He not only helped me during
Internship but also provide me with worthy advices and tips how to start Professional Career. He
also helped us to develop a professional attitude and how can I prepare myself for my future career.
I would really like to appreciate his efforts and time which is spent on me despite of his busy
schedule.

At the end I would like to thanks all the working staff of Laraib Energy Limited and TNB Remaco
Pakistan with their patience and openness they created a comfortable and enjoyable working
environment.
 Summary
Energy is considered to be life line of economy of a country. Energy is the most vital instrument
of progress and development of a country. Pakistan has huge Hydel Potential out of which 60,000
MW is identified. KPK, AJK and Northern Areas have most of the hydro potential.

As Pakistan is facing Energy crisis since 2007, and many new projects were installed to overcome
energy crisis, Hydel is the most growing sector especially in AJK. The reason I chose to do my
internship at Laraib was to get a sound knowledge of Hydro Power Plant. I want to learn the basic
layout of a plant, operation and functioning of Turbine, governor, generation and distribution of
electricity and Maintenance.

This report presents the activities performed during the 6 week internship at Laraib Energy
Limited. It contains the detail of all the experience and knowledge which I gained during
Internship. I will also describe and reflect my learning objects and personal goals which I set while
doing my internship.

It contains the detail of initial necessary parameters for the Installation of plant e.g. Occupational
Health and Safety Management Plan (OHSMP), Contingency Plan, Environmental and Social
Management Plan (ESMP), Initial Environmental Examination (IEE).

Study of O&M manual of turbine gave a detailed description of operating parameters and
operating limits of the turbine depending upon the net head available, power output, discharge
from tailrace and wicket gate opening limits.

Governor (Brain of Turbine) was also studied and internship report contains the key elements,
types, features and working principle of Governor.

The importance of maintenance for better life and better functioning of a plant can’t be
overemphasized. Maintenance is considered the key factor at Laraib. Review of Annual and
monthly maintenance helped me out to understand their maintenance planning and procedure.

Different case studies helped me to learn different tools like Process Hazard Analysis, Fish Bone
Analysis and Root Cause Analysis. Especially case study about the failure of shaft seal helped to
learn different problem solving techniques, procedure and process.
Contents
1. Project Profile ........................................................................................................................ 1
2. Introduction ............................................................................................................................ 2
Chapter 1 .................................................................................................................................... 3
Health, Safety and Environment, (HSE) .................................................................................... 3
1.1 Introduction: ......................................................................................................................... 3
1.1.1. Health, Safety and Environment Policy ....................................................................... 3
1.1.2. HSE Vision & Management ......................................................................................... 3
1.1.3 Management Safety Audit (MSA) ................................................................................ 4
1.1.4 Safety Induction ............................................................................................................ 5
1.1.5 Site Hazards................................................................................................................... 5
1.2. Process Safety Management (PSM) ................................................................................ 5
1.2.1 Process Hazard Analysis (PHA) ................................................................................... 6
1.2.2 PHA allows the employer to:..................................................................................... 6
1.2.3 PHA Requirements .................................................................................................... 7
1.2.4 PHA Addresses: ......................................................................................................... 7
1.2.5. My Understanding .................................................................................................... 7
1.3 Case Study ........................................................................................................................ 7
This case study strengthen my learning about Process Safety Management and Process
Hazard Analysis. .................................................................................................................... 8
1.4 Occupational Health and safety Management Plan OHSMP ........................................... 8
1.5 Contingency plans for operations ..................................................................................... 8
1.6 Environmental and social Management Plan (EMP) ....................................................... 9
1.7 Initial Environment Examination ................................................................................... 10
Chapter 2 .................................................................................................................................. 11
Operation.................................................................................................................................. 11
Operation of Turbine ............................................................................................................ 11
2.1 General description of turbine ........................................................................................ 11
2.1.1 Runner: .................................................................................................................... 11
2.1.2 Coupling Shaft: ........................................................................................................ 11
2.1.3 Draft Tube: .............................................................................................................. 11
2.1.4 Guide Apparatus: ..................................................................................................... 12
2.1.5 Shaft and Standstill sealing: .................................................................................... 12
 2.1.6 Turbine Guide Bearings: ......................................................................................... 12
2.1.7 Axial thrust and counter thrust bearings: ................................................................. 12
2.1.8 Brakes: ..................................................................................................................... 12
2.2 Operating limits of the turbine: ...................................................................................... 12
2.3 Mechanical Axillaries .................................................................................................... 12
2.3.1 Drainage Pump and Dewatering Pump ................................................................... 12
2.3.2 Water Treatment Plant ............................................................................................. 13
2.3.3 Overhead Cranes...................................................................................................... 13
2.3.4 Intake and Draft Tube Stop Log Gantry Cranes ...................................................... 13
Chapter 4 .................................................................................................................................. 14
Governor System ..................................................................................................................... 14
4.1 Digital Governor System................................................................................................ 14
4.1.1 Functions of Digital Governor ................................................................................. 14
4.2 Hydraulic governor ........................................................................................................ 15
4.3 oil pressure system ......................................................................................................... 15
4.4 Leakage oil tank ............................................................................................................. 15
4.5 Runner hub oil tank ........................................................................................................ 15
Chapter 5 .................................................................................................................................. 16
Maintenance ............................................................................................................................. 16
5.1 Maintenance ................................................................................................................... 16
5.2 Monthly Maintenance .................................................................................................... 17
5.3 Six monthly maintenance ............................................................................................... 18
5.4 Annually maintenance .................................................................................................... 18
5.5 Review of Monthly inspection report............................................................................. 19
5.6 Review of Annual maintenance report ........................................................................... 19
5.7 Fish Bone Analysis......................................................................................................... 20
Chapter 6 .................................................................................................................................. 21
Case study ................................................................................................................................ 21
6.1 Problem statement .......................................................................................................... 21
6.2 Solution: ......................................................................... Error! Bookmark not defined.
6.2.1 Shaft seal parameters ................................................................................................ 21
6.2.2 Shaft seal assembly .................................................................................................. 21
6.2.3 Working principal .................................................................................................... 21
6.3 Incident Description .................................................................................................... 22
6.4 Inspection of Incident ..................................................................................................... 22
 6.4 FISH BONE ANALYSIS .............................................................................................. 22
6.5 Causes of Shaft Seal Damage......................................................................................... 24
6.6 Root Cause Analysis ...................................................................................................... 25
6.7 Recommendations: ......................................................................................................... 25
Conclusion ............................................................................................................................... 26
Recommendations .................................................................................................................... 26
 1. Project Profile
New Bong Escape is first independent Hydel Power Producer (IPP) in Pakistan and Azad Kashmir. It is a
Run off River Technology and Installed Plant Capacity is 84 MW. It has an annual generation of 470 GWH.
This project was funded by Asian Development Bank, Islamic Development Bank, International Finance
Corporation, Proparco, National Bank of Pakistan and Habib Bank Limited. HUBCO is its main share hold.
HUBCO has 75% shares. The Project Commenced on 23rd March 2013. It is a trend setting project, who set
the new trend for rapid progress and development of Hydel power potential in Pakistan and AJ&K.

Laraib Energy Limited is the owner and developer of New Bong Escape Hydro Power Project. Laraib is a
subsidiary of HUBCO. HUBCO is an owner of 1292 MW. The Hub power station was one of the first and
largest Independent Power Producer (IPP) in Pakistan to be financed by the private sector in Southern Asia
and one of the largest private power projects in the newly industrialized world.

This project is located on Jhelum River 7.5 km downstream of the Mangla Dam. It runs water released from
the Mangla Dam and returns that water to the main stream of the River Jhelum through a 6.5 km long tailrace.
The project is constructed between the old and New Bong Escape Structure on Bong Canal. The main benefit
of this project is that it is run off river technology without any dam, storage or resettlement of human
habitation. And also this project does not have any kind of adverse impact on Environment.

The main purpose of this project is to supply generated electricity to National Grid. Generated electricity
will be sold to National Transmission and Dispatch Company (NTDC) for 25 years through a Power
Purchase Agreement (PPA). This project is clean, renewable and sustainable and contributing to somehow
mitigate the power shortage.

The operation and Maintenance of New Bong Escape is assigned to Tenaga Nasional Berhad Remaco
Pakistan (TNBRP). Tenaga Nasional Berhad (TNB) is the largest electricity utility in Malaysia and a leading
utility company in Asia. TNB’s core businesses is generation, transmission and distribution of electricity.

HUBCO Laraib is committed to provide the excellent services to the energy industry in Pakistan and AJK.

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 2. Introduction
This report is a short description of my 1 month internship at Laraib Energy Limited. The main
reason to choose the Laraib Energy Limited is that I wanted to gain the practical knowledge and I
also wanted to learn, improve and develop new set of skills.

At the start of my internship, I set several goals, which I want to achieve during my internship:

1. To understand the structure, functioning and working mechanism of a non-governmental

organization
2. To have an image of a professional environment
3. To use my gained skills and knowledge
4. To observe what skills and knowledge do I need to improve for professional career
5. To learn about field experience and practical implementation of theoretical knowledge
6. To enhance my communication skills

This internship report contains the detail of my activities during my internship which helped me to
achieve my set goals. The following chapters contains the description of my internship, reflection
of my learning and goals achieved during my internship.

1. Internship Activities:

My internship was focused on Mechanical Section of Power House. Apart from Mechanical Section
It was categorized in to the following section

1. Health, Safety and Environment,( HSE)

2. Operations
3. Maintenance
4. Case Study
5. Project Documentation

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Chapter 1

Health, Safety and Environment, (HSE)

1.1 Introduction:
This section contain the detailed knowledge of project’s terminology like Occupational Health and
Safety Management Plan (OHSMP), Contingency Plan, Environmental and Social Management
Plan (ESMP), MSA, Process Safety Management (PSM), Process Hazard Analysis (PHA) and
Process Safety Information (PSI) etc.

On my first day of internship I have to report at site office (Laraib Energy Limited). There are 5
more internee with me reported at site office, one internee was from Mechanical Department and
other 4 were from Electrical Department (Power& Electronics).

At the first, I had a unique experience because first day they did a safety induction session. I came
to know that they are committed to Occupational Health and safety and very keen about the safety
of not only their workers but also for the safety of visitors and internee. There slogan for safety is
“Your Safety is Dare to us.”

During this session Sir Sohail gave a presentation that how the Health and Safety Policy works and
how people play their role to ensure safety at LEL:

1.1.1. Health, Safety and Environment Policy

The HSE department of LEL has following Health, Safety and Environment Policy:

1. They are committed to protecting the health and safety of all working at or visiting their site
2. They plan, manage, conduct and supervise all their work with legislation and best practice
3. They make it sure that all workers are having a clear image of their roles and responsibilities.

1.1.2. HSE Vision & Management

Health, Safety and Environment policy and management is an essential and integral part of LEL.
Their goal is to protect their people, public, property and environment. They are making it possible
to run their plant without injuries or damage to equipment or environment. For this they are comply
with all applicable laws and relevant standards. For ensuring the best safety practices LEL also
evaluate the HSE of their equipment and services.

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LEL believes that HSE management has effective impacts on their business, that’s why they are
committed to the continuous improvement of HSE management practice. From top management to
entry level, everyone is responsible and accountable for HSE.

1.1.3 Management Safety Audit (MSA)

LEL is aiming to achieve “zero injuries and zero incident” at their work place. For this, they are
continuously improving their Safety management system by studying behavior and monitoring the
system. To ensure perfect safety on the site, they are emphasizing on major steps:

I. Participation and Communication

They want their workers, all staff and visitors take a keen interest in safety. For this purpose
different kind of Safety Management programs, workshops trainings and mock drills are being held,
so that every can get a sound knowledge of safety and have a strong sense of their roles and
responsibilities.

II. Accountability

To achieve the desired goal, accountability of everything is very important. To check the
implementation of HSE policies, LEL have a complete check and balance mechanism. To ensure
safety, LEL requires an attitude: “any injury and any incident would not be tolerated.” This is the
attitude which LEL expects from each and every one at their site.

III. Consistency

At LEL to avoid any unpleasant event, or any injury, safety practices are revised on each day and
on each shift, for the perfect safety record. Because LEL wants to achieve perfect safety record at
their initial start, which sometime and at some places is achieved year after year.

Different steps are taken for accident prevention:

a) Identification of Unsafe Act/Condition

b) Daily HSE inspection and monitoring
c) Tool Box Talk before the start of every activity
d) Weekly Meetings
e) Trainings/ Mock Drills
f) Sign Boards and Posters having information about risk/ hazards and precautions
g) Necessary Near Miss Investigation

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1.1.4 Safety Induction
LEL is also interested in Health and Safety of their visitors. To ensure their safety it is important
that visitors should aware site specific element and site hazards. This could be done by the safety
induction.

During induction Sir Sohail gave us information about the current site hazards and how to avoid
them.

1.1.5 Site Hazards

Some of the site hazards like Overhead High Voltages Lines, Confined spaces, Falling Object &
Overhead Cranes, Land Slopes, Fire Risks, High Noise Areas, Vehicle Movements and mosquitoes
etc. were explained by Sir Sohail.

 To avoid these hazards necessary information was provided for example, Evacuation layout,
different routes to leave site, Fire Alarm, Assembly Points, Fire Fighting Equipment,
restricted areas, requirement of special authorization for confined and restricted areas,
necessary PPE’s, First Aid Boxes etc.
 It was advised that in case of emergency inform control room as early as possible using
emergency phones and leave the site.
 Different signs, color coding and their meaning were also explained by inductor. For
example, Red Restricted/Prohibited Areas, Green Safe Area etc.
 It was advised to wear hard hat, toe shoes, safety goggles, ear plugs etc.

All these instructions were for visitor’s safety and were highly emphasized by safety inductor to
ensure our safety.

This induction was unique and was more pacifying that LEL is very concerned not only about the
safety of their workers but also for their visitors. This was very relaxing because after this induction
I was feeling very safe at site because I was aware of the hazards and how I can a keep myself safe
there.

1.2. Process Safety Management (PSM)

After the safety induction, second day was official start of the internship. At the start different documents
about the project were provided and it was expected from us to review them, so that we can get the necessary
information about the project.

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I chose the Process Safety Management, as I am doing my Final Year Project on Industrial Safety in
Pakistan. This documents can help me to have a better understanding of Safety Management System.

After reviewing this document I could develop the following understanding about PSM and PHA

A number of recent incidents in various parts of the world have highlighted the
increasing importance of effective process safety management (PSM). In a wide variety of industries,
processing highly hazardous chemicals can result in a number of dangers, including the unexpected
release of toxic, reactive, or flammable gasses and liquids. If proper safety precautions are not taken,
these risks can lead to disaster.

The potential for serious disaster in hazardous chemicals industries is present, so employers
working in these kind of industries should be aware that how dangerous materials can properly be
controlled. The Occupational Safety & Health Administration (OSHA) establishes several
standards to ensure that certain hazardous materials are transported, handled, and used safely to
avoid serious disaster like 1984 Bhopal’s Incident (India), 1989 Philips Petroleum Company
incident and 2006 Formosa Plastic’s Incident Texas etc.

Regardless of the industry, standards set by OSHA are critical to ensuring that workers are having
a safe work environment. Some important points of PSM include:

 Standards for basic operation and maintenance requirements, also appropriate action for
signs of leakage, corrosion, and other unsafe conditions/acts.
 Standards for correct operating, safety, and emergency procedures.
 Regulations for mixing, separating, and storing of hazardous materials and chemicals.
 Worker should be fully aware of and educated about reactiveness of chemicals also toxicity,
fire, or explosiveness of hazards chemicals.
 Employers and workers should have an emergency plan for any adverse incident or unusual
process condition.

 PSM is a proactive and systematic identification, evaluation, and mitigation or prevention

of chemical releases that could occur as a result of failures in process, procedures, or
equipment.

1.2.1 Process Hazard Analysis (PHA)

1.2.2 PHA allows the employer to:
 Determine locations of potential safety problems
 Identify corrective measures to improve safety
 Preplan emergency actions to be taken if safety controls fail
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1.2.3 PHA Requirements
 Use one or more established methodologies appropriate to the complexity of the process
 Performed by a team with expertise in engineering and process operations
 Includes personnel with experience and knowledge specific to the process being evaluated
and the hazard analysis methodology being used
1.2.4 PHA Addresses:
 The hazards of the process
 Identification of previous incidents with likely potential for catastrophic consequences
 Engineering and administrative controls applicable to the hazards and their
interrelationships
 Consequences of failure of engineering and administrative controls, especially those
affecting employees
 Facility siting; human factors
 The need to promptly resolve PHA findings and recommendations
1.2.5. My Understanding
These documents helped me to develop a strong understanding of Safety and gave me knowledge
about identification of risks/hazards associated with a working environment. What kind of
necessary standards should follow in operation and maintenance to avoid any kind of risks? How
to control, monitor and handle different situations associated with any risk. It gave me a systematic
approach to analyze, assess and proceed necessary steps and techniques to identify, evaluate and
mitigate risks, likelihood and consequences of failure/damage etc. I also learned that what steps
should take after happening of any unpleasant incident for example analysis of failure, its
consequences and impact, root causes of an incident and recommendation to avoid failure in future
etc.

These learned tools and terminology will help me in my future professional life.

1.3 Case Study

Fire at Formosa Plastic Corporation

After developing my understanding, for further clarity I studied a Process Hazard Analysis about
fire in Formosa Plastic Corporation Texas, USA.

This case study was about fire and series of explosion in Olefins production at Formosa Plastic
Corporation which lasted for 5 days. After studying this case study I gained knowledge how to do
PHA of an Incident. A PHA include:

 Detailed description of an Incident e.g. working principle, parameters, technical data etc.

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  Incident Analysis e.g. Incident Sequence, Emergency Response Team’s planning and its
response on emergency, Incident Consequences and Impact.
 Process Hazard Analysis e.g. Identify and evaluate the causes of failure, Enlist the expected
Causes, finding out the main cause etc.
 Study of previous incidents if any occurred in past years.
 The main cause and final findings.
 Lesson Gained from incident and future planning.
 Recommendations for future to avoid these kind of incident.

This case study strengthen my learning about Process Safety Management and Process Hazard
Analysis.

1.4 Occupational Health and safety Management Plan OHSMP

Occupational Health and safety Management Plan (OHSMP) provides the systematic approach to
address the health and safety issues of the project. The basic purpose of OHSMP:

 To identify and consolidate the obligation on project regarding to Health and Safety
Management during Operation Phase
 To develop a plan for the implementation, including Resources and Procedure
 Define the Environmental, Social, and Occupational Health Safety (ESOHS)
organizational structure, owners and O&M operator and also the monitoring mechanism.

ESOHS is applied during project construction, operation and maintenance phase. The main
objectives of Laraib ESOHS is to define environmental responsibilities of management by
establishing environmental organization, apply prudent practices to reduce and prevent pollution,
communicate the polices to Laraib employees, EPC contractor, O&M operators and Project Landers
and police is reviewed and updated by top management.

There are different laws in Pakistan regarding to health and safety: Factories act, Pakistan
environmental protection act, AJ&K Environmental Protection Agency (EPA), National
Environment Quality Standards (NEQS).

1.5 Contingency plans for operations

Contingency plan provides a designated mechanism and set of procedures for any emergency
situation at the project site. Contingency plan will be implemented when any adverse condition
occurs at site. The procedures to implement this plan includes:

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  Evacuate the personnel to the designated safe areas, e.g. Assembly Area and count head,
 Isolate the hazardous area,
 To develop a communication center and take necessary step to minimize the property
damages.

1.4.1 Project Threats

There are many threats regarding to this project which include Dam safety issues like old or new bong
escape gates, headrace channel dike failure, issues related to the hazardous materials, traffic threats, natural
threats like flood release from the Mangla spillway and earthquake and terrorism attack.

1.4.2 Emergency Levels

There are three levels of the emergency:

 Level 1: Incident may require normal operation to be temporarily suspended or shut down.
This emergency shall be dealt by the operator/Emergency Response Team (ERT).
 Level 2: Incident may results in serious injuries, significant fire or explosion. This type of
emergency shall be dealt by the operator in coordination with the company.
 Level 3: Incident may have resulted in a fatality, major explosion etc. Company
management shall be involved in this type of emergency and clear guidelines shall be
obtained.

1.4.3 Emergency Response Team

Emergency Response Team is divided into 4 categorize:

 Acid Protection Team

 Fire Fighting Team
 Security Team
 Media Team

These teams are fully trained in their respective fields and accountable to do their jobs at any
emergency situation. Contingency Plan is a key element of any company and it is the most important
document. It contains necessary plan and procedure’s detail for any emergency situation at plant.

1.6 Environmental and social Management Plan (EMP)

EMP indicates the measure and procedures proposed to be taken to manage the environmental
impacts for life of the project. The main objective of EMP is to facilitate the implementation of
mitigation measurements and also to monitor the effectiveness of all mitigation measures. Whereas
ESMP provide a delivery mechanism to address the adverse environmental impacts of a project

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during its operation to enhance project benefits. The main objective of ESMP is to identify and
consolidate the obligation on project, develop the plan for implementation and define the EHS
organizational structure, responsibilities of owners and O&M operator and monitoring mechanism.

Laraib EOHSP is applied during project construction, operation and maintenance phase. The main
objectives of Laraib EOHSP is to define environmental responsibilities of management by
establishing environmental organization, apply prudent practices to reduce and prevent pollution,
communicate the police to Laraib employees, EPC contractor, O&M operators and Project Landers
and police is reviewed and updated by top management.

There are many impacts during operations such as air deterioration, soil erosion, noise, hazardous
materials and waste management, human health safety etc. O&M operator takes measure to reduce
these impacts such as to reduce the noise, noise mufflers in the vehicles is used and worker will
wear the earplugs in the vicinity of the strong noise. There is the monitoring plan which
systematically observe the activities and ensure the activities with compliance with the ESMP. It
also record the environmental incidents and related actions and measures.

1.7 Initial Environment Examination

The NBE HPP was originally conceived as a 45 MW run-of-the-river HPP. It received NOC on 20
august 1996 from EPA of Pakistan and on 6 Jan 1997 from EPA of AJ&K based on ESSA report
submitted in April 1996. The EPA of AJ&K reconfirmed no objection on 23 august 2004 for the
generation capacity of 79 MW as it increases from 49 MW. The IEE of the 79 MW power plant
confirmed that the findings and conclusion of the pervious ESSA is still valid for the 79 MW
generation capacity.

Study of these documents reveals that this project is a clean contributions towards the local and
national economy. It has a huge effect on sustainable development of local community. Also the
main benefit of this project is that it is run off river technology without any dam, storage or resettlement of
human habitation. And also this project does not have any kind of adverse impact on Environment or social
life of community.

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Chapter 2

Operation
For better understanding it is important to understand the structure and layout of a system. To grow
a better understanding of plant layout and design study of different drawings of construction and
installation phase from As built manual is necessary. After reviewing As Built manual, I am able to
understand the layout and design of plant and installed 4 units. I also got understanding about the
installation sequence of 4 units and positioning of all installed parts of Kaplan Bulb Turbine e.g.
Turbine housing, runner, runner hub, turbine shaft, wicket gates, hydraulic links of wicket gate,
anchor ring, draft tube etc.

By reviewing these schematic drawings, I am able to read and understand Mechanical drawings.

After studying As built manual and, I focused on operation of turbine, studied following operations
of turbine:

Operation of Turbine
New Bong Escape HPP has 4 Bulb Turbines of capacity 21 MW. During my internship in Laraib
Energy Limited I observed and thoroughly studied about the bulb turbine. I understand the different
parts of the turbine, functioning of the turbine, operating limits of the turbine daily data recoded to
measure the operating limits of the turbine and also the different axillaries of the power plant. I also
learnt the function of the guide bearing, thrust and counter thrust bearings etc.

The following points gives my understanding about the parts, operations and axillaries of the
turbine:

2.1 General description of turbine

2.1.1 Runner:
The runner is equipped with 4 stainless steel blades. A servomotor is used to position the blades of
the runner. The runner hub is filled with oil which is used for lubrication and prevent leakage into
the hub.

2.1.2 Coupling Shaft:

A shaft is used to transmit the torque of the runner to the generator.

2.1.3 Draft Tube:

The draft tube reduces the speed of water through cross section extension. It is also used to protect
the civil structure of the power plant.

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2.1.4 Guide Apparatus:
Guide apparatus serves to regulate and turn off the operating water. In the NBE HPP Wicket gates
are connected with operating ring by 16 lever and links. Wicket gates are opened by a pressure oil
controlled servomotor and closed by a closing weight.

2.1.5 Shaft and Standstill sealing:

An axial shaft seal is arranged at the inner wicket gate barrel to prevent the penetration of the
process water into the turbine chamber. A lip seal is used for this purpose. The leakage water is
drained into a collecting tank from which it is discharge through drain pipe. 5 labyrinth seals are
also used to for the same purpose.

Standstill seal is built as an inflatable rubber hollow section. Standstill seal is also used as the
maintenance seal.

2.1.6 Turbine Guide Bearings:

A shell bearing is used to support the shaft of the turbine. The guide bearing is placed near the
runner. The bearing is lubricated and cooled by mean of a central hydraulic oil supply.

2.1.7 Axial thrust and counter thrust bearings:

On both side of the generator thrust and counter thrust bearings are installed to take up the radial
and axial forces.

2.1.8 Brakes:
Turbine is equipped with a compressed air controlled brake for sudden shutdown of the turbine.

2.2 Operating limits of the turbine:

During the visit to the plant it is observed that operating range of the turbine depends upon the net
head available, power output, discharge through the tailrace and the guide vane opening limits. All
these values are calculated from the turbine hill chart.

To achieved the above mentioned parameter some checks are performed on daily bases like
inspection of the components and monitoring instruments, Record of the data etc.

2.3 Mechanical Axillaries

There are many axillaries that are used in the plant that I observed and studied during my visit to
the power plant.

2.3.1 Drainage Pump and Dewatering Pump

Drainage pump and dewatering pump is present at 227 Elevation. Drainage pump is used to drain
the water from the drainage pit. The seepage water of the power plant is collected in the drainage
pit that is pumped into the tail race canal by the drainage pump. Two drainage pups are used: one
operating and one stand by.
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Dewatering pump is used to grain the water from the turbine for the maintenance purpose. Stop logs
of intake and draft tube is lowered and water is drained from the turbine.

In case of the failure of the drainage pump dewatering pump is used as a drainage pump.
2.3.2 Water Treatment Plant
Water treatment plant is located at 245 elevation. Water treatment plant is used to treat the water
coming from the well. Water is pumped from the water well using 2 centrifugal pumps (one is
operating, one is stand by). Water from the storage tank is transferred to filters using 4 motor
operated crossed valve. Water is treated by passing it through different filters like sand filter, carbon
filter, cartridge and UV filter. Then 1 drop of chlorine is added to 1000L water. This water is used
for cooling of different parts (e.g. shaft seals), flushing and bathing purposes.

2.3.3 Overhead Cranes

There are 2 overhead cranes in machine hall which are used to transfer heavy load from off-bay to
machine and machine hall to off-bay. One crane has 30 Ton lifting capacity and 5 Ton auxiliary
and other has 80 Ton lifting capacity and 5 Ton auxiliary capacity.

2.3.4 Intake and Draft Tube Stop Log Gantry Cranes

Two gantry cranes are provided, one is at inlet side and other is at draft tube side. Gantry crane at
intake side has a 110 Ton lifting capacity and used to lower the stop logs at intake side for
dewatering the unit for maintenance. Similarly another gantry crane is provided at draft tube side
to lower the stop logs at draft tube side. It has a lifting capacity of 70 ton.

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Chapter 4

Governor System
During the visit to the power plant the governing system is closely observed and studied.
Understanding is developed about the working principal and maintenance of the governing system
of a hydropower plant. There are two types of the governors that are used in the NBE HPP. These
are the hydraulic governor and the digital governor. Hydraulic governor system is mainly consists
of hydraulic control valves. While digital governor system is mainly consists of a standard PID
controller. I also understand the function of Proportional integral derivative controller which
measure the difference between the set point value and actual value to the turbine and take measures
to reduce the difference.

Following points explains my understanding about the governing system of the NBE HPP:

4.1 Digital Governor System

There are three types of CPUs that are installed in the digital governor.

 2 CPUs are used for the logic control and mathematic calculations
 1 monitoring CPU will check the state of both CPUs
Digital governor is equipped with two types of switches:

 Push button for emergency shut down

 Three switches: local, remote and revision
There are four display which shows:

 Wicket gate opening

 Runner blade opening
 Unit speed
 Active power of the unit

4.1.1 Functions of Digital Governor

Following are the main functions that are performed by the digital governor:

 Positioning of wicket gate

 Positioning or runner
 WG and RU opening control for grid operation
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  Load rejection speed control
 System communication with other system

4.2 Hydraulic governor

The hydraulic governor mainly consists of a main proportional valve, cartridge valve, pilot valve
solenoid valve and emergency shut down valve. The pilot valve receive the electrical signal from
the digital governor and convert it into the oil control command which further control the WG and
RU opening and closing.
Hydraulic governor has two pipe lines for the RU servomotors from them oil either goes to the
servomotor opening and closing side and one pipe line for the WG servomotor.

4.3 oil pressure system

A piston type accumulator is used to increase the pressure of the oil. Nitrogen gas bottles are used
to increase the total volume. The rated pressure for the oil pressure system is 120 bar. An oil cooling
system is also provided.

There are also two pumps are present on the sump tank which are operated when the system pressure
is less than 107 bar and stops when the pressure reaches at 120 bar.

4.4 Leakage oil tank

A leakage oil tank is present at el. 227 which collect all the leakage oil and then send it back to the
sump tank through pump.

4.5 Runner hub oil tank

Runner hub oil tank supply the oil to the runner hub through gravity. Runner hub tank is present at
245 elevation.

After reviewing the documents about the governor and visit to the power house a strong
understanding is built about the governing system of the turbine. I understand the operation of the

15
Chapter 5

Maintenance

Importance of maintenance can’t be overemphasized. Maintenance plays an important rule for

smooth processing and to maintain the life time of equipment. Maintenance is a key factor to
maintain a process, a machine or a system.

Maintenance and inspection plan is prepared by the TNB Remaco Pakistan (private) Limited, the
O&M operator of the NBE HPP. Than this plan is forwarded to the NPCC according to which the
turbine units are shut down for the maintenance.

During my internship I understand the procedures that has been carried out for the maintenance of
all the units and auxiliaries of plant. Permit to Work (PTW) is issued by the authorized person.
After getting PTW, Tool Box Talk (TBT) is carried out and the roles and responsibilities of each
maintenance individual is defined according to which maintenance is performed. After PTW and
TBT maintenance of the unit started and carried out according to parameters defined in the check
sheets. After the maintenance these check sheets are reviewed by the authorized person according
to his experience, previous maintenance data etc. If any abnormality observed than the corrective
maintenance is carried out of that part.

The maintenance of the plant includes:

1. Monthly maintenance
2. Six monthly maintenance
3. Annually maintenance

5.1 Maintenance
Followings are the types of the maintenance:

Preventive maintenance:

Preventive maintenance is the pre-planned maintenance that is regularly performed on an equipment

to lessen the chance of failure.

Corrective maintenance:

It is unplanned maintenance which is performed on a failed system so that it resorted to its

operational condition.

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Predictive maintenance:

Predictive maintenance helps to determine the condition of in-service equipment in order to predict
when maintenance should be performed. This approach promises cost savings over routine or time-
based preventive maintenance

5.2 Monthly Maintenance

Monthly maintenance is actually base on the visual inspection of the unit. It doesn’t includes the
detailed inspection of the plant components. In the monthly maintenance usually preventive
maintenance has been done.

In the monthly maintenance the unit is shut down for the 3 hours as by the plan approved by the
NPCC. Monthly maintenance has been done on 17-21 equipment’s. Monthly inspection of the unit
is carried according to the check sheets. These are:

 Firefighting system monthly maintenance

 Diesel generator set (750KVA) monthly maintenance
 Air compressor No.1 monthly maintenance
 Air compressor No.2 monthly maintenance
 Station passenger lift monthly maintenance
 Station cargo lift monthly maintenance
 Station overhead crane (85 tons) monthly maintenance
 Station overhead crane (30 tons) monthly maintenance
 Intake crane monthly maintenance
 Intake stop logs monthly maintenance
 Draft tube crane monthly maintenance
 Draft tube logs monthly maintenance
 Air handling unit monthly maintenance
 Radial gate monthly maintenance
 Water treatment plant monthly maintenance
 Waste water system monthly maintenance
 NBE diesel generator set (80 KVA) monthly maintenance
 Drainage pump monthly maintenance
 Petrol generator at siren point monthly maintenance

17
5.3 Six monthly maintenance
6 monthly maintenance has been done only of 7 axillaries. These includes the detailed maintenance
of these axillaries. These axillaries are:

 Air compressor No.1 six monthly maintenance

 Air compressor No.2 six monthly maintenance
 Station overhead crane (85 tons) six monthly maintenance
 Station overhead crane (30 tons) six monthly maintenance
 Intake crane six monthly maintenance
 Draft tube crane six monthly maintenance

5.4 Annually maintenance

Annual maintenance include the detailed maintenance of all the plant units. The duration for the
annual maintenance is 3 months in which each unit is shut down for the 18 day for the maintenance.
Intake and draft tube stop logs are placed at inlet and outlet of the turbine unit and turbine is
completely dewatered by using dewatering pumps. It includes:

 Runner annual maintenance

 Governor oil system annual maintenance
 Guide vanes annual maintenance
 Cooling water annual maintenance
 Firefighting system annual maintenance
 Diesel generator set (750KVA) annual maintenance
 Air compressor No.1 annual maintenance
 Air compressor No.2 annual maintenance
 Station passenger lift annual maintenance
 Station cargo lift annual maintenance
 Station overhead crane (85 tons) annual maintenance
 Station overhead crane (30 tons) annual maintenance
 Intake crane annual maintenance
 Intake stop logs annual maintenance
 Draft tube crane annual maintenance
 Draft tube logs annual maintenance
 Air handling unit annual maintenance
 Radial gate annual maintenance

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  Turbine shaft seal annual maintenance
 HP oil injection pump and bearing oil plant annual maintenance
 Generator combine bearing annual maintenance
 Generator brake system annual maintenance
 Lube and hydraulic oil purification plant annual maintenance
 Dewatering and drainage system annual maintenance
 Draft tube annual maintenance
 Oil vapor exhaust fan and filtering system annual maintenance
 Oil purification annual maintenance
 Drainage pump annual maintenance
 Dewatering pump annual maintenance
 Drainage pit annual maintenance
 Water treatment plant annual maintenance
 Waste water system annual maintenance
 NBE diesel generator set (80 KVA) annual maintenance

5.5 Review of Monthly inspection report

Monthly inspection is carried out for three hours every month of each unit. Monthly inspection
report is reviewed and understanding is developed about the monthly inspection report and review
of the inspection report.

During my internship I reviewed the monthly inspection report of the month august.

5.6 Review of Annual maintenance report

Annual maintenance is used carried out according to the schedule approved by the NPCC. First of
all intake and draft tube stop logs are lowered and turbine is dewatered using dewatering pump.
Inspection and maintenance is carried out according to the check sheet prepared by the operator
according to experience, OEM instruction and O&M manual. Than these check sheets are reviewed
by comparing them with the previous maintenance data, O&M manual and parameters given by the
OEM.

During my internship I studied the annual maintenance report of the year 2014-2015 and understand
different maintenance work performed during the annual maintenance. I got understanding of the
process and procedure which is followed to carry out monthly and annually maintenance. Review
of monthly check sheets gave information how prevent maintenance is planned, what factors and
steps are involved for planning PM and how problems identified.

19
5.7 Fish Bone Analysis
During my internship I also leans the different tools that are used for the analysis of any failure.
Fish bone analysis is one of them. In the fish bone analysis we defined the different causes which
can take part in the failure of any equipment. We define different causes and sub causes like:

 Man
 Method
 Environment
 Material
 Design
 Machine
After defining the necessary causes we discuss each cause and eliminate the cause if not
participate in the failure of the part.

This approach help us to find the root cause of any failure and steps to find out the root cause.

20
Chapter 6

Case study

6.1 Problem statement

There are four units are installed in the NBE HPP. In august a sever leakage was observed from
shaft seal in 3 units. It was observed that unit 1 has leakage rate of 1000 l/ min. Unit 2 has leakage
rate of 735.36 l/min and from unit 3 it is observed 666 l/min.

The expected range of the leakage rate through shaft seal is 0-15 l/min. And the maximum range
is 36 l/min. this leakage was quit threatening.

Procedure
6.2.1 Shaft seal parameters
Type Axial lip type

Material Rubber counter face with ceramic element

Speed of rotating part 100 RPM

Flushing Water flow rate 18 l/min

Flushing water pressure 2 bar

Expected leakage water 0-15 l/min

Max. Expected leakage water 36 l/min

Cooling of Shaft Seal Flush water coming from water treatment plant

6.2.2 Shaft seal assembly

Shaft seal consists of following parts:

1. Lip Seal
2. Labyrinth Seal
3. Ceramic Seal

6.2.3 Working principal

The main shaft seal in a hydro turbine is a key component of the turbine system. The axial shaft
seal is arranged at the inner wicket gate barrel to prevent the process water from penetrating into
the turbine chamber. The main shaft seal function is not to eliminate the leakage water but more
21
to control the leakage water. The lip sealing is fastened to the inner wicket gate barrel; the silicon
carbide running surface is rotating with the turbine shaft.

6.3 Incident Description

At NBE HPP 4 units are installed. Leakage was observed in 3 units in the monthly maintenance of
August. In august a sever leakage was observed from shaft seal in 3 units. It was observed that
unit 1 has leakage rate of 1000 l/ min. Unit 2 has leakage rate of 735.36 l/min and from unit 3 it is
observed 666 l/min.

Joint inspection reveals that the following parts of the seal were badly damaged:

 O-ring
 Lip Seal
 Labyrinth Seal
 Ceramic Seal

6.4 Inspection of Incident

To inspect this incident the following producer was adopted:
1. Annual Maintenance Report
After reviewing annual maintenance report of operation of 2014-15, no abnormality was
observed. Only Cleaning and flushing of shaft seal was carried out.

This reveals that failure of shaft seal was all sudden.

2. Monthly Maintenance
Report of the monthly maintenance reveal that the following parts of the seal were badly damaged:

 O-ring
 Lip Seal
 Labyrinth Seal
 Ceramic Seal

6.5FISH BONE ANALYSIS

In order to identify the main cause we use fish bone analysis. All the possible causes were listed.
Each listed cause was studied in detail and found the most effecting cause.

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From fish bone analysis contributed and un-contributed causes are:

Un-contributed Causes Contributed Causes

1.Man 1.Material
Unskilled Person Thermal Expansion
Lack of Supervision
Unauthorized person
2.Machine
Operation
Maintenance
3.Method
Improper Functioning
4.Environment
Fouling
5.Design
Improper Design
Surface Finish

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6.5 Causes of Shaft Seal Damage
Shaft Seal should last until the ceramic/metal face wears away. The expected life of a shaft seal is
5 to 10 years. Two key challenges for the design are that the seal must provide the high wear
resistance against abrasive within the water and be able to operate at high rubbing velocities with
low leakage.

The main reasons of failure of shafts seals could be:

 Size
 Thermal Expansion
 Surface Finish of Seal Ring
 Design
Size:

Hydro-electric equipment is typically large. The machining tolerance for the casing into which the
polymer face ring gets installed may also be subsequently large, both on dimension and surface
finish. This variance adds unevenness to the installed sealing surface. The polymer sealing ring is
commonly fastened into its casing with bolts. This results in localized deformation in the vicinity
of the fasteners with consequent distortion of the sealing surface. Large seal rings are manufactured
from segments and any mismatch at a segment joints will result in increased leakage.

Surface finish:

The characteristics of the material mean that a sealing face of elastic polymer cannot be machined
or lapped to a very fine level of finish and flatness. Precise machining of such material is expensive
and since the material may deform afterwards would be somewhat pointless. Gaps between the
mating surfaces can also cause leakage.

Thermal expansion

Polymer materials generally have higher coefficients of thermal expansion than metals. Differential
expansion or contraction therefore occurs between the various parts when operating temperatures
change. These differential dimension changes can cause small localized or global deformations of
the polymer.

Many problems associated with seal failure such as, dry running, loss of flush and accidental
rubbing of metal to metal cause seal destruction because of the heat which may be generated.

24
Design:

Another failure of a shaft seal can be design of shaft seal. Sometime selection of incorrect seal or
badly designed seal. Also incorrect installation of seal can also cause leakage

6.6 Root Cause Analysis

In order to find out the root cause of the failure we enlist different causes of failure. After studying
and discussing enlisted causes it was found that many of enlisted causes has no contribution towards
the failure of shaft seal.

The cause which we identify is “Thermal Expansion”. Many problems associated with seal failure
such are improper cooling of shaft seal, dry running, and loss of flush and accidental rubbing of
metal to metal cause seal destruction because of the heat which may be generated.

After reviewing of annual maintenance report and pictures of damaged shaft seal it was found shaft
seal was not cooled properly which generated excessive heat. Heat causes several problems that are
not always obvious. When the seal contains a sliding elastomer in the face and the face is running
hot, the elastomer will be hardened over a period of time. The hardening then reaches the point
where leakage starts. The underlying reason for the failure was the heat.

The blocks of ceramic seal was broken by excessive heat and sharp edges of ceramic formed. These
sharp edges started to damage the rubber lip seal.

According to our findings excessive heat generated due to loss of flush water coming from the water
treatment plant. This flushing water is used for cooling of shat seal.

6.7 Recommendations:
In order to avoid this kind of failure in future we recommend that:

1. In order to avoid the failure cause by the loss of flush, dry running ceramic material (Diamond
Coated Silicon Carbide) should be used. Diamond Coated Silicon Carbide has High Thermal
Conductivity and High Dry Run Tolerance.

2. A temperature sensor should be installed in shaft seal assembly to monitor the temperature.

25
 Conclusion
The past 6 weeks of my internship have been very instructive for me. LEL offered me opportunities
to learn and develop myself in many areas. I gained a lot of experience especially in HSE field. I
worked in different areas and learned about diverse effects. This gave me a chance to find out an
area in which I want to start my professional career after my education. The area I found more
interesting is Health, Safety and Environment. I had to study a lot of documents about Health, Safety
and Environment and studied different case studies. After studying these documents I came to
realize this field is very challenging and growing. It has a lot of potential for improvement which
required a lot of skills. It is the best field where one can use.

I also got clear understanding of Operation and Maintenance of plant. During internship I gained
knowledge about operational parameters and planning and procedure of maintenance.

It was a unique experience to be in Laraib Energy Limited and to study Organizational structure,
behavior and rules and responsibilities. It also helped me to understand layout and working
mechanism of a power plant and helped me to strengthen my knowledge related to Mechanical
field.

This internship was very beneficial for me and I am grateful to LEL that I got experience and learned
my useful stuffs.

Recommendations
LEL is a great learning opportunity for students of Mirpur University of Science & Technology
(MUST). It was the first time that any internship opportunity was provided to MUST students. I
would recommend LEL to continue this program and keep hiring internees from MUST. I will help
students of MUST to develop, improve and polish their skills.

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Signature Sheet

1-Initial Review

Final Review

27