Scope of work during Hydro Power Project health checkup & Site

assessment :

Following are the areas and work scope to quantify the errors, differences,
variations etc. w.r.t. the pre commissioning machinries parameters / at the
time of COD and doing site adjustments accordingly and advising
suggestions for recifications of bigger faults (If any)

1. Mechanical assessment

1. Operational data study to analyze the machine behaviour.

2. Unit trip and alarm study to check & identify the abnormal areas of improvement.
3. Dismantling the turbine for internal inspection.
4. Runner inspection without removal for healthiness
5. Runner coupling healthiness and tightening check with proper torque.
6. All type of sealing item‘s condition checks (Sevomotor, Nozzal seat, other leakages)
7. Visual & instrumentational checks for Internal hydraulic profile to ensure the
further operations.
8. T-G Shaft condition checks.
9. Turbine and Generator, Foundation and Foundation bolt checks
10. Visual & instrumentational checks of MIV & Bypass valves
11. All type of sealing checks for MIV and bypass valves
12. Healthiness checks of all instruments in Turbine and Valves. (Pr. Gauges, RTD’s,
Position trnasducers, temperature gaauges, MIV limit switch etc)
13. Generator End shield cover dismantling to check internal condition.
14. Dismantling of Generator Bearing top cover for internal inspection.
15. Stator winding checks physically and further routine test
16. Air Cooling system checks in Generator stator to ensure the good performance and
efficiency.
17. Rotor condition checks and tightness checks
18. Generator Static or brush-less exciter checks
19. T-G alignment checks and verify for further assessment to avoid abnormal
behaviour of units during operation.
20. Vibration Checks in Turbine & Generator bearings
21. Noise level test
22. Generator and bearing instruments test and verify for correctness
23. All Oil sample tests to check the healthiness.
24. Visual & functional checks on all Turbine and Generator Auxiliary system such as
OPU, Cooling water, Generator bearing Lub Oil system, D&D and air compressor
system to insure the functionality of individual systems.
25. Piping, pumps, motor and filters checks.
26. Spares inventory checks and recommendation to avoid long time breakdown.

2. Electrical & Automation assessment:

1. Visual checks of cables & Terminations

 2. Visual and functional checks of all protection panels
3. Ensure the operational functionality of all protection relays.
4. Trip Matrix test and ensure the protection of unit in time.
5. Unit operational sequence test to check the interruption if any.
6. Automation parameters check during standstill and ruining condition.
7. Turbine Governor test and test the load rejection to ensure the running safety limits.
8. AVR functional checks for various control.
9. Spares inventory checks and recommendation to avoid long time breakdown.
10. Switchyard equipment healthiness checks
11. Power Transformer Routine test to check the healthiness
12. Low voltage system checks to ensure the proper operation and its interlocks
13. DG operational checks
14. DC system checks

A) Generator:
1) Visual checks
2) Bearing dismantling to be done for inside inspection to check the PADs condition
3) Oil Sampling check
4) Healthiness of RTD;s
5) IR & PI test on Stator
6) IR & PI test on Rotor
7) Generator End shield cover dismantling to check the internal inspection
8) Generator Cooling Fan condition visual checks
9) Rotor inspection
10) Vibration and noise level test during no-load operation
11) Vibration and noise level test during part load 25%, 50%, 75%, 100% & 110% operation
12) Shaft leakage voltage and current measurement test
13) Over speed test on generator during Load rejection at various load.
14) Stator cooling test to ensure that the natural air cooling system is working satisfactory
in stator and rotor.
15) OCC test to check the excitation functionality and Generator behavior during no load
operation.
16) Actual fault simulation test on generator such as 64, 87, 50/51, 59, 27, 24, 81 etc. to
ensure the system tripping.

B) Transformer: (Aux & Main )

1) Visual checks to ensure any external damage and any abnormal oil leakages.
2) Oil sample testing
3) All instruments healthiness checks and simulation with protection system to test the fault
activation during simulation.
4) IR & PI test (If required)
5) Ratio test
6) Analysis the frequent faults in transformer captured during operation if any.

the above test shall be covered during health assessment in transformer and Generator to
prevent or identify the abnormality on existing system.

Civil assessment:
Physical and visual checks of civil structure
Visual and operational checks of all the Gates and flushing valves.

Penstock assessment:
Welding joints checks
Dismantling joints checks
Manholes condition checks
Visual checks/ Thickness of liner checking
Foundation checks