OPERATION AND MAINTENANCE MANUAL

2016

DAGACHHU HYDROPOWER PLANT

FORWARD
KEYNOTE FROM CHIEF EXECUTIVE OFFICER
 ACRONYMS

ABT : Availality Based Tarriff

ALSPA : Alstom Plant Automation

AVR : Automatic Voltage Regulator

ASTM : American Society for Testing and Materials

CB : Circuit Breaker

CR : Control Room

CSA : Canadian Standards Association

CVS : Central View Station

DCS : Distributed Control System

DE : Drive End

DHPC : Dagachhu Hydro Power Corporation Limited

ACRONYMS

DIN : Deutsches Institut fuer Normung

DPT : Dye Penetrate Test

DSM : Deviation Settlement Mechanism

EN : European Standard (Europa-Norm)

EL : Elevation

FRL : Full Reservoir Level

GIS : Gas Insulated Switchgear

GMT : Greenwich Mean Time

GPS : Global Positioning System

GSU : Generator Step-Up

HVAC : Heating, Ventilation and Air Conditioning

IEC : International Electrotechnical Commission

I/O : Input/Output
 IP : Internet Protocal

kVA : Kilo Volt Ampere

LED : Light Emitting Diode

MASL : Meter Above Sea Level

MFC : Multi-Function Controller

MVA : Mega Volt Ampere

MVar : Mega Volt Ampere Reactive

NDE : Non-Drive End

NLDC : National Load Dispatch Center

PTZ : Pan Tilt Zoom

RAID : Redundancy Array Independent Disk

ACRONYMS

RPM : Rotation Per Minute

SCADA : Supervisory Control and Data Aquisition

SCM : Screen Cleaning Machine

SF6 : Sulphur Hexafluoride

TRCM : Trash Rack Cleaning Machine

UL : Underwriters Laboratory

VCB : Vacuum Circuit Breaker

VDE : Vereinigung Deutscher Elektrizitätswerke

VRLA : Valve Regulated Lead Acid

 TABLE OF CONTENT

Table of Contents
FORWARD............................................................................................................................................II
KEYNOTE FROM CHIEF EXECUTIVE OFFICER.....................................................................................III
ACRONYMS.........................................................................................................................................IV
SECTION A: OPERATION MANUAL.......................................................................................................1
CHAPTER 1: SALIENT FEATURES OF THE PLANT.................................................................................2
1.1 LOCATION........................................................................................................................................2
1.2 HYDROLOGY....................................................................................................................................2
1.3 DIVERSION WEIR.............................................................................................................................3
1.4 INTAKE...........................................................................................................................................3
1.5 FISH LADDER...................................................................................................................................4
1.6 DESILTING CHAMBER.......................................................................................................................4
1.6.1 Desilter Inlet Gate...................................................................................................................4
1.6.2 Flushing Gate.........................................................................................................................4
1.6.3 Desilter Outlet Gate...............................................................................................................4
1.7 WATER CONDUCTING SYSTEM............................................................................................................5
1.7.1 Connection intake-Desilter.....................................................................................................5
1.7.2 Headrace Channel...................................................................................................................5
1.7.3 Headrace Tunnel....................................................................................................................5
1.7.4 Surge Shaft............................................................................................................................5
1.7.5 Pressure Shaft........................................................................................................................5
1.7.6 Pressure Tunnel.....................................................................................................................5
1.8 POWERHOUSE COMPLEX..................................................................................................................6
1.8.1 Power house cavern...............................................................................................................6
1.8.2 Transformer cavern...............................................................................................................6
1.8.3 Access Tunnel........................................................................................................................6
1.8.4 Emergency Exit Tunnel..........................................................................................................6
1.8.5 Tailrace Tunnel......................................................................................................................6
1.8.6 Bus duct.................................................................................................................................6
1.8.7 Main Equipment.....................................................................................................................7
1.9 TRANSMISSION LINE........................................................................................................................9
1.10 COMMISSIONING DATES..................................................................................................................9
1.11 ENERGY GENERATION....................................................................................................................10
CHAPTER 2: GENERATOR....................................................................................................................11
2.1 INTRODUCTION...............................................................................................................................13
2.2 START-UP CHECKS AT STANDSTILL....................................................................................................13
2.3 CHECKS DURING OPERATION...........................................................................................................14
2.4 SHUTDOWN...................................................................................................................................15
2.4.1 Normal shutdown.................................................................................................................15
2.4.2 Shutdown by mechanical fault (QSD 1)................................................................................15
2.4.3 Shutdown by electrical fault (QSD 2)...................................................................................16
 2.5 BRAKE OPERATION.........................................................................................................................16
2.6 PRESERVATION FOR LONGER STANDSTILLS........................................................................................17
2.7 GENERATOR SETTINGS....................................................................................................................18
2.8 OPERATIONAL FAULT.....................................................................................................................18
CHAPTER 3: STATIC EXCITATION SYSTEM........................................................................................20
3.1 INTRODUCTION..............................................................................................................................20
3.2 STATIC EXCITATION SYSTEM TECHNICAL DATA...................................................................................22
3.3 EQUIPMENT DESCRIPTION...............................................................................................................22
3.3.1 Industrial PC with touch screen............................................................................................22
3.3.2 Key switch (Pad) S111 Layout & LED description...................................................................23
3.3.3 Field Circuit Breaker.............................................................................................................24
3.3.4 AC Power Circuit & Thyristor Bridges..................................................................................24
3.3.5 Over Voltage Protection......................................................................................................25
3.3.6 Voltage Supply.....................................................................................................................25
3.3.7 Excitation Transformer........................................................................................................25
3.3.8 Excitation Transformer overheating protection.................................................................25
3.3.9 Excitation Transformer Overcurrent Protection.................................................................26
3.3.10 Fans....................................................................................................................................26
3.3.11 Dynamic Braking (Electrical)...............................................................................................26
3.3.11.1 Technical data of dynamic braking.............................................................................27
3.4 OPERATION..................................................................................................................................27
3.4.1 Control.................................................................................................................................27
3.4.1.1 Conditions for switching excitation equipment “ON”:...............................................27
3.4.1.2 Conditions for switching excitation “OFF”:................................................................28
3.4.1.3 Synchronization release..............................................................................................28
3.4.2 Operation of the equipment from a control room (REMOTE).............................................28
3.4.3 Using keypad S111................................................................................................................29
3.4.3.1 Key layout....................................................................................................................29
3.4.3.2 LED layout....................................................................................................................29
3.4.4 Manual Mode......................................................................................................................30
CHAPTER 4: TURBINE & AUXILIARIES................................................................................................31
4.1 INTRODUCTION..............................................................................................................................31
4.2 TECHNICAL DATA............................................................................................................................31
4.3 DESCRIPTION................................................................................................................................32
4.3.1 Turbine Assembly.................................................................................................................32
4.3.1.1 Main Components of Turbine......................................................................................32
4.3.2 Pelton Runner......................................................................................................................32
4.3.3 Turbine Shaft.......................................................................................................................33
4.3.4 Overspeed Pendulum..........................................................................................................33
4.3.5 Speed sensing device...........................................................................................................34
4.3.6 Turbine Guide Bearing.........................................................................................................35
4.3.7 Distributor...........................................................................................................................36
4.3.8 Turbine Housing and water passage shield.........................................................................36
4.3.9 Nozzle and Deflector...........................................................................................................36
4.3.10 Brakejet and Piping............................................................................................................38
4.4 OPERATION..................................................................................................................................38
 4.4.1 Checks before start-up.........................................................................................................38
4.4.2 Start-up of the turbine........................................................................................................38
4.4.3 Checks during operation.....................................................................................................39
4.4.4 Shutdown of the turbine....................................................................................................39
4.4.5 Filling the turbine................................................................................................................39
4.4.6 Draining the turbine............................................................................................................39
4.4.7 Limits of operation..............................................................................................................39
CHAPTER 5: MAIN INLET VALVE & AUXILIARIES...............................................................................41
5.1 INTRODUCTION..............................................................................................................................41
5.2 MAIN COMPONENTS OF MAIN INLET VALVE......................................................................................41
5.3 OPERATION..................................................................................................................................42
5.3.1 Filling the spherical valve and bypass line............................................................................42
5.3.2 Filling of Distributor.............................................................................................................43
5.3.3 Manual closing of the spherical valve..................................................................................43
5.3.4 Decommissioning for maintenance / revision......................................................................44
CHAPTER 6: GOVERNING SYSTEM.....................................................................................................45
6.1 HYDRAULIC GOVERNOR..................................................................................................................45
6.1.2 Technical Data:.....................................................................................................................45
6.1.3 Hydraulic Governor Components.........................................................................................46
6.1.4 Operation............................................................................................................................46
6.1.4.1 Checks to be made before the Start-up......................................................................46
6.1.4.2 Start-up of the Turbine................................................................................................47
6.1.4.3 Shutdown of the Turbine............................................................................................47
6.2 DIGITAL GOVERNOR......................................................................................................................48
6.2.1 Operation (Functionality of Touch Panel)............................................................................48
6.2.1.1 Display Overview.........................................................................................................48
6.2.1.2 Display Controller Overview........................................................................................50
6.2.1.3 Display Level Controller...............................................................................................51
6.2.1.4 Display Flow Controller...............................................................................................52
6.2.1.5 Display Power Controller.............................................................................................53
6.2.1.6 Display Speed Controller.............................................................................................54
6.2.1.7 Display Opening Limiter..............................................................................................55
6.2.1.8 Display Positioning Circuit Deflector..........................................................................56
6.2.1.9 Display Positioning Circuit Needle..............................................................................57
6.2.1.10 Display Needle Selection...........................................................................................58
6.2.1.11 Display Feedback Calibration.....................................................................................59
6.2.1.12 Display Special Functions...........................................................................................60
6.2.1.13 Display Trend Diagram................................................................................................61
6.2.1.14 Display System Control..............................................................................................62
6.2.1.15 Display Alarm Signal List............................................................................................63
6.2.1.16 Display Chronological Event List...............................................................................64
CHAPTER 7: GENERATOR STEP-UP TRANSFORMERS.......................................................................65
7.1 INTRODUCTION..............................................................................................................................65
7.2 TECHNICAL DATA...........................................................................................................................65
7.3 OPERATION..................................................................................................................................67
 7.4 ROUTINE/PERIODIC INSPECTION SCHEDULE FOR TRANSFORMER:..........................................................67
CHAPTER 8: STATION AUXILIARY TRANSFORMERS........................................................................69
8.1 STATION AUXILIARY TRANSFORMER, 5MVA, 220 KV/33KV...............................................................69
8.1.1 Introduction.........................................................................................................................69
8.1.2 Transformer Rating:............................................................................................................69
8.1.3 Operation............................................................................................................................70
8.1.4 Routine/periodic inspection schedule for Transformer:.......................................................71
CHAPTER 9: 220KV GAS INSULATED SWITCHGEAR..........................................................................72
9.1 INTRODUCTION..............................................................................................................................72
9.2 TECHNICAL DATA OF 220 KV GAS INSULATED SWITCHGEAR................................................................72
9.3 OPERATION..................................................................................................................................73
9.3.1 SF6 Circuit Breaker...............................................................................................................73
9.3.2 Disconnecting Switch...........................................................................................................73
9.3.3 Maintenance Earth Switch...................................................................................................74
9.3.4 High-Speed Earth Switch (HSES).........................................................................................74
9.3.5 Daily Checklist for Operation:..............................................................................................74
CHAPTER 10: 220 KV POT HEAD YARD...............................................................................................76
10.1 INTRODUCTION............................................................................................................................76
10.2 ISOLATOR WITH EARTH SWITCHES..................................................................................................76
10.2.1 Technical Details of Isolator................................................................................................77
10.3 LIGHTNING ARRESTER...................................................................................................................77
10.3.1 Technical Details of Lightning Arrester...............................................................................77
10.4 OPERATION................................................................................................................................78
CHAPTER 11: AUXILIARY SUPPLY SYSTEM........................................................................................79
11.1 INTRODUCTION.............................................................................................................................79
11.2 OPERATION.................................................................................................................................79
11.2.1 Auxiliary Supply from External Source (220kV)...................................................................79
11.2.1.1 Charging of 220kV Bus bar at GIS................................................................................79
11.2.1.2 Charging of 33kV Power Cavern (20BBA00GH001)...................................................80
11.2.1.3 Charging of Power Cavern Main Distribution Board (20BFA00GH001)....................80
11.2.1.4 Charging of 33kV Control Building Main Distribution Board (25BBA00GH001).......80
11.2.1.5 Charging of 400V Control Building Main Distribution Board.....................................81
11.2.1.6 Charging of 400V Diversion Weir Main Distribution Board.......................................81
11.2.1.7 Charging of 400V Desilter Main Distribution Board...................................................82
11.2.1.8 Charging of 400V Surge Tank Main Distribution Board.............................................82
11.2.2 Auxiliary Supply from Generating Units..............................................................................82
11.2.3 Auxiliary Supply from Emergency Diesel Generators/ Black Start.......................................82
11.2.3.1 Extension of Supply from 400kVA DG Set.................................................................83
11.2.3.2 Extension of 160kVA DG set.......................................................................................84
11.2.3.3 Supply changeover.....................................................................................................84
CHAPTER 12: DIVERSION WEIR AND DESILTER EQUIPMENT...........................................................86
12.1 DIVERSION WEIR INTAKE GATE......................................................................................................86
12.1.1 Operation of Intake Gate....................................................................................................86
12.1.1.1 Opening of Intake Gate...............................................................................................87
 12.1.1.2 Closing of Intake gate.................................................................................................90
12.1.1.3 Gate droop control (leakage recuperation)...............................................................91
12.1.2 Operation of Intake Gate without control voltage (or PLC fault).......................................92
12.1.2.1 Raising of Gate............................................................................................................92
12.1.2.2 Lowering of Gate........................................................................................................93
12.1.3 Operation of Intake Gate without power supply................................................................93
12.1.3.1 Opening of the Gate...................................................................................................93
12.1.3.2 Closing of the Gate.....................................................................................................94
12.2 DIVERSION WEIR GATES...............................................................................................................94
12.2.1 Operation............................................................................................................................95
12.2.1.1 Opening of Radial Gate 1 =51LNC11.............................................................................95
12.2.1.2 Closing of Radial Gate 1 =51LNC11...............................................................................97
12.2.1.3 Closing of Flap Gate 1 =51LNC12.................................................................................98
12.2.1.4 Opening of Flap Gate................................................................................................100
12.2.1.5 Maintenance Mode of Weir Gates...........................................................................100
12.2.1.5.1 Maintenance operation of one Radial Gate.......................................................101
12.2.1.5.2 Maintenance operation of one Flap Gate..........................................................101
12.2.1.6 Operation of the Weir Gates without control voltage (or PLC fault)......................101
12.2.1.6.1 Operation of one Radial Gate without control voltage.....................................102
12.2.1.6.2 Closing of one Radial Gate without control voltage.........................................102
12.2.1.6.3 Closing of one Flap Gate without control voltage............................................102
12.2.1.6.4 Opening of one Flap Gate without control voltage..........................................103
12.2.1.7 Operation of Weir Gates without power supply......................................................103
12.2.1.7.1 Opening of one Radial Gate without power supply..........................................103
12.2.1.7.2 Closing of one Radial Gate without power supply............................................103
12.2.1.7.3 Closing of one Flap Gate without power supply...............................................103
12.2.1.7.4 Opening of one Flap Gate without power supply.............................................104
12.3 TRASH RACK CLEANING MACHINE................................................................................................104
12.3.1 Touch Panel Control Unit...................................................................................................105
12.3.1.1 Start Screen...............................................................................................................105
12.3.1.2 Operational Display...................................................................................................106
12.3.1.3 Setting.......................................................................................................................106
12.3.1.4 Positions....................................................................................................................107
12.3.1.5 Pre-selections............................................................................................................108
12.3.2 Local control.....................................................................................................................108
12.4 DESILTER..................................................................................................................................109
12.4.1 Desilter Inlet Gate..............................................................................................................109
12.4.2 Desilter Flushing Gates......................................................................................................109
12.4.3 Desilter Outlet Gate...........................................................................................................110
12.4.4 Screen Cleaning Machine...................................................................................................110
12.4.5 Sediment Measuring System.............................................................................................110
12.4.6 Operation of Desilter Gates...............................................................................................111
12.4.6.1 Touch Panel Control Unit...........................................................................................111
12.4.6.2 Local Control boxes on the Gates............................................................................116
12.4.7 Operation of Screen Cleaning Machine..............................................................................116
12.4.7.1 Touch Panel Control Unit..........................................................................................116
12.4.7.2 Local control position of machine...........................................................................120
CHAPTER 13: FIRE DETECTION AND PROTECTION SYSTEM............................................................122
13.1 INTRODUCTION:...........................................................................................................................122
13.2 OPERATIONAL DETAILS................................................................................................................122
13.2.1 Spray System.....................................................................................................................122
13.2.2 Automatic high velocity water spray system....................................................................122
13.2.3 Operation of deluge valve.................................................................................................123
13.2.4 Auto operation of deluge valve.........................................................................................123
13.2.5 Manual operation..............................................................................................................123
CHAPTER 14: DIESEL GENERATORS.................................................................................................124
14.1 400KVA DIESEL GENERATOR.......................................................................................................124
14.1.1 Operation...........................................................................................................................124
14.1.1.1 Starting the Engine....................................................................................................124
14.1.1.2 Engine Warm-Up........................................................................................................125
14.1.1.3 Engine Shut Down.....................................................................................................125
14.2 160KVA DIESEL GENERATOR.......................................................................................................125
14.2.1 Operation..........................................................................................................................125
14.2.1.1 Starting the Engine....................................................................................................125
14.2.1.2 Stopping the engine..................................................................................................125
14.2.1.3 Operating the engine................................................................................................125
CHAPTER 15: CONTROL SYSTEMS....................................................................................................127
15.1 OVERVIEW..................................................................................................................................127
15.1.1 Locations............................................................................................................................128
15.1.2 Plant Areas –Automation Cells..........................................................................................128
15.2 CONTROL ROOM........................................................................................................................129
15.2.1 Control Room Equipment..................................................................................................130
15.2.2 Startup of Operating Station.............................................................................................131
15.3 LOCAL HMI................................................................................................................................131
15.3.1 Local HMI Equipment.........................................................................................................131
15.3.2 Startup of local HMI..........................................................................................................132
15.4 COMMUNICATION.......................................................................................................................132
15.4.1 E8000 – Field Bus...............................................................................................................132
15.4.2 S8000-E – Process Bus.......................................................................................................132
15.4.3 Site Network-Enterprise Bus.............................................................................................132
15.4.4 TCP/IP Site Network Addresses.........................................................................................133
15.4.5 S8000-E TCP/IP Unit Network Addresses..........................................................................133
15.5 DATA ACQUISITION.....................................................................................................................134
15.5.1 Cell Controller - MFC1000...................................................................................................134
15.5.2 Field Controller - CE1000....................................................................................................135
15.5.2.1 Analogous Inputs......................................................................................................136
15.5.2.2 Temperature Inputs..................................................................................................137
15.5.2.3 Digital Inputs.............................................................................................................137
15.5.2.4 Analog Outputs........................................................................................................138
15.5.2.5 Digital Outputs.........................................................................................................139
15.5.2.6 Power Supply...........................................................................................................140
15.5.2.7 Bus controller...........................................................................................................140
15.5.2.8 Bus controller Extension 10-Base T HUB..................................................................141
 15.5.2.9 Bus controller Extension 100 FX HUB.......................................................................141
15.5.2.10 Bus transmitter.......................................................................................................142
15.5.2.11 Bus Receiver.............................................................................................................143
15.5.2.12 Alstom SW X20 License Module.............................................................................143
15.5.2.13 Bus Module X20BB80.............................................................................................144
15.5.2.14 Bus Module X20BM11..............................................................................................144
15.5.2.15 Bus Module X20BM01.............................................................................................144
15.6 HMI OPERATION.......................................................................................................................144
15.6.1 HMI Database....................................................................................................................144
15.6.2 Time Server / Time tagging...............................................................................................145
15.6.3 Users.................................................................................................................................145
15.6.4 LOCAL/ REMOTE Switches.................................................................................................145
15.6.5 Alarms and Events............................................................................................................146
15.6.6 Audible Alarms.................................................................................................................147
15.6.7 Naming of Mimics’............................................................................................................147
15.7 MIMIC VIEWS.............................................................................................................................148
15.7.1 Process symbol description...............................................................................................148
15.7.1.1 Status indication........................................................................................................148
15.7.1.2 Control Window and Synthetic Variable concept....................................................150
15.7.1.3 Control Window for Set points.................................................................................151
15.7.1.4 General buttons present in all mimics......................................................................152
15.7.1.4.1 Local / Remote window......................................................................................152
15.7.1.4.2 Emergency Stop Button.....................................................................................153
15.7.2 Overview mimics...............................................................................................................153
15.7.2.1 220kV Overview.........................................................................................................154
15.7.2.2 Overview Control......................................................................................................155
15.7.2.3 Overview Electrical...................................................................................................156
15.7.2.4 Overview Heating / Ventilation / Air Conditioning...................................................157
15.7.2.5 Overview Hydraulic..................................................................................................158
15.7.2.6 Overview System......................................................................................................159
15.7.3 Unit Mimics.......................................................................................................................159
15.7.3.1 Unit 110V DC..............................................................................................................160
15.7.3.2 Unit 400V Distribution..............................................................................................161
15.7.3.3 Unit Cooling Water System......................................................................................162
15.3.3.4 Unit ESD (Emergency Shutdown)............................................................................163
15.7.3.5 Unit Generator.........................................................................................................164
15.7.3.6 Unit Main Inlet Valve................................................................................................165
15.7.3.7 Unit Main Transformer.............................................................................................166
15.7.3.8 Unit Overview...........................................................................................................167
15.7.3.9 Unit Prestart Conditions (1 - 4).................................................................................170
15.7.3.10 Unit QSD (Quick Shutdown)...................................................................................172
15.7.3.11 Unit Start sequence.................................................................................................174
15.7.3.12 Unit Stop Sequence.................................................................................................175
15.7.3.13 Unit System.............................................................................................................176
15.7.3.14 Unit Turbine.............................................................................................................177
15.7.4 Power Cavern Mimics........................................................................................................178
15.7.4.1 Power Cavern 110V Common Distribution...............................................................178
15.7.4.2 Power Cavern 110V Main Distribution......................................................................179
 15.7.4.3 Power Cavern 110V Transformer Distribution.........................................................180
15.7.4.4 Power Cavern 33kV...................................................................................................181
15.7.4.5 Power Cavern 400V Main Distribution....................................................................182
15.7.4.6 Power Cavern 400V Sub-distribution 1....................................................................183
15.7.4.7 Power Cavern 400V Sub-distribution 2....................................................................184
15.7.4.8 Power Cavern 400V Sub-distribution 3...................................................................185
15.7.4.9 Power Cavern Air Supply.........................................................................................186
15.7.4.10 Power Cavern System.............................................................................................187
15.7.4.11 Power Cavern Station Transformer........................................................................188
15.7.5 Dam/Desilter Mimics.........................................................................................................188
15.7.5.1 Dam 400V Distribution.............................................................................................189
15.7.5.2 Dam Hydro................................................................................................................190
15.7.5.3 Dam System..............................................................................................................192
15.7.5.4 Desilter 400V Distribution........................................................................................193
15.7.5.5 Desilter Hydro...........................................................................................................194
15.7.5.6 Desilter System........................................................................................................195
15.7.5.7 Surge Tank 400V Distribution..................................................................................196
15.7.6 Control Building Mimics....................................................................................................197
15.7.6.1 Control Building 110V Distribution............................................................................197
15.7.6.2 Control Building 33kV...............................................................................................198
15.7.6.3 Control Building 400V Distribution..........................................................................199
15.8 400V AUXILIARY SWITCHOVER...................................................................................................200
15.8.1 Interlocking......................................................................................................................200
15.8.2 Control Function...............................................................................................................201
15.8.3 Incoming Feeders and Diesel.............................................................................................201
15.8.4 Diesel Unit.........................................................................................................................201
15.8.5 Automatic switchover......................................................................................................202
15.8.6 Automatic switchover topologies....................................................................................202
15.8.7 Priority of the Auxiliary Supply........................................................................................202
15.8.8 Emergency Supply............................................................................................................203
15.8.9 Manual Operation............................................................................................................203
15.8.10 Alarm..............................................................................................................................203
CHAPTER 16: ISLANDED MODE OF OPERATION.............................................................................204
16.1. INTRODUCTION.........................................................................................................................204
16.2 OPERATION PROCEDURES...........................................................................................................204
16.2.1 Failure of 220kV Dagachhu-Tsirang line............................................................................204
16.2.2 Failures of other transmission line except our line...........................................................205
CHAPTER 17: GENERATION SCHEDULING AND SYSTEM COORDINATION....................................206
17.1 GENERATION SCHEDULING...........................................................................................................206
17.2 MESSAGE..................................................................................................................................207
17.2.1 Purpose of Message..........................................................................................................207
17.2.2 Scope of application.........................................................................................................207
17.2.3 Type of Messages..............................................................................................................207
17.2.4 Message Procedure..........................................................................................................207
17.3 PLANNED OUTAGES MANAGEMENT..............................................................................................207
17.4 COORDINATION OF SYSTEM OPERATION.......................................................................................208
CHAPTER 18: ENERGY METERING AND METER READING..............................................................209
18.1 ENERGY METERING....................................................................................................................209
18.2 ENERGY METER READING...........................................................................................................209
CHAPTER 19: BILING AND PAYMENT................................................................................................211
19.1 BILLING......................................................................................................................................211
19.2 PAYMENT...................................................................................................................................211
CHAPTER 20: DATA KEEPING AND REPORTING...............................................................................212
20.1 SHIFT CHANGE OVER...................................................................................................................212
20.2 DATA RECORDING......................................................................................................................212
20.3 PRODUCTION INCENTIVE SYSTEM (PIS) DATA PREPARATION...........................................................213
CHAPTER 21: IP CAMERA MANAGEMENT........................................................................................215
21.1 INTRODUCTION............................................................................................................................215
21.2 INDIGO VISION CONTROL CENTER.................................................................................................215
21.3 USERS AND USER GROUPS............................................................................................................215
21.4 OPERATION...............................................................................................................................216
21.4.1 How to add camera in indigovision control centre software............................................216
21.4.2 Camera setting:.................................................................................................................217
21.4.2.1 Camera encoder setting:...........................................................................................217
21.4.2.2 Camera time setting:................................................................................................218
21.4.2.3 Set login password for Camera:...............................................................................218
21.4.2.4 Set camera for video recording:..............................................................................219
21.4.3 Export recorded video to external drive:.........................................................................220
21.4.4 Create sequence for camera automatic rotation:.............................................................222
21.4.5 Network Video Recorder (NVR):.......................................................................................227
21.4.6 Archiving..........................................................................................................................228
CHAPTER 22: VENTILATION SYSTEM...............................................................................................229
22.1 INTRODUCTION..........................................................................................................................229
22.2 OVERVIEW OF HVAC SYSTEM......................................................................................................229
22.3 EVACUATION OF SMOKE DURING FIRE INSIDE POWER CAVERN..........................................................230
22.4 OPERATION PROCEDURE FOR POWER CAVERN VENTILATION SYSTEM.................................................231
22.4.1 In winter season, run the following mechanical ventilation:.............................................231
22.4.2 In summer season.............................................................................................................231
SECTION B: MAINTENANCE MANUAL....................................................264
CHAPTER 1: GENERATOR..................................................................................................................265
1.1 INTRODUCTION.............................................................................................................................265
1.2 SAFETY INSTRUCTIONS FOR MAINTENANCE.....................................................................................265
1.3 PREVENTIVE MAINTENANCE..........................................................................................................266
1.4 RECOMMENDED INSPECTIONS........................................................................................................267
1.5 RECOMMENDED OVERHAULS........................................................................................................269
1.6 OVERHAUL PLANS:.......................................................................................................................272
1.7 SAMPLE CHECKLISTS.....................................................................................................................278
CHAPTER 2: EXCITATION SYSTEM...................................................................................................285
 2.1 SPU 232 PROCESSOR CARD...........................................................................................................285
2.2 CLEANING...................................................................................................................................285
2.3 CHECKING SCREWS AND BOLTS......................................................................................................285
2.4 LUBRICATION..............................................................................................................................286
2.5 MAINTENANCE OF THREE-PHASE SWITCHES, DE-EXCITATION SWITCH, ISOLATING SWITCHES AND POWER
CONTACTORS....................................................................................................................................286
2.6 FAN...........................................................................................................................................286
2.7 POWER SUPPLY UNITS..................................................................................................................286
2.8 INSPECTION................................................................................................................................286
2.9 HOW TO DETECT A SEMICONDUCTOR DEFECT..................................................................................286
2.10 OVERVIEW OF MAINTENANCE WORK.............................................................................................287
2.11 CHANGE OF HARDWARE COMPONENTS RUNNING WITH A SOFTWARE.................................................288
CHAPTER 3: TURBINE & AUXILIARIES.............................................................................................289
3.1INSPECTION AND MAINTENANCE PLAN............................................................................................289
3.1.1 Activities during operation.................................................................................................289
3.1.2 Activities during the Maintenance......................................................................................291
3.1.3 Maintenance or inspection activities..................................................................................292
3.1.3.1 Pelton Runner.............................................................................................................292
3.1.3.2 Turbine shaft..............................................................................................................293
3.1.3.3 Turbine guide bearing................................................................................................293
3.1.3.4 Nozzles and deflectors..............................................................................................293
3.1.3.5 Over speed device.....................................................................................................294
3.1.3.6 Turbine casing............................................................................................................294
3.1.3.7 Electrical devices........................................................................................................294
3.1.4 Troubleshooting................................................................................................................294
CHAPTER 4: MAIN INLET VALVE & AUXILIARIES............................................................................295
4.1 MAINTENANCE............................................................................................................................295
4.4.1 Maintenance and inspection plan......................................................................................295
4.4.1.1 Activities during operation........................................................................................295
4.4.1.2 Activities in case of Shut down machine..................................................................299
4.4.2 Troubleshooting................................................................................................................301
CHAPTER 5: GOVERNING SYSTEM...............................................................................................302
5.1 HYDRAULIC GOVERNOR................................................................................................................302
5.1.1 Safety instructions..............................................................................................................302
5.1.2 Remarks for disassembly / reassembly of hydraulic Governor Equipment.........................302
5.1.3 Maintenance and inspection plan......................................................................................303
5.1.3.1 Activities during operation........................................................................................304
5.1.3.2 Activities in case of shut-down machine...................................................................305
5.1.4 Troubleshooting................................................................................................................306
5.2 DIGITAL GOVERNOR.....................................................................................................................306
CHAPTER 6: GENERATOR STEP-UP TRANSFORMER.......................................................................307
6.1 MAINTENANCE SCHEDULE.............................................................................................................307
6.2 OIL SAMPLING............................................................................................................................307
6.2.1 Electric Strength:...............................................................................................................307
6.2.2 Moisture Content:..............................................................................................................307
 6.2.3 Acidity:..............................................................................................................................307
6.3 SAMPLING PROCEDURE................................................................................................................308
6.3.1 Tools required....................................................................................................................308
6.3.2 Procedure..........................................................................................................................308
6.4 WINDING TEMPERATURE INDICATOR TESTS....................................................................................308
6.4.1 Tools and materials...........................................................................................................308
6.4.2 Procedures........................................................................................................................308
6.4.3 Calibration.........................................................................................................................309
6.5 BUCHHOLZ RELAY FUNCTIONAL TEST............................................................................................309
6.5.1 Tools and Materials Required............................................................................................309
6.5.2 Procedures........................................................................................................................309
6.6 TAP-CHANGER OPERATION...........................................................................................................309
6.7 OIL FILTRATION...........................................................................................................................310
6.8.1 Tools and Materials............................................................................................................310
6.7.2 Procedure...........................................................................................................................310
6.8 CORRECTIVE MAINTENANCE..........................................................................................................310
6.9 REMOVING AND REFIXING OF PUMPS.............................................................................................310
6.9.1 Tools and materials............................................................................................................310
6.9.2 Procedure..........................................................................................................................310
6.10 TROUBLE SHOOTING...................................................................................................................311
CHAPTER 7: STATION AUXILIARY TRANSFORMERS.......................................................................312
7.1 STATION AUXILIARY TRANSFORMER, 220/11KV, 5MVA.....................................................................312
7.1.1 Routine Inspection Schedule...............................................................................................312
7.1.2 Oil sampling........................................................................................................................313
7.1.3 Maintenance Schedule........................................................................................................313
7.1.3.1 Electric Strength:........................................................................................................314
7.1.3.2 Moisture Content:......................................................................................................314
7.1.3.3 Acidity:........................................................................................................................314
7.1.4 Sampling procedure...........................................................................................................314
7.1.4.1 Tools required.............................................................................................................314
7.1.4.2 Procedure...................................................................................................................314
7.1.5 Winding Temperature indicator tests.................................................................................315
7.1.5.1 Tools and materials.....................................................................................................315
7.1.5.2 Procedures..................................................................................................................315
7.1.5.3 Calibration...................................................................................................................315
7.1.6 Buchholz Relay Functional Test..........................................................................................315
7.1.6.1 Tools and Materials Required.....................................................................................315
7.1.6.2 Procedures.................................................................................................................316
7.1.7 Tap-changer Operation.......................................................................................................316
7.1.8 Oil Filtration........................................................................................................................316
7.1.8.1 Tools and Materials....................................................................................................316
7.1.8.2 Procedure...................................................................................................................316
7.1.9 Corrective Maintenance......................................................................................................317
7.1.10 Removing and Re-fixing of Pumps.....................................................................................317
7.1.10.1 Tools and materials...................................................................................................317
7.1.10.2 Procedure..................................................................................................................317
7.1.11 Trouble Shooting...............................................................................................................317
 7.2 AUXILIARY TRANSFORMER, 33/0.4KV (800 KVA)...........................................................................317
7.2.1 Introduction........................................................................................................................317
7.2.2 Technical Data....................................................................................................................318
7.2.3 Maintenance.......................................................................................................................318
7.2.3.1 Yearly Maintenance....................................................................................................318
CHAPTER 8: GAS INSULATED SWITCHGEAR....................................................................................319
8.1 MAINTENANCE.............................................................................................................................319
8.1.1 GIS inspection over view:....................................................................................................319
8.1.2 Check List (After Maintenance) for GIS Bays:.....................................................................320
CHAPTER 9: POT HEAD YARD...........................................................................................................321
9.1 MAINTENANCE.............................................................................................................................321
9.1.1 Yearly Maintenance:............................................................................................................321
CHAPTER 10: CROSSED LINKED POLYETHYLELE (XLPE) CABLE.....................................................322
10.1 INTRODUCTION...........................................................................................................................322
10.2 TECHNICAL DETAILS OF XLPE......................................................................................................322
10.3 MAINTENANCE:..........................................................................................................................322
CHAPTER 11: AUXILIARY SUPPLY SYSTEM......................................................................................324
11.1 MAINTENANCE OF 33KV SWITCHGEAR...........................................................................................324
11.1.1 Levels of maintenance:......................................................................................................324
11.1.2 Preventive maintenance of the moving parts:..................................................................324
11.1.3 Preventive maintenance of the functional units:...............................................................325
11.1.4 Preventive maintenance of Bus bar compartment...........................................................326
11.1.5 Preventive maintenance of the High Voltage Cables compartment..................................326
11.1.6 Preventive maintenance of the Low Voltage Box..............................................................327
11.1.7 Maintenance on 33 kV Vacuum circuit breakers................................................................327
11.1.8 Maintenance on Metering and protection Instruments:...................................................328
11.1.8.1 Current transformer:.................................................................................................328
11.1.8.2 Potential transformers:............................................................................................329
11.2 MAINTENANCE OF 400V SUPPLY SYSTEM.....................................................................................329
11.2.1 Yearly/Annual maintenance...............................................................................................329
CHAPTER 12: DIVERSION WEIR AND DESILTER...............................................................................330
12.1 INTAKE GATE..............................................................................................................................330
12.1.1 Periodic Inspection and Maintenance................................................................................330
12.2 DIVERSION WEIR GATES..............................................................................................................331
12.2.1 Periodic Inspection and Maintenance................................................................................331
12.3 Trash Rack Cleaning Machine...............................................................................................332
12.3.1 Periodic Inspection and Maintenance...............................................................................332
12.4 DESILTER..................................................................................................................................333
12.4.1 Mechanic and steel structure............................................................................................333
12.4.2 Screws and fastening elements........................................................................................334
12.4.3 Control after Flooding......................................................................................................334
12.4.4 Hydraulic System..............................................................................................................334
12.4.5 Maintenance planning and inspection..............................................................................334
12.5 TROUBLESHOOTING....................................................................................................................335
 12.6 REPLACEMENT OF SEAL...............................................................................................................335
CHAPTER 13: FIRE DETECTION AND PROTECTION SYSTEM...........................................................336
13.1 MAINTENANCE HYDRANTS AND HOSE REEL....................................................................................336
13.2 YEARLY INSPECTIONS:.................................................................................................................336
13.3 MAINTENANCE OF DELUGE VALVE.................................................................................................336
13.4 PERIODICAL TESTING AND MAINTENANCE OF HVW SPRAY SYSTEM..................................................336
CHAPTER 14: DIESEL GENERATORS.................................................................................................338
14.1 400KVA DIESEL GENERATOR......................................................................................................338
14.1.1 Preventive Maintenance...................................................................................................338
14.1.2 Stand-By Generator set Maintenance...............................................................................338
14.2 160KVA MAINTENANCE SCHEDULE..............................................................................................341
CHAPTER 15: CONTROL AND PROTECTION SYSTEMS....................................................................343
15.1 CONTROL SYSTEM......................................................................................................................343
15.1.1 Optimum Environmental Conditions.................................................................................343
15.1.2 Dust cleaning.....................................................................................................................343
15.1.3 Cleaning of the modules...................................................................................................343
15.1.4 Electrical checking............................................................................................................344
15.1.5 Ventilation cleaning..........................................................................................................344
15.1.6 Functional test..................................................................................................................344
15.1.7 Power sources checking....................................................................................................344
15.1.8 Stations maintenance.......................................................................................................344
15.1.9 Printer maintenance.........................................................................................................345
15.1.9.1 General cleaning.......................................................................................................345
15.1.9.2 Cleaning of the print-head.......................................................................................345
15.1.9.3 Print test...................................................................................................................345
15.1.10 Maintenance of the spare part........................................................................................345
15.1.11 Maintenance of the Ethernet network............................................................................346
15.2 AUTOMATIC SYNCHRONIZER (SYNCHROTACT 5)........................................................................346
15.2.1 Maintenance Instructions.................................................................................................346
15.2.2 Troubleshooting...............................................................................................................347
15.3 PROTECTION SYSTEM..................................................................................................................347
15.3.1 Startup of System start-up check list for Protection........................................................347
15.3.2 Visual Function Check.......................................................................................................348
15.3.3 Shutting Down Protection System...................................................................................349
15.3.4 Faults................................................................................................................................349
15.3.5 Maintenance.....................................................................................................................349
15.3.6 Maintenance period.........................................................................................................353
15.3.7 Maintenance checks.........................................................................................................353
15.3.8 Method of repair..............................................................................................................354
15.3.9 Post modification tests....................................................................................................356
15.3.10 Cleaning..........................................................................................................................356
CHAPTER 16: IP CAMERA SYSTEM...................................................................................................357
16.1 MAINTENANCE...........................................................................................................................357
CHAPTER 17: HEATING, AIR CONDITIONING & VENTILATION SYSTEM (HVAC)............................358
 17.1 MAINTENANCE SCHEDULE............................................................................................................358
CHAPTER 18: DC SUPPLY SYSTEM...................................................................................................359
18.1 TECHNICAL DETAILS OF THE 110V DC, 440AH FLOAT CUM BOOST BATTERY CHARGER.................359
18.2 GENERAL FEATURES...................................................................................................................360
18.3 CHARGING WORKING PHILOSOPHY..............................................................................................360
18.4 PREVENTIVE MAINTENANCE.........................................................................................................361
18.5 ANNUAL MAINTENANCE..............................................................................................................361
18.6 TROUBLESHOOTING....................................................................................................................361
SECTION C: SAFETY AND WORK PERMIT..................................................................443
CHAPTER 1: PERMIT TO WORK-LOCK OUT/ TAG OUT....................................................................444
1.1 INTRODUCTION............................................................................................................................444
1.2 SCOPE AND FIELD OF APPLICATION.................................................................................................444
1.3 RESPONSIBILITIES........................................................................................................................445
1.4 POLICY.......................................................................................................................................445
1.5 DEFINITIONS...............................................................................................................................446
1.6 PERMIT TO WORK.......................................................................................................................448
1.7 PROCEDURE OF LOCKOUT & TAGOUT.............................................................................................449
1.7.1 Preparation of Lockout and Tagout...................................................................................449
1.7.2 Sequence of Lockout and Tagout.......................................................................................450
1.7.3 Re-commissioning / Taking back in line, of systems after maintenance.............................451
1.7.4 Lockout and Tagout Procedure involving more than one Person/group............................451
1.7.5 Lockout and Tagout Procedures Involving Shifts...............................................................452
1.7.6 Temporary Removal of Lockout/Tagout Devices...............................................................452
1.7.7 Maintenance requiring undisrupted energy supply............................................................453
1.7.8 Lockout Devices and Locks.................................................................................................453
1.7.9 Tagout and Tags.................................................................................................................454
1.7.10 Contractors.......................................................................................................................455
1.8 EXCEPTIONS.........................................................................................................................455
1.9 REVIEW OF LOTO COMPLETION....................................................................................................455
1.10 AUDIT.......................................................................................................................................455
1.11 TRAINING & RECORD KEEPING......................................................................................................455
1.12 ANNEXURES...............................................................................................................................457
CHAPTER 2: SAFETY AND OCCUPATIONAL HEALTH......................................................................463
2.1 INTRODUCTION............................................................................................................................463
2.2 GENERAL SAFETY RULES..............................................................................................................463
2.3 WORK SITE SAFETY.....................................................................................................................464
2.4 ELECTRICAL HAZARDS..................................................................................................................464
2.4.1 Dangers from Electrical Shock and its Effects....................................................................464
2.4.2 Rescue from Electric Shock................................................................................................465
2.4.3 Dangers from Arcs and Blasts............................................................................................465
2.4.4 Lockout and Tagout..........................................................................................................465
2.4.5 Fire Hazards.......................................................................................................................466
2.5 PERSONNEL PROTECTIVE EQUIPMENT............................................................................................466
2.5.1 Head Protection.................................................................................................................466
2.5.2 Eye and Face Protection.....................................................................................................467
 2.5.3 Foot Protection.................................................................................................................468
2.5.4 Hand Protection................................................................................................................468
2.5.5 Hearing Protection............................................................................................................468
2.5.6 Life Jackets and Safety Belts.............................................................................................469
2.5.7 Respiratory Protection......................................................................................................469
2.6 TOOLS AND EQUIPMENT..............................................................................................................469
2.6.1 Hand Tools.........................................................................................................................469
2.6.2 Ladders- Portable..............................................................................................................469
2.6.3 Hoisting and Rigging..........................................................................................................470
2.6.4 Welding, Cutting and Brazing............................................................................................470
2.6.5 Air-Operated Tools............................................................................................................470
2.7 FIRST AID....................................................................................................................................471
2.7.1 Work Injury and Mishap Reports........................................................................................471
REFERENCES.....................................................................................................................................472
ACKNOWLEDGEMENT......................................................................................................................473

LIST OF ANNEXURES (OPERATION MANUAL)

ANNEXURE 0 1: PROCEDURE FOR FILLING AND DE-WATERING OF WATER CONDUCTING SYSTEM...........234

ANNEXURE 0 2: SILT FLUSHING OF DESILTING CHAMBER...............................................................................241
ANNEXURE 0 3: RESERVOIR SCOURING PROCEDURE.....................................................................................244
ANNEXURE 0 4: DATA FORMATS......................................................................................................................246
ANNEXURE 0 5: MONTHLY ENERGY BILL..........................................................................................................256
ANNEXURE 0 6: CONTINGENCY PLAN...............................................................................................................257

LIST OF ANNEXURES (MAINTENANCE MANUAL)

ANNEXURE M 1: TROUBLESHOOTING OF DIVERSION WEIR AND DESILTER EQUIPMENT...........................363

ANNEXURE M 2: TROUBLESHOOTING OF DC SYSTEM....................................................................................388
ANNEXURE M 3: TROUBLESHOOTING OF DIGITAL GOVERNOR.....................................................................400
ANNEXURE M 4: TROUBLESHOOTING OF HYDRAULIC GOVERNOR...............................................................403
ANNEXURE M 5: REPLACEMENT OF SEALS......................................................................................................406
ANNEXURE M 6: TROUBLESHOOTING OF TURBINE AND ITS AUXILIARIES...................................................418
ANNEXURE M 7: NOZZLE TIP DE-ASSEMBLY SEQUENCE.................................................................................421
ANNEXURE M 8: TROUBLESHOOTING OF MAIN INLET VALVE AND ITS AUXILIARIES..................................425
ANNEXURE M 9: REPLACEMENT OF SYNCHROTACT 5....................................................................................426
ANNEXURE M 10: TROUBLESHOOTING OF SYNCHROTACT 5..........................................................................430
ANNEXURE M 11: TROUBLESHOOTING OF 24MVA GSU TRANSFORMER AND 5MVA AUXILIARY STATION
TRANSFORMER..........................................................................................................................................433
 SECTION A: OPERATION MANUAL
SECTION A: OPERATION MANUAL
 SECTION A:

OPERATION MANUAL CHAPTER 1: SALIENT FEATURES OF THE

CHAPTER 1 PLANT

The 126 MW (2x63 MW) Dagachhu Hydropower Plant, located in the south-western part of
Bhutan under Dagana Dzongkhag, is a run-of-the-river scheme being developed on the left bank
of river Dagachhu, located between 10.5 km and 20.2 km upstream of the confluence with the
Punatsangchhu. The elevation of the project area and the catchment area ranges from 500 m to
almost 4,000 m above mean sea level. The mean annual generation from the project is 515 GWh
and 90% dependable energy production is 360 GWh.
The project was approved for implementation at an estimated cost of US$ 201.50 million,
corresponding to Nu. 8.16 billion (2008 price levels and exchange rates) at 60:40 debt equity
ratio. Taking into consideration the actual costs of award of major contracts, encountering of
poorer geology, geological surprises and assumption of the geological conditions of the
remaining length of headrace tunnel excavations, variation in quantity of supports and a stronger
US $ and Euro than at the time of decision of investment, cost to completion of the project has
been revised to Nu. 12,226.739 million. DGPC holds 59% equity, Tata Power Company Limited,
India 26% and National Pension & Provident Fund of Bhutan the remaining 15% of the equity. Asian
Development Bank is providing loan of USD 51 million for financing the civil works; RZB, Austria is
providing loan of Euro 41.23 million for financing the E&M works, and the NPPF is providing loan
of Nu. 600 million.
To meet the additional fund required for project, the Asian Development Bank has already
committed to Ministry of Finance, Royal Government of Bhutan to provide additional debt
financing to Dagachhu Hydropower project.
Besides the royalty energy, all the power from the project shall be evacuated to India through a
long-term Power Purchase Agreement with Tata Power Trading Company Limited, India.

1.1 Location

River : Dagachhu River

Dam Site : Guethang

Power house : Chulumithang

District : Dagana

1.2 Hydrology

Catchment Area : 676 km²

Water Resource : Dagachhu

 Specific Run-off : 41.11 l/s/km2

Annual Mean Flow : 27.8 m3/s

Firm Flow (95% : 5 m3/sec excluding Residual Flow (1.4 m3/sec)

availability)

Mean Annual Yield (usable) : 733 million m3 excluding Residual Flow and Flood

1.3 Diversion Weir

Maximum Reservoir Level : 843.30 m.a.s.l

Normal Operating Level : 841.10 m.a.s.l

Type : Reinforced concrete gravity Wall

Crest length : 18.2 m , Two sections 2 x 9.1 m

Dead Storage : 200,000 m3

Design Flood : 859 m³/s HQ10 000

Radial Gates

Type : Sluice Radial

Number :2

Size : 9.1 m (L) x 4 m (W)

Bottom crest level : 825 m.a.s.l

Flap Gates

Number :2

Size : 9.1 m (L) x 4 m (W)

Bottom crest level : 839.80 m.a.s.l

1.4 Intake

Type : Straight and funnel shaped

Location : Left bank of Dagachhu River

Number :2

Number of Gates :1
Invert of Intake : 838.80 m.a.s.l

1.5 Fish Ladder

Type : Vertical Slot Pass type

Length : 280m and 15 resting basins

1.6Desilting Chamber

Number : 3 nos.

Size : 240 x 30.5 x 11 m, incl. transitions

1.6.1 Desilter Inlet Gate

Size : 7.25 m (H) x 4.8 m (W)

Number : 3 nos.

Invert Level : 835.05 m.a.s.l

Stroke speed : 300 mm/min

Lowering Speed : 300 mm/min

Seal type : 4-sided seal

1.6.2 Flushing Gate

Size : 2 m (H) x 2.7 m (W)

Invert Level : 828.44 m.a.s.l

Stroke speed : 300 mm/min

Lowering Speed : 300 mm/min

Seal type : 4-sided seal

1.6.3 Desilter Outlet Gate

Size : 3.3 m (H) x 3.5 m (W)

Invert Level : 837.90 m.a.s.l

Stroke speed : 300 mm/min

Lowering Speed : 300 mm/min

Seal type : 4-sided seal

1.7 Water Conducting system

1.7.1 Connection intake-Desilter

Channel size : 270 m (L) x 5m (W) x 4.3m (H)

Channel type : Rectangular shape

Gradient : 0.25%

Tunnel size : 476 m (L) x 4.16 m (base width) x 4.65 m (H)

Tunnel type : Inverted Horseshoe type

1.7.2 Headrace Channel

Size : 261 m (L) x 5 m (W) x 4.3 m (H) with gradient 0.25%

Type : Rectangular shape

1.7.3 Headrace Tunnel

Size (incl. Side Adits) : 7,795 m (L) and Diameter 4.4-4.8 m

1.7.4 Surge Shaft

Size : 45m (H), 21m (inner diameter)

Base elevation : 808.50 m.a.s.l

Type : Vertical Cylindrical Tank

Orifice diameter : 4.10 m

1.7.5 Pressure Shaft

Size : 271 m (H) and 3.4 m (inner diameter)

Number : 1 only

Inclination : 90 °

1.7.6 Pressure Tunnel

Size : 41 m (L) and 3.4 m (inner diameter)

1.8 PowerhouseComplex

1.8.1 Power house cavern

Type : Underground and Reinforced Concrete

Size : 62.5 m (L) x 25 m (W) x 36.5 m (H)

Turbine stilling chamber elevation : 531.80 m.a.s.l

Turbine nozzle center line : 537.00 m.a.s.l

1.8.2 Transformer cavern

Size : 38 m (L) x 15.5 m (W) x 17.5 m (H)

Transformer Cavern elevation : 549.55 m.a.s.l

GIS floor elevation : 557.65 m.a.s.l

1.8.3 Access Tunnel

Size : 250 m (L) x 5 m (W) x 6.2 m (H)

Type : Inverted horseshoe

1.8.4 Emergency Exit Tunnel

Size : 290 m (L) x 3.29 m (W) x 4.3 m (H)

Type : Inverted horseshoe

1.8.5 Tailrace Tunnel

Length : 679 m

Diameter : 4.25/5.0 m

Type : Horseshoe

1.8.6 Bus duct

Type : Horseshoe and reinforced concrete

Size : 14.45 m (L) x 4.30 m (W) x 3.5 m (H)

1.8.7 Main Equipment

Turbine

Type : Vertical Pelton

Number : 2 Nos.

Capacity : 62.222 MW

Nominal speed : 272.7 rpm

Runaway speed : 505 rpm

Rated net head : 282 m

Rated discharge : 25 m3/sec

Centreline turbine runner : 537 m.a.s.l

Direction of Rotation : Clockwise

Diameter of Inlet Valve : 2.1 m

Stilling chamber :5mx4m

Runner diameter (D1) : 2.45 m

Runner bucket height (B2) : 0.86 m

Number of Nozzles :6

Operating oil pressure : 60 bar

Nozzle stroke : 0.268 m

Generator

Type : Vertical Shaft, Synchronous machine

Rated Output : 70 MVA

Rated Voltage : 11000 V

Rated Current : 3674 A

Nominal Voltage range : +/- 10%

Rated frequency : 50 Hz
Rated power factor : 0.9

Rated Speed : 272.7 rpm

Number of Poles : 22

Number of phases :3

Moment of inertia of generator : 3805 tm2

Excitation System : Static Excitation

Rated excitation voltage : 182 V

Rated excitation current : 973 A

Transformer

Make : Areva India Limited

Number :6

Rated Power, HV : 24 MVA

Rated Power, LV : 24 MVA

Rated Voltage, HV : 220/√3 kV

Rated Voltage, LV : 11 kV

Rated line current, HV : 188.72 A

Rate line current, LV : 2181.82 A

No. of phase :1

No. of taps :4

Type of Cooling : OFWF

Tap changing : Off load tap changer

220kV XLPE cable

Type : Single core high voltage cable

Material of conductor : Aluminum

Length of Cable : 3 x 343 m

Cross-section of conductor : 400 mm2

11kV Bus duct

Type : Isolated phase bus duct

Number :2

Rated Current : 4000A/2310A/250A

Fire Detection & Protection System

Transformer : Water hydrant System

EOT Crane

Power Cavern : 2 Nos., 80/15/1T

GIS Floor : 1 No., 8 T

1.9 Transmission Line

Name of the feeder CT ratio Nominal Length Conductor

Power (MVA) (km) type

220kV Dagachhu-Tsirang Feeder 400/1A 224.82 20 Zebra

220kV Dagachhu-Jigmeling Feeder 400/1A 224.82 54.7 Zebra

Table 1. 1: Transmission line parameters

1.10 Commissioning Dates

Name of the Generating Unit Date of commissioning

Unit No-1 21.02.2015

Unit No-2 15.03.2015

Name of Feeder Synchronized with grid

220kV Dagachhu-Tsirang Feeder 03.12.2013

220kV Dagacchu-Jigmeling Feeder Not Yet

Table 1. 2: Dates of commissioning of the generating units and feeders

1.11 Energy Generation

 Firm Power 90 % Dependable Year Average Year

Total Annual Energy GWh 360 515

Table 1. 3: Energy Generation details

 SECTION A:

OPERATION MANUAL CHAPTER2: GENERATOR

CHAPTER 2

The Generator is of vertical shaft with salient pole design and

corresponds to the type of construction IM8425 (W42) in accordance with the IEC Standards
60034-7.The machine is of suspended type i.e. having combined thrust and guide bearing above
rotor and another guide bearing below the rotor. Two generator shafts i.e. generator top shaft
and bottom shaft is provided. The driving end shaft has a forged coupling flange for direct
coupling with the turbine shaft.The bearings are installed for sustaining the outward thrust of
rotor and keeping shaft vertically. The generator slip rings are located at the top. The generator
excitation is provided by separate static excitation equipment. Braking is by
pneumatic/mechanical system as well as by electrically dynamic braking. Necessary thermometer,
thermostats and RTDs are provided to monitor the temperature of bearings and stator core and
windings. Also, various instruments and devices for alarm control and protection and monitoring
have been provided.

Technical Data of Generator

Details Specification

Manufacturer Alstom

Manufacturer’s type designation SAV 435/175/22

Elevation 545 m.a.s.l

Type Suspended rotor type

Rated Power 70 MVA

Normal Voltage 11 kV

Rated Current 3674 A

Rated Frequency 50 Hz

Rated Power Factor 0.9 lagging

Rated exciter voltage 182 V

Rated exciter current 973 A

Rated Speed 272.7 rpm

Runaway Speed 505 rpm

Insulation Class F
Direction of Rotation when seen from Turbine Wheel Anti-Clockwise

Moment of inertia 3805 TM2

Rated Power at Turbine Shaft (Max) 65.97 MW

Maximum Noise Level (at 1 m distance in Machine hall) 85-90 dB

Guaranteed Efficiencies:

Reference temperature of winding (including excitation 75 °c

losses)

Efficiency value at 0.85 pf:

100% load 98.58

75% load 98.47

50% load 98.10

25% load 96.75

Table 2. 1:Technical data of synchronous generator

Figure 2.1:Generator Capability Curve

2.1 Introduction

General
To ensure the continuing operational integrity of generators, generator temperatures, vibration
and various generator auxiliary systems must be closely monitored. Any abnormalities must be
reported and investigated in a timely manner.
Start-up Operation
Prior to the start-up of the generator all the checks at stand still must be completed.
Atnotime,shouldexcitationinterlocksorrelayprotectionbedisabledormade non-
automaticforthepurposeofestablishingageneratorfield.Furthermore,agenerator
fieldshouldnotbere-establishedafteraprotectiverelayhastrippedthegeneratoruntil
athoroughinvestigationofthecausehasbeencompleted.
Ageneratorfieldshouldnotbeappliedormaintainedataturbinespeedaboveor
belowthevaluegivenbythemanufacturer.
Asmoothsynchronizationofthegeneratortothegridwillpreventhighstresseson statorandrotor.
On-line operation
Thegeneratorsshouldbeoperatedwithintheircapabilitycurves,
withlimitedloadandfieldcurrent.Operationsbeyondtheselimitswillresultingeneratoroverheating.
Duringnormaloperation,the voltageregulatorandwhereapplicable,the powersystem
stabilizer(PSS)shouldbecontinuouslyinservice.
Shut-down operation
Thereactiveandactivepowershouldbereducedto0MVAbeforeopeningthe generator
circuitbreakerandthefieldbreaker. Wicketgatesandinletvalveshould be closed.HP-
jackingoilpumpshould be switchedonandmechanicalbrakesmustbeapplied.
Theactualsettingsaredefinedinthecommissioningreport.Atstandstill,theauxiliary
systemswillbeswitchedoff(nocoolingwaterflow)andthespaceheatersareinoperation.

2.2 Start-up Checks at Standstill

Preconditions
The generator is ready to restart after a normal shutdown due to plant utilization and water
availability after confirming the following preconditions:
 The down time did not exceed 1week.
 Auxiliary equipment is turned off.
 Space heaters of the generator are in operation
 The unit should be in stop stable condition.
 Verify that all portable earth devices have been removed.
 Check tap changer position.
Start-up sequences
Thefollowingsequencetostart-upthegeneratorshouldbeapplied.
Note:
 Remainonthewalkwayaroundthestatorframewhilecarryingouttheinspection.
 Donotresetalarmsandtrips,ifyoudon'tknowthecauseoftheproblem.
 Generatorisonlyreadyforoperation,whenallchecksunderpointNo.1are
completedandtheresultsaresatisfactory.
1. Inspectiontouraroundandthroughthegenerator.
a) Checkforoilandwaterleakagesonthebearings.
b) Check oil levels on the bearings. Oil level must be at normal.
c)Check, if space heaters are running and if the generator is dry (no condensation).
d) Check for anomalies on the unit.
e) Check and reset alarms and trips.
f) Check, if excitation and protection system is enabled and operational.
2. HP-jacking oil system is in operation. Oil pressure is applied (feedback signal from the pressure
switch).
3. Oil mist suction system is in operation.
4. Carbon dust suction system is in operation.
5. Mechanical brake is released (feedback signal from the limit switches).
6. Cooling water is turned on (feedback signal from the flow monitors).
7. Firefighting system is ready.
8. Space heaters are turned off.
9. Start unit. Apply excitation at n > 95%.
10. Synchronize the unit to the grid.
11. Apply load.
Note: Forfurtheranddetailedstart-upsequenceinformationrefertotheplantcontrol documentation.

2.3 Checks during Operation

Tomaintaintheintegrityofoperationofthegenerator, thefollowingchecksshouldbe
routinelyperformed on hourly/daily basis duringtheinspectiontour.
1. Check cooling water flow to the stator, air/water cooler and to the bearing oil/water
cooler.
2. Check stator core temperatures.
3. Check stator winding temperatures.
4. Check cold and warm air temperatures.
5. Check bearing oil temperatures.
6. Check bearing oil levels.
 7. Check bearing vibration levels.
8. Check brake air pressure.
9. Check alarm and trip annunciation. Solve problems, if annunciation board indicates alarms.
10. Check generator protection.
Anomaliesfoundduringtheroutineinspectionsshouldbemonitoredandworkorders
shouldbepreparedtoresolve the problems.
Compare actual temperature readings of the generator (stator core, stator winding, cold and
warm air and bearing oil) with the long-term temperature pattern. Deviations must be analyzed
and corrective actions must be initiated in order to prevent the generator from tripping.

2.4 Shutdown

The reactive and active power should be reduced to 0 MVA before opening the generator circuit
breaker and the field breaker. Wicket gates and inlet valve form the turbine are closing. HP-
jacking oil pump is switched on and mechanical brakes will be applied. The actual settings are
defined in the commissioning report. At standstill, the auxiliary systems will be switched off (no
cooling water flow) and the space heaters are in operation.

2.4.1 Normal shutdown

1. The generator is operated with active and reactive load.

2. The shutdown is initiated.
3. The active and the reactive load are reduced to zero (0 MVA).
4. The generator and the field breakers are opened.
5. The turbine and generator is shut down.
Checks for shut-down
6. HP-jacking oil system is off.
7. Oil mist suction system is off.
8. Carbon dust suction system is off.
9. Cooling water system is turned off.
10. Check, if space heaters are in operation.
11. Check for oil and water leakages on the bearings.
12. Check oil levels on the bearings. Oil level must be at normal.
13. Check for anomalies on the unit.

2.4.2 Shutdown by mechanical fault (QSD 1)

1. The turbine is shut down with governor in operation.

2. The active and the reactive load are reduced to zero (0 MVA).
3. The generator breaker and the field breaker are opened.
 4. Emergency braking with mechanical brakes, if foreseen.
Checks after shutdown by mechanical fault
1. HP-jacking oil system is off.
2. Oil mist suction system is off.
3. Carbon dust suction system is off.
4. Cooling water system is turned off.
5. Check, if space heaters are in operation.
6. Investigate the cause of the shutdown by mechanical fault (bearings, vibration, oil and
cooling water).
7. Correct the basic cause.
 Lock, tag out and ground the generator and excitation (work permit) first.
 Apply the necessary safety measures.
 Do not reset alarms and trips until problem is solved.
8. Prepare the generator to put back into the service.

2.4.3Shutdown by electrical fault (QSD 2)

1. Thegeneratorbreakerandthefieldbreakerareopened.
2. Theturbineissimultaneouslyshutdownwith the governorinoperation.
Shutdown by electrical fault
1. HP-jackingoilsystemisoff.
2. Oil mist suction system is off.
3. Carbon dust suction system is off.
4. Cooling water system is turned off.
5. Check, if space heaters are in operation.
6. Investigate the cause of the shutdown by electrical fault (trip by generator protection)
7. Correct the basic cause.
8. Prepare to put back the generator into service.

2.5 Brake operation

Automatic braking
Thefollowingtaskshavetobeexecuted,ifthegeneratorwillnotbeoperatedbetween
one(1)andfour(4)weeks.
1. Carbonbrushesmustberemovedfromthesliprings.Carbonbrushescancause
corrosiononthesliprings.
2. Spaceheatersmustbeinoperation.Temperatureinsidethegeneratormustbe
abovethedewpointtopreventcondensation.
3. Protect slip ring covering against dust and humidity. Do not use solvents for cleaning the
areas close to the carbon brushes.
 4. Dry or heat air in the power house to prevent condensation (excitation, protection and
control system).
Manual braking
Thefollowingtaskshavetobeexecuted,ifthegeneratorwillnotbeoperatedformore
thanfour(4)weeks.
1. Carbonbrushesmustberemovedfromthesliprings.Carbonbrushescancause
corrosiononthesliprings.
2. Space heaters must be in operation. Temperature inside the generator must be above the
dew point to prevent condensation.
3. Protect slip ring covering against dust and humidity. Do not use solvents for cleaning areas
close to the carbon brushes.
4. Dry or heat air in the power house to prevent condensation (excitation, protection and
control system).
5. Check bearing oil temperatures.
6. Check bearing oil levels.
7. Check bearing vibration levels.
Note:
 Lock,tagoutandgroundgeneratorandexcitation(workpermit)first.
 Applythenecessarysafetymeasures.
8. Check brake air pressure.
9. Check alarm and trip annunciation. Solve problems, if annunciation board indicates alarms.
10. Check generator protection.

2.6 Preservation for longer Standstills

Standstill 1 (4 weeks)
Thefollowingtaskshavetobeexecuted,ifthegeneratorwillnotbeoperatedbetween
one(1)andfour(4)weeks.
1. Carbonbrushesmustberemovedfromthesliprings.Carbonbrushescancause
corrosiononthesliprings.
2. Space heaters must be in operation. Temperature inside the generator must be above the
dew point to prevent condensation.
3. Protect slip ring covering against dust and humidity. Do not use solvents for cleaning areas
close to the carbon brushes.
4. Dry or heat air in the power house to prevent condensation (excitation, protection and
control system).
Standstill 2 (over 4 weeks)
Thefollowingtaskshavetobeexecuted,ifthegeneratorwillnotbeoperatedformore
thanfour(4)weeks.
1. Carbonbrushesmustberemovedfromthesliprings.Carbonbrushescancause
corrosiononthesliprings.
2. Space heaters must be in operation. Temperature inside the generator must be above the
dew point to prevent condensation.
3. Protect slip ring covering against dust and humidity. Do not use solvents for cleaning areas
close to the carbon brushes.
4. Dry or heat air in the power house to prevent condensation (excitation, protection and
control system).
5. Check bearing oil temperatures.
6. Check bearing oil levels.
7. Check bearing vibration levels.
Note:
 Lock,tagoutandgroundgeneratorandexcitation(workpermit)first.
 Applythenecessarysafetymeasures.
8. Check brake air pressure.
9. Check alarm and trip annunciation. Solve problems, if annunciation board indicates alarms.
10. Check generator protection.

2.7 Generator settings

Thesettingvaluesforthegeneratoraredefinedinthe"Operatingtable" andthe "Alarmandtrippinglist"

and formeasuredvalues,refertothecommissioningreportofthe generator.

2.8 Operational fault

Faultscanbeofmechanicalorelectricalnature.Dependingontheirseriousness,they
actuateprotectiondevices,which can causeemergencyorrapidshutdowns,loadreductions
orsimplygivealarmsignals.
Inallcases,makesurethatthereisnooperationoftheindicatororundue
measurementandinspectthecomponent,whichcausedtheunittotriporthe
protectiondevicetooperate.
Operationalfaults(mechanical)

Element Signals Measures

Generator Generatoroveralltemperaturesabovespecified• Reduceloading

limits • Checkcoolingwaterflowrate
 • Checkair/
watercoolersfordirt

Coolingair Airtemperaturetoohigh • Reduceloading

• Checkcoolingwaterflowrate
• Checkair/
watercoolersfordirt

Coolingwater Nocoolingwaterflow • Checkvalves,filtersandpump

s
• Checkcoolingwaterflowrate

Bearingpads Temperaturetoohigh • Checkbearingoilflow

• Checkbearingoillevel

Bearingoil Temperaturetoohigh • Checkcoolingwaterflow

• Checkbearingoillevel

Lubricationpressuretoolow • Checkvalves,filtersandpump
s
• Checkcoolingwaterflowrate

High Pressuretoolow • Checkvalves,filtersandpump

pressurelubricati s
on • Checkcoolingwaterflowrate

Pressuretoohigh • Checkpressurecontrolvalve
• Checkvalveposition

Table 2. 2: Operational Faults (mechanical)

 SECTION A:

OPERATION MANUAL

CHAPTER 3

CHAPTER 3: STATIC EXCITATION SYSTEM

3.1 Introduction

The static excitation equipment converts a 3-phase alternating current into a direct current which
is used to generate the magnetic field in the synchronous machine. The excitation current can
influence the machine voltage, the reactive power and the cos φ. Furthermore, the active power
and/or the rotor displacement angle can be dynamically influenced (not stationary).

Figure 3.1:Schematic diagram of Excitation System

The excitation equipment includes two separate control loops (modes of operation).
a) Automatic mode, i.e. control of the machine voltage, including droop and/or voltage drop
compensation, plus coordinating reactive power and/or cos ϕ control. The system
specifications of the equipment indicate whether reactive-power and/or cos ϕ control is
implemented. Machine voltage control forms part of the automatic mode in each equipment.
 In the automatic channel, excitation current control is additionally foreseen as integrated
manual mode.
b) Manual mode, i.e. excitation current control as a separate unit with dedicated power supply
and separate pulse unit. The separate manual channel can be replaced with a second
automatic channel option. This then performs the same functions as automatic channel 1. A
manual channel as a pure excitation current controller then exists in each of the
twoautomatic channels.
As a precondition for activating the equipment, no (internal or external) "off" command may be
active and the signal "n>95%" (machine speed greater than 95% of the nominal speed) must be
available.
a) After the equipment has been switched on, the machine voltage set point is set at nominal
voltage. If a reactive-power / cos ϕ controller is fitted, the given reactive power is set after
the machine has been connected to the mains. The "set point up" and "set point down"
buttons can be used to change the machine voltage set point and at the same time the
reactive-power and/or cos-ϕ set point as well as the excitation current set point.
Furthermore, the following excitation limiters are available in automatic mode:
1. Under excitation limitation control
2. Excitation current limitation to surge excitation current (in most cases, 1.5 times the
nominal excitation current)
3. Excitation current limitation (to nominal excitation current, time-dependent)
4. Machine current limitation (to nominal current, time, dependent)
5. U/F limitation
6. Active-load and frequency-dependent rotor stabilization (PSS - Power System Stabilizer)
7. Voltage limitation to permissible voltage limits.
Most excitation limiters can be switched ON and OFF by option bits via the control panel of the
equipment.
8. The manual mode should only be used in emergency cases and for service or
commissioning purposes. Excitation limiters are not included in the manual mode. If the
equipment is switched on in manual mode, the current set point is 0. This means that no
excitation current flows at the beginning. A small set point is pre-set in the case of
equipment connected to the machine leads. The appropriate excitation current can then
be set using the "set point up" and "set point down" buttons. In the case of a problem in
automatic mode (described in the trouble-shooting manual) which would trigger an
emergency-off signal from the excitation equipment, the manual mode is automatically
activated. In the case of a malfunction of the manual mode, the excitation current
controller included in the automatic channel is activated. If this is also at fault, the
equipment is shut down by the "protection-off" function. If the equipment is fitted with a
2nd automatic channel (refer to system specifications), this 2nd automatic channel is
activated. If the 2nd automatic channel is also at fault, the excitation current controller
not being at fault which is included in the two automatic channels is activated.
"protection off" function is triggered if both excitation current controllers are at fault. In
order to ensure smooth switching over, the outputs of the controllers not active for the
time being are updated during operation. The operating mode can be changed manually
 even during operation. In order to enable checking whether smooth switching over is
taking place, the difference between the two controllers is displayed on the control
panel. The faults occurring in the excitation equipment are displayed on the display of the
control panel of the equipment. The message displayed includes a description of the fault
and a reference to the circuit diagram page where the fault message is generated. The
red fault LED on the cubicle door of the equipment serves as a group signal. After the
cause of the fault has been cleared, the reset button on the keypad of the excitation
equipment must be pressed. Operation of the excitation equipment is possible both via
the keypad at the equipment and/or via the control panel as well as at a central control
room. A key-operated switch on the keypad is used to decide whether the equipment is
to be controlled "locally" or "remotely". The excitation can only be switched on and off
and the set points can only be changed via the control point selected. Fault messages can
be reset via the keypad at the excitation equipment only.

3.2 Static Excitation System Technical Data

Details Technical features

Manufacturer ALSTOM

Manufacturer’s type designation SEMIPOL

Rated voltage 176.7 Volt

Ceiling voltage 318.1 Volt

Rated current 987.4 Amps

Impulse current/duration 1777.3A/10sec.

Supply voltage 267 Volt

Power consumption 6.3 KW without excitation transformer

Voltage of exciter transformer 267 Volt

Rated power of exciter transformer 404 KVA

Number of thyristor bridges 1

Capacity of one thyristor bridge 1225 Amps

Table 3. 1: Technical specification of Excitation System

3.3 Equipment Description

3.3.1 Industrial PC with touch screen

The Control unit offers all the programs & functions:

 a) Configuration & Engineering: LogiCAD configuration software, loading software for
processor cards.
b) Commissioning: Parameterization, adjusting functions, online oscilloscope
c) Operation: “Local”
mouse is moved by moving the finger, a simple
touch corresponds to a click with the left mouse
key. A quick double touch corresponds to a double
click with the left mouse key. Longer contact with
a point corresponds to a click with the right mouse
key.
Numbers and letters are entered via a touch
keyboard. This is opened automatically on entries
within the WOP-iT operating software by touching
the input fields; in the case of external programs, a
keyboard is started via MAIN MENU>EXT by
touching the “touch key board” button.

Figure 3.2: Touch screen of Excitation System

d) Monitoring: Generator diagram, actual values, cross start status, equipment status.
e) Diagnosis: Fault display with help function, signal recorder evaluation, event list, LogiCAD
online mode, remote maintenance.

3.3.2 Key switch (Pad) S111 Layout & LED description

Figure 3.3:Key switch to layout and LED description

Operation of the equipment is possible both via the key pad at the equipment or via the control
panel as well as at a control room. A key operated switch (S111) is used to decide whether
equipment is to be controlled “locally or remotely”. The excitation can only be switched ON and
OFF and the set points can be changed via the control point selected. Fault message can be reset
via the key pad at the excitation equipment only.
As a precondition for remote control of the equipment from control room, the key operated
switch on keypad S111 must be in remote (vertical) position for entering the voltage set point,
reactive power set point, etc. and also for selecting the control mode (Voltage, Reactive, etc.
control).

3.3.3 Field Circuit Breaker

The field circuit breaker in the field circuit is used to isolate the field circuit from the converter. It
is capable of switching off the synchronous machine from full load under the maximum
conditions of a 3-phase short circuit.
In addition to its main contacts, the field circuit-breaker
also has a de-excitation contact with which the field
energy stored in the field can be dissipated across the
de-excitation resistor. The de-excitation contact closes
shortly before the main contacts open so as to ensure
proper commutation of the field current from the main
contacts to the de-excitation contact when the field
breaker is switched off.

Figure 3.4:Field breaker of Excitation System

The field circuit-breaker is switched on by electromagnetic force and is kept switched on by a
mechanical latch. When the latch is released by a trip coil, the circuit-breaker is open. The circuit-
breaker also has auxiliary contacts that report its status.

3.3.4 AC Power Circuit & Thyristor Bridges

Feeding the power circuit of the equipment at the three-phase end is possible in two ways:
Supply from the medium voltage station service switchgear: The converter transformer is
connected at the primary end via the power switch to
the medium voltage supply. The converter
transformer feeds the thyristor-bridge as well as the
control transformer. The DC flows from the thyristors
via the de-excitation switch and the shunt (which
serves for measuring the controlled variable) to the
excitation winding of the synchronous machine.
Depending on the position of their firing pulses, the
thyristor supplies a continuously adjustable DC
voltage and hence a variable DC for the excitation of
the machine. The DC voltage can be continuously
adjusted between +100% and -87% with continuous DC
by adjusting the thyristor pulses.

Figure 3.5:Thyristor bridges and AC Power circuit

3.3.5 Over Voltage Protection

The DC over voltage protection consists of 2 anti-parallel

thyristors, a protective resistor connected in series with
these thyristors, as well as the thyristor protection board
(thyristor protection). Its purpose is to protect thyristors of
the three-phase bridge and the rotor against excessive over
voltages. Over voltage would occur because the thyristors of
the three bridges are unable to carry this current which
occurs in the reverse direction. When one of the two
thyristors of the over voltage protection system have fired,
the voltage drop at the protective resistor is detected by the
thyristor protection and relay is energized.
Figure 3.6:Over Voltage protection

3.3.6 Voltage Supply

The main incoming supply for DC60V and DC24V is routed via the 2.5KVA control transformers
and power supply converter (T112 & T114) for channel-1 and 2 respectively. One control
transformer feeds one automatic channel or the manual mode. By means of transformers &
power supply converter, DC24V and DC60V are supplied separately for automatic channel-1 and
automatic channel-2 or for the manual mode from the main excitation or auxiliary transformer.

3.3.7 Excitation Transformer

Dry type cast coil excitation transformers are used in static excitation system to feed excitation
power to the generator. The primary of transformer is connected to the generator bus. The
secondary of the transformer is connected to the thyristor converter which provides controlled
excitation power to the generator field.

3.3.8 Excitation Transformer overheating protection

This equipment monitors the excitation transformer for overheating in the windings that could
result from over current, short-circuits, or inadequate natural cooling.
The monitoring uses temperature monitoring modules, in conjunction
with the PTC temperature sensors built into the windings. Normally,
the temperature is monitored in two stages: the first stage sets off an
alarm (120°C), the second causes a trip of the excitation (130°C).
Temperature sensors are embedded into the cast coil to measure the
temperature of the low voltage winding in each phase. Two separate
signal systems, one for alarm and the other for trip are incorporated.
Figure 3.7:Main excitation transformer temperature monitoring screen
3.3.9 Excitation Transformer Overcurrent Protection

The overcurrent protection included in the P143 relay provides four stage
non-directional/directional three phase overcurrent protection with independent time delay
characteristics. All overcurrent and directional settings apply to three phases but are
independent for each of the two stages.

Functions Settings (50/51 O/C relay)

I>set 0.1 In

Delay type IDMT

T reset 0 ms

TMS 0.5

I>>set 1.1In

Delay type DMT

T>> set 0ms

T reset 0ms

Table 3. 2: Overcurrent protection settings

3.3.10 Fans

The thyristor cubicle is fitted with two fans which work parallel in order to cool the thyristors
bridge. The fan motors are fed via circuit breakers from the control transformers.

3.3.11 Dynamic Braking (Electrical)

In addition to normal pneumatic braking, each generator is equipped with dynamic braking. This
method of braking shall bring the machine to rest quickly during normal shut down or tripped on
quick shut down (tripping inputs related to governor, bearings, etc.).

3.3.11.1 Technical data of dynamic braking

Particular Details

Type SBIFB-114198

Ur 12kV

Up 75kV

Ir 6300A
 Ik 63000A

Fr 50

Ud 28

Table 3. 3: Technical specification of dynamic braking system

The dynamic braking system has separate transformer and stator terminal shorting cubicle. The
dynamic braking will come into action during normal shut down and quick shutdown (QSD). The
stator terminal shall be shorted at 65% of the rated speed during the normal and quick shutdown
of the generating Units.

3.4 Operation

3.4.1 Control

3.4.1.1 Conditions for switching excitation equipment “ON”:

1) No fault/error message triggering deactivation by the protection equipment may be pending

 The red LED on the cubicle door must be OFF.
 The RESET key on keypad S111 can be pressed in order to acknowledge fault/error
messages which are no longer active.
2) No “OFF” command may be active
3) No “protection off” command from the machine protection may be pending.
4) The interlocking condition "speed greater than 95…97 %" must be fulfilled as precondition
for activating the normal excitation.
 In the case of excitation equipment where the "resistive braking" or "braking via short
circuit" mode is activated, activation of the baking excitation is only possible if the
isolating switch to the braking resistors or the short circuit, respectively, is closed.
 In the case of excitation equipment working in conjunction with a starting converter, the
"starting excitation" or "braking excitation 'on'" mode can only be activated by the
controller of the active starting converter.
5) The de-excitation switch must be open.

3.4.1.2 Conditions for switching excitation “OFF”:

The following condition must be fulfilled as a precondition for switching the excitation
equipment off:
The synchronous machine may not be connected to the grid, i.e. the machine power switch must
be open.
In test mode, switching off is also possible if the power switch is closed. A "protection off" circuit
is always possible.
Protection off is possible as follows:
  By the electric machine protection
 Internal "protection off" from within the excitation equipment
 Manual protection switch S101 on the excitation equipment.

3.4.1.3 Synchronization release

A "release for synchronization" signal can be generated when the de-excitation switch is "on"
and if the machine voltage is greater than 80% of the nominal voltage.

3.4.2 Operation of the equipment from a control room (REMOTE)

As a precondition for remote control of the equipment from a control room, the key-operated
switch on keypad S111 on the equipment must be in the REMOTE (vertical) position.
If the excitation equipment communicates with a control system via a data bus, the following
functions are then exclusively available in the control room.

 Excitation ON
 Excitation OFF
 Entering the machine voltage set point in % of the nominal machine voltage if the automatic
channel is active and if neither the reactive-power controller nor the cos-ϕ- controller are
active.
 Entering the reactive-power set points directly in MVar if the reactive-power controller is
active, where a positive value corresponds to over excited and a negative value to under
excited reactive power.
 Entering the cos-ϕ set point directly as a numerical value, i.e. +0.xx….+1.0 or1…-0.0,
respectively, where the range of 0.xx…1 corresponds to overexcited and the range of –0.xx
…-1 to under excited reactive power.
 The value of +1 or –1, respectively, represents a reactive power of 0.
 Switching between manual and automatic channel or automatic 1 to automatic 2 channel,
respectively.
 Entering the excitation current set point directly in A (or %) when an excitation current
controller (manual controller) is active.
 If the excitation equipment is connected to the control room by hardware, the following
functions
 are then exclusively available in the control room.
 Excitation ON
 Excitation OFF
 Set point raise*
 Set point lower*
 Switching between manual and automatic channel or automatic 1 to automatic 2channel,
respectively.
* The set points for machine voltage, reactive power or cos ϕand excitation current are variedwith
the set gradients. The changed set point of the control loop which is active for the timebeing comes
into effect. The other set points are readjusted a) as lower-level controllers(voltage set point with
reactive-power and/or cos-ϕcontrol) or b) by the set pointreadjustment functions of the manual
and/or automatic channels (voltage set point withmanual mode, excitation current set point with
automatic mode).
The permissible limits of machine voltage, reactive power or cos ϕand excitation current, as
wellas their gradients, are determined during commissioning, but can also be changed at a
laterstage.If the key-operated switch is not in the REMOTE positions, these functions are not
available in the control room.

3.4.3 Using keypad S111

3.4.3.1 Key layout

Figure 3.8:Key layout of Excitation Touch Panel

3.4.3.2 LED layout

LED Description

S1 ON Fault in channel 1

S2 ON Fault in channel 2

S3 Not used

S4 Not used

S5 ON & S7 ON Manual channel 1 active

S5 ON & S7 OFF Automatic channel 1 active

S6 ON & S7 ON Manual channel 2 active

S6 ON & S7 OFF Automatic channel 2 active

 SECTION A:

OPERATION MANUAL

CHAPTER 4

S8 Simulation active

I (green) ON Excitation is “on”

I (green) Field switch is “on”

flashing

O (red) ON Excitation is “off”

Table 3. 4: LED layout of Excitation Touch Panel

3.4.4 Manual Mode

The manual mode serves as emergency mode and for service or commissioning purposes.
It consists of a pure excitation current control function. Excitation limiters are not included in the
manual mode.
When the equipment is switched on in manual mode, the current set point is 0. This means that
no excitation current is initially flowing.
In the case of excitation equipment receiving is power supply from the machine leads, a small set
point is pre-set at the time of switching on.
The excitation current set point can be adjusted both in the control room and on the excitation
equipment.
If the excitation equipment is connected to the control room by hardware, the "set point raise"
or "set point lower" buttons in the control room can be used in order to set the desired
excitation current. If the excitation equipment communicates with the control room via a control
bus, the excitation current value can be entered directly as an Ampere (or %) value.
The key-operated switch on keypad S111 must be in the Remote position for this purpose. If the
key-operated switch on keypad –S111 is in the Local position, the excitation current set point can
only be varied by pressing the "set point raise" and "set point lower" buttons on keypad –S111.

CHAPTER4: TURBINE& AUXILIARIES

4.1 Introduction
The Dagachhu hydro power plant is equipped with two vertical Pelton type turbines and the
associated governing equipment and main inlet valves.
The rotating parts of the turbine are equipped by one guide bearing which is located close to the
turbine runner. The thrust bearing is located in the generator. The water will enter the turbine
through the main inlet valve, followed by the distributor where the flow will be diverted and
guided to the six nozzles. The nozzles are fixed on the distribution pipe inside the turbine
housing. The flow and therefore discharge will be controlled by the opening of the nozzle. Each
nozzle is equipped with a separate servomotor and a deflector incl. deflector servomotor. The
water jet then will impact on the sophisticatedly designed Pelton runner buckets to ensure the
highest efficiency possible. The water is then guided by the water passage shield and the turbine
housing to the tailrace channel and exits the powerhouse.

4.2Technical data

Type : Vertical Pelton

Number : 2 Nos.

Capacity : 62.222 MW

Nominal speed : 272.7 rpm

Runaway speed : 505 rpm

Rated net head : 282 m

Rated discharge : 25 m3/sec

Centreline turbine runner : 537 m.a.s.l

Direction of Rotation : Clockwise

Diameter of Inlet Valve : 2100 mm

Stilling chamber :5mx4m

Runner diameter (D1) : 2450 mm

Runner bucket height (B2) : 806 mm

Number of Nozzles :6

Operating oil pressure : 60 bar

Nozzle stroke : 268 mm

4.3 Description

4.3.1 Turbine Assembly

The Dagachhu hydro power plant is equipped with two vertical Pelton type turbines and the
associated governing equipment and main inlet valves. The rotating parts of the turbine are
equipped by one guide bearing which is located close to the turbine runner. The thrust bearing is
located in the generator.

The water will enter the turbine through the main inlet valve, followed by the distributor where
the flow will be diverted and guided to the six nozzles. The nozzles are fixed on the distribution
pipe inside the turbine housing. The flow and therefore discharge will be controlled by the
opening of the nozzle. Each nozzle is equipped with a separate servomotor and a deflector
including deflector servomotor. The water jet then will impact on the sophisticatedly designed
Pelton runner buckets to ensure the highest efficiency possible. The water is then guided by the
water passage shield and the turbine housing to the tailrace channel and exits the powerhouse.

4.3.1.1 Main Components of Turbine

Item Components Item Components

1150 Runner 2400 Nozzle

1200 Shaft 2900 Water Passage shield

1400 Turbine Guide Bearing 4600 Cooling water system

2100 Distributor 8400 Inspection Platform

2300 Turbine housing

Table 4. 1: Main Components of Turbine

4.3.2 Pelton Runner

The fully forged runner is made of X3CrNiMo13-4 stainless steel (1.4317) and equipped with
twenty (20) buckets.

The connection of the runner to the turbine shaft is done with fourteen (14) pre-stressed
coupling bolts.

The finished machined runner is statically balanced in order to ensure good, low-vibration
operating conditions. The weight of the finished runner is approximately 14875 kg.

4.3.3 Turbine Shaft

Nominal shaft diameter: 700 mm, total length 5974,8 mm Weight: 19.956 kg

Forged of material C35E with integrally forged flanges for coupling to runner on the downstream
end and to generator on the upstream end.

The entire shaft is machine bored hollow to provide operating space for the runner lifting device.

Handling:
Always use rubber or other protection material when slinging the turbine shaft. Never provide
supports directly to the guide bearing area of the shaft, supporting only shall be done in the
areas near to the flanges.

For NDT Testing of transition to flange there is no painting applied in this area. NDT Testing shall
be applied for crack detection at every change or replacement of the runner Coupling of shaft to
runner and turbine shat to generator shaft is made of friction type (Ekagrip Foils 1205) with pre-
stressed coupling bolts.

Please mind at installation: The “high”-point of the plane surface of the flange shall be coupled to
the “low”-point of the counter flange of the generator shaft.

4.3.4 Overspeed Pendulum

The hydraulic/mechanical overspeed pendulum is a safety device that activates a shutdown

independently of the electronic governor in the event of impermissible overspeed.

Nominal Speed : 272.7 rpm

Releasing Speed : 386 rpm

Figure 4.2:Overspeed Pendulum (symbolic illustration)

Item Component Item Component Item Component

1290 Console 8102 3/2-way valve (spring - 8114 Lock
actuated)
8100- Limit switch 1261 Casing 1263 Handle
33
8140 Casing 1270 Clamping plate 1275 Holder
1200 Turbine shaft 8100- Reset handle
32
Table 4. 2: Components of Overspeed pendulum

Normal operation:
In normal operation, the parts mounted on the turbine shaft (brackets 1261, handle 1263,
clamping plate 1270, holder 1275) rotate. The casing (8140) for the lock (8114) and the 3/2-way
valve (8102) remain stationary.

The gap ("S") between the handle (1263) and the lock (8114) was set during installation work.

Overspeed:

If the turbine speed is increasing, greater centrifugal force acts on the weight of the handle
(1263), the handle (1263) starts to swing out.

At the defined activating speed, the handle (1263) strikes the lock (8114).The lock (8114) changes
its position and unlocks the shaft of the springoperated3/2-way valve (8102). The limit switches
(8100-33) are activatedand change their signal status.

The turbine is shut down via the 3/2-way valve and the hydraulic governor.The limit switches
report the shutdown to the control system.

Reset:

If the turbine speed is decreasing, the centrifugal forces acting on thehandle (1263) weight also
decrease. If the pendulum has sufficient springforce, the handle (1263) returns to its starting
position.

The static part of the pendulum is not reset automatically, but must bereturned to the correct
position by means of the reset handle (8100-32).

4.3.5 Speed sensing device

For controlling the turbine three non-contact speed sensors (3950-1) are placed on the top of the
turbine bearing. A pole band (3950-2) fixed on the turbine shaft generates the signals.

Figure 4.3:Speed sensing device

4.3.6 Turbine Guide Bearing

The turbine guide bearing is of type radial segment bearing.

Nominal bearing diameter : 1000 mm

Bearing length : 300 mm
Number of segments :6
The bearing segments are adjustable and removeable, they are lined withBabbit material
SnSb12Cu6Pb, a high-grade anti-friction metal, 3 mm thickness. The bearing is designed for auto
oil lubrication with stationary oilreservoir and will permit axial movement of the shaft.

The bearing support is part of the turbine casing and designed to transmitthe load due to the side
thrust of the runner to the turbine housing.The bearing is equipped with connections to an
external water/oil heatfor cooling of the bearing oil.The bearing is equipped with resistance
temperature detectors in the oil aswell as in the bearing segments.

To prevent an overflow of the oil due to vacuum in the area between theguide bearing cover and
the guide bearing casing this area isventilated. The labyrinth ring housing is ventilated via a filter,
too.

Figure 4.4:Turbine Guide Bearing

Installation:

Remarks on Installation are as follows:

 Install all pads to zero and adjust then back to nominal gap of 0,4 - 0,45mm. The exact gap
shall be decided at commissioning and may be reduced if considered necessary.
 The adjustment of the oil flow through the bearing can be done by number of holes in the
turbine
 Watch the temperature: if temperature changes, the oil system shall be checked.
 Removing of the oil shall be done by a small pump from above via the cover. The plug (Pos.
23) in the inner housing shall be used for draining completely.

Attention:

Runaway speed: After any case of full runaway speed the bearing must be checked for
soundness. The bearing pads shall be inspected visually.
 Attention:

Re-installation:Do not interchange the bearing pads at re-installations, always install

thepads as done initially at first erection. Proper parking is recommended.

4.3.7 Distributor

The distributor pipe is made of fabricated steel construction and is completely embedded in the
concrete. It is designed to withstand the maximum internal pressure with the steel shell only.

The distributor will be supplied to site in suitable pieces for transportation and fit together by
welding at site.

The embedding in the concrete shall be directly without use of any compressible wrapping, the
distributor shall be closed with test heads and pressure of 50% of the design pressure shall be
applied during embedding/ concreting.

The distributor contains block-flanges on bottom for draining and on top for aeration.

4.3.8 Turbine Housing and water passage shield

The turbine housing, made of carbon steel, is supplied to site in single pieces as practicable for
handling and shipment, installed and welded at site and for complete embedding in concrete.

The turbine casing consists of:

 6 nos. of side walls

 the watertight access door and
 the roof parts with supporting beams.

4.3.9 Nozzle and Deflector

Each of the turbines is equipped with six (6) nozzles (or jets). The nozzlesare of straight flow type
with internal servomotor. The alignment of thenozzles is made at the initial installation and can
be realized by anadjustment flange for each nozzle.

The entire nozzle is completely removable from the distributor flange formaintenance.The
needle tips and the set rings are made of stainless steel. The needletips and seal rings are
removable.The nozzles are mechanically protected against splashing water by theprotection
roof.

The nozzle servomotor is a double acting cylinder balanced by a compression spring in order to
have a small work capacity of the hydraulic governor.

If no oil pressure is applied at closing or opening connection, the nozzle remains in a middle
position. Hence for filling the distributor with water, oil pressure has to be applied at the closing
connection.
Figure 4.5: Nozzle

The jet deflectors are made of massive cast material GX4CrNi13-4 and are acted by hydraulic
servomotors to deflect the jet from the runner for emergency close down.

The servomotors for the deflectors are single acting cylinders, operated by oil pressure for
opening, but closed by spring action.

Deflectors:

The jet deflectors are made of massive cast material GX4CrNi13-4 and are acted by hydraulic
servomotors to deflect the jet from the runner for emergency close down.

The servomotors for the deflectors are single acting cylinders, operated by oil pressure for
opening, but closed by spring action.

Figure 4.6:Deflector
4.3.10 Brakejet and Piping

To enable a quick standstill of the generating sets in case of a generator brake failure, in
particular to avoid turning of the generating set in the mixed friction range of the generator
bearings, the turbines are equipped with brake nozzles.

Figure 4.7: Brakejet

4.4 Operation

Please find here below some general remarks for start-up of the turbine. The main components
of Turbine are given below:

4.4.1 Checks before start-up

The automatic control system ensures that the turbine cannot be started before all requirements
for the start-up will be met. When all requirements for the start-up are met, clearance for start-up
is given.

4.4.2 Start-up of the turbine

The turbine has to be started according to the sequence of the control operations diagram (see
Unit start sequence 15.7.3.11 and Unit Turbine 15.7.3.14). The start-up command signal has to be
only accepted, when all requirements are met.
4.4.3 Checks during operation

Whenever a malfunction is indicated, the cause therefore must be detected and corrected
immediately. Inspection must be carried out during operation of the Generating Units and it is
given in table 3.1 of Maintenance Manual.

4.4.4 Shutdown of the turbine

The turbine is to shut down according to the sequence of control operation diagram (see Unit
stop sequence 15.7.3.12)

4.4.5 Filling the turbine

Before start of the turbine the filling is done according to the sequence of the control operations
diagram (see Unit start sequence 15.7.3.11)

4.4.6 Draining the turbine

Draining of the distributor is done according to the sequence of the control operations diagram
(see stop sequence 15.7.3.12)

4.4.7 Limits of operation

The operating range of the turbine is limited by the opening range of the nozzle programmed in
the governor. The operation personnel have to be instructed not to operate the turbine outside
the recommended limits. The operator is requested to record the relevant parameters, such as
power, head, downstream level and operating hours for the duration of the warranty period. The
supplier shall be allowed the opportunity to check these.
The turbine efficiency curve is given in Figure 4.8.
Figure 4.8:Turbine Efficiency Curve
 SECTION A:

OPERATION MANUAL CHAPTER 5: MAIN INLET VALVE&

CHAPTER 5 AUXILIARIES

5.1 Introduction

Dagachhu Hydro Power Plant has two generating Units and each of the Pelton turbines of the is
equipped with one separate main inlet valve (MIV). The inlet valves are of the spherical valve type
and operate as conventional turbine inlet valves. The inlet valve is used for shut-off the water
flow during normal stop of the turbines. In case of an emergency it will work as a safety shut-off
valve.
The opening and closing of the valve rotor (2100) is done by oil pressure. It opens and closes by
means of 2 servomotors (4200) with oil pressure supplied by the hydraulic power unit (please
refer to operation and maintenance manual of hydraulic governor).Prior to the opening of the
valve rotor, an equalization of the pressure in the inlet pipe - upstream (8100) and the
downstream pipe (8300) is established by the by-pass line (5400).
Furthermore, the moveable seal rings (1400) must be opened prior to the opening of the valve
rotor. The opening and closing of the moveable seal rings is done by water pressure supplied
from the penstock. The valve body is bolted to the upstream pipe (8100) which is site welded to
the penstock.
For the disassembly of the butterfly valve, the connection between the downstream pipe (8300)
and the turbine distribution pipe is designed as a dismantling joint (8200) with a moveable
compensating flange.

5.2 Main Components of Main Inlet Valve

Figure 5.1:Spherical valve (Main Inlet Valve) with item number

Item Component Item Component

0001-1 Air Discharge valve 1200 Locking device

4200 Servomotor 6100 Limit switch arrangement

8200 Dismantling flange 1101 Valve body

2100 Valve rotor 5300 Bypass needle valve

6400 Position indicator 8300 Downstream pipe

1180 Bypass DN25 4100 Operator

5400 Bypass line 8100 Upstream pipe

Table 5. 1: Components of Main Inlet Valve

5.3 Operation

5.3.1 Filling the spherical valve and bypass line

Preconditions:

 Make sure that the waterway (penstock, turbine, draft tube and tailrace cannel) is clean
and free of anything that could damage the inlet valve or the turbine. An inspection
report has to be issued.
 Complete all commissioning dry tests and record the results.
 Manhole in downstream pipe must be closed.
  Water control system and hydraulic governor ready for operation.
Filling:

Step Activity

1 Closing of the operation seal

2 Closing of the dewatering valve of the spherical valve

3 Manual de-locking of the maintenance seal locking device (1200). All five (5) locking
screws have to be opened.

4 Manual opening of the gate valve of the bypass line

5 Opening of the de-aeration valve on top of the spherical valve

6 Check if the bypass needle valve is in closed position (position indicator)

7 Manual opening of the ball valves of the small by-pass line DN25

8 Closing of the de-aeration valve

9 Manual opening of the maintenance seal

10 Manual closing of the ball valves of the small by-pass lineDN25

11 After filling of the spherical valve and the bypass line all connections (valves etc.) have
to be checked for tightness (visual check).

12 Removal of the mechanical locking of the servomotors

5.3.2 Filling of Distributor

Preconditions:
Spherical valve filled according section 5.3.1.
Filling:

Step Activity

1 Opening of the bypass needle valve

2 Activation of the differential pressure measurement; pressure balance between

upstream and downstream side of the MIV are opening condition for the operating
seal.

3 Opening of the operating seal.

5.3.3 Manual closing of the spherical valve

The following procedure describes the manual closing of the spherical valve for filling of the
penstock.

Step Activity

1 Closing of the valve rotor

2 Closing of the maintenance seal

3 Closing of the operating seal

4 Closing of all gate valves on the upstream side of the MIV

5 Closing of the bypass needle valve

6 Activation of the mechanical locking device of the maintenance seal (5x)

7 Activation of the mechanical locking device of the servomotors

5.3.4 Decommissioning for maintenance / revision

Precondition:

 Standstill of the turbine

Decommissioning:

Step Activity

1 100% Dewatering of the distributor

2 Closing of the maintenance seal

3 Mechanical locking of the maintenance seal

4 Mechanical locking of the servomotors

5 Dewatering of the spherical valve (dewatering valve to be kept in open position)

6 Opening of the operating seal and fixing in open position

7 Opening of manhole in the downstream pipe if necessary

Information:
Closing of the maintenance seal
Closing of the maintenance seal can be done whether by use of the hydraulic governor or by use of
the mechanical locking device. Prior closing of the maintenance seal.
 SECTION A:

OPERATION MANUAL Caution:

CHAPTER 6 Closing of the maintenance seal

Prior to closing of the maintenance seal the moveable seal ring
chambershall be flushed to prevent damages to the moveable seal
ring due to dirtor sediments.
Caution:
Mechanical locking device
When using the maintenance seal locking device for closing of the maintenance seal, take care that
all five (5) locking devices are screwed in equally to prevent inclination of the moveable seal ring.

CHAPTER6:GOVERNING SYSTEM

6.1 Hydraulic Governor

The hydraulic governor essentially performs the following functions:

 Oil storage in the sump tank for governing functions.

 Pressurizing of the pressure vessel with operating oil by means of governor oil pumps (axial
piston type) MEX11AP001 and MEX12AP001 with squirrel cage motors MEX11AP001-M01 and
MEX12AP001-M01.
 Opening and closing of the nozzles (Nx) by means of nozzle servomotors via main control
valves MEX21..26 AA020-B01. The throttle valves for Nx servomotor opening and closing time
adjustment MEX21..26 AA701 to MEX21..26 AA702 are installed (same as the control valves)
inside the turbine pit. Opening and closing of the deflectors (DEx) by means of deflector
servomotors via main control valves MEX31..36 AA020 / MEX31..36 AA010- B01. The cartridge
valves for DEx servomotor opening time adjustment MEX31..36 AA011are installed (same as
the control valves) inside the turbine pit.
 Start-up, shut-down and shut-down in case of a mechanical / hydraulically or electrical fault
via shut-down valves MEX51AA001, MEX51AA002-Y01 and MEX51AA003-Y01.
 Shut off the main oil supply to the hydraulic governor in case of standstill via cartridge valve
MEX16AA001, pilot operated via MEX16AA002-Y01.
 Opening and closing of the Inlet Valve (IVx) by means of inlet valve servomotors via control
valve MEX52 AA001, pilot operated by MEX52AA002-Y01. IVx servomotor opening/closing
time adjustment with throttle check valves MEX52AA701 and MEX52 AA702.
 Opening and closing of the Bypass Valve (BPx) by means of bypass valve servomotor via
solenoid valve MEX50AA001-Y01-Y02.

6.1.2 Technical Data:

Turbine Hydraulic Governor-No.: : DAG09-GOV-1000

Type : RWP6D 2711

Max. Capacity : 2711 kNm at 61 bar

Year of Manufacture: : 2011

Number of new Units :2

Nominal Size of Sump Tank : 5500 l

Max. Operating Pressure : 60 bar

Oil Pump Capacity : 2 x 200 l/min

Oil Pump Motor Capacity : 2 x 30 kW

Power Supply for Motors : 3 x 400 V, 50 Hz

Power Supply for Solenoid Valves : 110 VDC

Hydraulic Oil Type : HLP - ISO VG46

Nominal Size of Nozzle Control Valve : 6x NG 10

(Proportional Valve)

Nominal Size of Deflector Control Valve : 6x NG 16

(Proportional Valve)

Max. Valve Capacity Nozzle Control Valve : 40 l/min

Max. Valve Capacity Deflector Control Valve : 200 l/min

Command Signal for Proportional Valves : 4 – 20 mA

Pressure Vessel-No.: : DAG09-GOV-2400

Nominal Size of Pressure Vessel : 4200 l

Type of Digital Governor : TC 1703

Table 6. 1: Technical specifications of Hydraulic Governor

6.1.3 Hydraulic Governor Components

The Hydraulic Governor system mainly consists of the following components:

 Turbine hydraulic governor and

 Pressure Vessel

6.1.4 Operation

6.1.4.1 Checks to be made before the Start-up

The automatic control system ensures that the turbine cannot be started before all requirements
for the start-up will be met and only if all preconditions for start-up are fulfilled the clearance for
start-up is given.
Prior to each turbine start the below stated items have to be considered and it has to be made
sure that the following functions are performed and the corresponding devices are in operating
position on the hydraulic governor.

These functions are:

 All power supplies okay

 No alarms existing
 All control and selector switches in “AUTO”-position
 All pre-start conditions performed (please refer to plant control system)
 All (isolating) valves for pressure and control supply open
 Normal operating pressure of the hydraulic system available (60 bar)
 All auxiliaries (e.g. for turbine etc.) in operating condition

6.1.4.2 Start-up of the Turbine

The turbine has to be started according to the sequence of the control operations diagram (See
separate operation and maintenance manuals of control system).
The start-up command signal has to be only accepted when all pre-start conditions are met.
The start-up sequence on the hydraulic governor is as follows:

 Energize one unloader valve MEX11/12AA001-Y01 and start corresponding governor oil
pump MEX11/12AP001-M01, de-energize unloader valve after motor reaches nominal
speed
 start oil circulation pump MEX14AP001-M01
 Pilot valve for hydraulic stop valve MEX16AA002-Y01 solenoid needs to be de-energized.
In this position the control oil for this valve is released to the tank and the main oil supply
valve MEX16AA001 will open by hydraulic force and pressure oil is supplied to the main
 circuit of the hydraulic actuator. Position switch MEX16AA001–S01 will indicate that the
main oil supply valve is opened.
 Shutdown valve MEX51AA002-Y01 and start/stop valve MEX51AA003-Y01 solenoids needs
to be energized. In this position the control pressure oil from the pressure tank brings the
hydraulic operated failsafe block of main inlet valve MEX70AA001 into operating position
and furthermore the pilot valve MEX52AA002-Y01 is supplied with control oil and main
control valve for inlet valve MEX52AA001 is ready for operation. In addition, the failsafe
blocks MEX41…46AA011 and the pilot operated check valves MEX31…36AA701of the
deflector control valves MEX31…36AA010-B01 / MEX31…36AA020 and the pilot operated
check valves MEX21…26AA710/AA711of the nozzle control valves MEX21…26AA020-
B01are brought to operation position (main control valves for deflectors and nozzles
ready for operation). This action is monitored by pressure switch MEX51CP001-S01.
 Start-up of the turbine unit, by means of opening the main inlet valve by energizing the
pilot valve MEX52AA002-Y01 (command signal from unit control). If the main inlet valve is
open the deflector and nozzle servomotors operation is done by signals of the digital
governor to the pilot/main valves MEX21…26AA020-B01 and MEX31…36AA010-B01, to
bring the unit to nominal speed. When the unit is synchronized, opening and closing
signals from the digital governor will load or de-load the unit.

6.1.4.3 Shutdown of the Turbine

The turbine has to be stopped according to the sequence of the control operations diagram.
The stop-sequence on the hydraulic governor is as follows:

 De-loading of the unit, main circuit breaker – “OFF” and main inlet valve closed (auto
program sequence).
 When the unit is in shut-down condition the shutdown valve MEX51AA002-Y01 and start-
stop valve MEX51AA003-Y01 needs to be de-energized. Spring load of these valves forces
the control pistons to the “STOP”-position and as a consequence the pressure at the port
of the hydraulic operated failsafe plates MEX70AA001 and MEX41…46AA011 will be
released. The released pressure at the failsafe plates will hydraulically force the control
piston of main control valves MEX52AA001, MEX21…26AA020-B01 and MEX31…36AA020
to the fully closed position. That means that closing pressure is applied to the main inlet
valve servomotors, the deflector and nozzle servomotors.
 When the nozzles are fully closed, and it is assured that water flow from the penstock to
the turbine is interrupted solenoid valve MEX16AA002-Y01 needs to be energized. Oil
pressure will move the piston of main oil supply valve MEX16AA001 to closed position and
main oil supply from the pressure tank is closed.
 Stop governor oil pumps MEX11/12AP001 and oil circulation pump MEX14AP001-M01
The description of the overall START-STOP sequence can be found in the operating and
maintenance manuals of control system.

6.2 Digital Governor

6.2.1Operation (Functionality of Touch Panel)

6.2.1.1 Display Overview

Figure 6.1:Display (touch screen) overview

The fundamental structure of the touch panel for thePelton turbine is structured into the
following parts:
Header (1)
Here, besides the current display title, the data and timeof the system is also displayed.
At the left side of time and date some additional itemswill be displayed:

 automatically or manual operation

 local or remote operation
 island detection (internal or external)
 turbine in limited state
 current active controller (POC- Power Controller, LEC - Level Controller, OPC- Opening
Controller, SPC –Speed Controller, FLC-Flow Controller)
Main window (2)
Here the respective operating- and monitoring windowsare superimposed.
Navigation menu (3)
The display navigation is carried out using the buttonsof this menu. There is a navigation menu
foreachdisplay that displays all pictures that can be called fromthis display.This Touch-Panel
program contains five display levels,of which one, the lowest level in the hierarchy, can onlybe
reached via the supplementary menu.
Some navigation menus are structured in three pagesin order to accommodate the large number
of detaileddisplays.
Main menu buttons:

-Main overview display

- Back to last open display

- Next Page

- Previous page

Supplementary menu (5):

The additional images can be opened using the buttons of this menu. This supplementary menu is
available in this form in all displays, with the exception of the supplementary displays themselves.
Supplementary menu buttons:
- System control
-Trend diagram
- Overview of measured values
- quit isolated network operation
- quit horn
- Alarm Signal List
- Chronologic Event List
-And
- Changes to the opening limiter at any time
6.2.1.2 Display Controller Overview

Figure 6.2:Display Controller Overview

This controller overview display combines the mostimportant values of the machine and the
associatedcontroller in one single Figure. In this main window,the controller operating mode can
be switched over toanother one. To do so, actuate the respectivecontroller buttons (1,
2).Activation of the levelcontroller is only possible from the control system.
The speed controller cannot be activated explicitly, asit is activated automatically depending on
theoperating state of the machine. The pertinentcontroller set-points can be increased or
lowered, asnecessary, by actuating the buttons (+) and (-) (3 and4 or 5 and 6). The set-points are
moved in the desireddirection as long as the respective button is keptactuated. The pertinent
readjustment gradients can beadapted on the associated detailed controller displays.
In addition, this display indicates the most importantmachine data. The state of the needles is
also shownon this display(9).
In standstill, you can activate the bearing heat runmode by pressing the button(7). In this mode,
youhave to ramp up the OPL manually after governor isgetting the start command.
So, you can start up theunit slowly from standstill to speed 100%.
If f-net following (8) is activated, governor will blockthe raise or lower commands of the
synchronizer. Thespeed setpoint during synchronizing will be the gridfrequency.
From this display, you can open all detailed controllerdisplays and the feedback sensor calibration
as wellas the commissioning display via the navigationmenu. The selection buttons for the two
latter displaysare on the third page of the menu.
- Next Page

6.2.1.3 Display Level Controller

Figure 6.3:Display Level Controller

This detailed controller display constitutes the blockdiagram of the level controller. Besides the
level setpoint(1), important parameters of this controller canalso be modified here. They include
the gradient forthe readjustment of the level set-point (2) as well asthe controller parameters K P
and TN (3 and 4).
6.2.1.4 Display Flow Controller

Figure 6.4:Display Flow Controller

This detailed controller display constitutes the block diagram of the flow controller. Besides the
flow set-point (1 and 2), important parameters of this controller can also be modified here. They
include the gradient (3) for the readjustment of the flow set-point by using the (+) and (-) buttons
(4), the gradient for the external flow set-point value (5) as well as the frequency flow droop (6).
6.2.1.5 Display Power Controller

Figure 6.5:Display Power Controller

This detailed controller display constitutes the block diagram of the power controller. Besides the
power set-point (1), important parameters of this controller can also be modified here. They
include the gradient (2) for the readjustment of the power set-point by using the (+) and (-)
buttons (3), the gradient for the external power set-point (4), the frequency power droop (5), as
well as the controller parameters KP and TN (6 and 7).
6.2.1.6 Display Speed Controller

Figure 6.6:Display Speed Controller

This detailed controller display constitutes the block diagram of the speed controller. Contrary to
the other controllers, various set-point values can be defined and modified here as a function of
current operating state. The same applies to the controller parameters K P and TN (1 and 2). The
controller parameter TD (3) does not depend on the respective operating state. Furthermore, the
gradient (4) for the readjustment of the speed set-point by using the (+) and (-) buttons (5) as
well as the permanent speed droop (6) can be altered here.
6.2.1.7 Display Opening Limiter

Figure 6.7:Display Opening Limiter

This detailed display constitutes the block diagram of the opening limit. Besides the actual
limitation (1) the associated gradient for the readjustment of this limit value (2) can be altered
here. This gradient be effective only in the case of abrupt changes of the opening limitation. The
opening set-point corresponds to the set-point of the positioning circuits described hereafter.
6.2.1.8 Display Positioning Circuit Deflector

Figure 6.8:Display Positioning Circuit Deflector

This display represents the block diagram of the positioning circuit for the deflector. In this
display, not only the controller parameters K P and TD(1 and 2) can be set, also switchover to a
manual set-point for the positioning can be carried out (3). This manual set-point can be specified
individually (4).
6.2.1.9 Display Positioning Circuit Needle

Figure 6.9: Display Positioning Circuit Needle

This display represents the block diagram of the positioning circuit for the needles. This display
exists a total of six times in the visualization, according to the number of needles. All displays
have the same construction, for example purposes the positioning circuit for needle 1 is
presented here. In this display as well, not only the controller parameter K P (1) can be set, also
switchover to a manual set-point for the positioning can be carried out (2). This manual set-point
can be specified individually here too (3).
6.2.1.10 Display Needle Selection

Figure 6.10:Display Needle Selection

This display is used for manual selection of the priority of needles (1). The status of each
individual needle is shown (2).
6.2.1.11 Display Feedback Calibration

Figure 6.11:Display Feedback Calibration

This display is intended for use by commissioning staff only. This is where one can calibrate the
feedback sensors of the deflector servomotors and the needle servomotors. To do so, first select
the feedback sensor to be calibrated by activating the appropriate switch (1). Then, set the
desired lower and upper limits (2 and 3). With the help of the deflection (4) the opening or
closing velocity can be influenced. Now, use the (+) and (-) buttons (5 and 6) to move the
servomotor all the way to the desired end position. As soon as the servomotor has reached the
desired end position, actuate the appropriate “save” button (7 or 8) to adjust the set-point to the
actual position (9). The successful saving process is confirmed by an indication (see 7 and 8).
6.2.1.12 Display Special Functions

Figure 6.12:Display Special Functions

Just like the preceding one, this display is also intended for use by commissioning staff only. It
can be used to adapt not only the offsets for the headwater level (1) and the head (2) and the
gradients for the external set-point values (3) but also the limits for isolated network detection
(4) and the upper limit for the speed set-point (5). The same applies for the gradient for smooth
needle shifting (6). In addition, a manual value for the head can be defined (7), and the over-
speed test can be activated on (8).
6.2.1.13 Display Trend Diagram

Figure 6.13:Display Trend Diagram

This diagram shows the chronological progress of the most important analogue values of the
machine. They are the same analogue values that are also indicated on the main overview display.
The legend pertaining to the curves including the measuring ranges and the curve colours is
disposed above the diagram. In addition to the known buttons, the supplementary menu
contains a close button. Using this button, the user can close the trend diagram, and the
display from where the trend diagram was called up will be opened again.
6.2.1.14 Display System Control

Figure 6.14:Display System Control

This picture has an only main menu with additional functions.
With the -button one can log-on to the system. This is carried out by means of the
following dialog:

Figure 6.15:Picture Login

The input of the data is carried out using the virtualkeypad on the Touch-Panel. After entering the
username and the associated password, correspondinglyprotected function calls or operator
inputs can also becarried out. If the current authorizations for a particularfunction call or a
particular operator input areinsufficient, then with its selection the same logindialog is called up.
Button operation
-log-on/off from the system
- terminate visualization (SAT250 runtime) program
- close system control and open the window which was opened before

6.2.1.15 Display Alarm Signal List

Figure 6.16:Display Alarm Signal List

With this display it has to do with the Alarm SignalList. In the list window all alarms (red),
warnings(yellow) and trips (light blue) are listed in thecorresponding colour and with the
associatedidentifier, the long text, the state, the time ofoccurrence, the time of
acknowledgement and thetime of going.Besides the familiar -button
thesupplementary menu contains a -button, withwhich the Alarm Signal List can be closed
and thatdisplay opened from where one called up the AlarmSignal List.
6.2.1.16 Display Chronological Event List

Figure 6.17:Display Chronological Event List

With this display it has to do with the ChronologicEvent-List. Here in the list window, besides all
alarms(red), warnings (yellow) and trips (light blue), allbinary information (green) as well as set-
point valuechanges and other operator inputs (dark blue) arealso listed. As with the Alarm Signal
List the listing iscarried out in the corresponding colour together withthe associated identifier,
the long text, the state and the time of the occurrence.
Besides the familiar -button thesupplementary menu contains a - button,
withwhich the Chronologic Event List can be closed andthat display activated from where one
called up theChronological Event List.
 SECTION A:

OPERATION MANUAL CHAPTER7: GENERATOR STEP-UP

CHAPTER 7 TRANSFORMERS

7.1 Introduction

General:
Each generating unit are provided with three single phase transformers. The transformer is
connected between 220/√3 kV and 11 kV system, which is effectively earthed, and is suitable for bi-
directional power flow. The transformer is rated for 24MVA under OFWF cooling respectively.
Core and Winding:
The magnetic circuit is of three limb Step-Lap construction, each limb bearing mitered jointed
with the top and bottom yokes. The laminations are made of high grade, non-ageing cold rolled
grain oriented steel. The limbs and yoke laminations are firmly clamped together by Green belts
along with the yoke clamps.
The winding is arranged on the core limbs in a concentric manner. For mechanical rigidity under
short circuit, the winding has been wound on a rigid cylinder made of pre-compressed
pressboard. The HV winding is placed over the LV winding and HVT winding is placed over HV
winding after placement of adequate insulation. The 220/√3 kV line lead emerges from the center
of HV winding stack. The HV windings are wound by adopting intershielded disc type of winding
which gives excellent voltage gradation under impulse. Oil ducts are so arranged to provide a
maximum circulation of oil to each and every part if the winding and therefore eliminates
occurrence of any “hot-spot”.
Core and Windings together with the insulation are dried and processed under vacuum. Windings
are sized to the correct dimension and are firmly clamped under pressure.
Off circuit tap changer:
The Off-load tap changer is also provided on HV neutral side for variation of voltage from
+2x2.5%to -1x2.5% in 4equal steps. The tapping arrangement is linear type

7.2 Technical Data

Make M/s Areva, India

Continuous Rating 24 MVA (Single phase)

Voltage HV /LV 220/√3 /11 Kv

No of phases 1

Current at rated load and voltage on principal tap

HV 188.72Amps
LV 2181.82 Amps

Frequency 50Hz

Connections
HV winding STAR
LV winding DELTA
Vector group -3 phase Ynd5

Tap changing equipment Off load tap changer on (OLTC)

Tapping range +2x2.5% to-1x2.5%

No of steps 4
Type of tap changing switch Off circuit

Temperature rise on rated load

Oil 60° C
Winding 65° C
Limit of hotspot 98 C

Type of cooling OFWF

Maximum efficiency

Load at which maximum efficiency occurs

Transformer impedance 12±7.5%

Insulating and cooling medium Oil

Governing standard of insulation oil IS 335

No load losses at rated voltage and frequency

Principal taps 25KW
no load losses at the voltage corresponding to
the highest tap
25KW

Total losses at normal ratio 85.5KW

Type of winding Helical

Table 7. 1: Technical specification of Generator Step-Up Transformer

7.3 Operation

After the inspection and pre-commissioning tests are successfully completed the transformer can
be energized at no load.

 Oil soaking/settling duration of 1-2 days for transformers up to 245 kV class after
completion of hot oil circulation and before energizing.
 Transformer shall be observed for any abnormality.
 If any gas is collected inside the Buchholz relay, it shall be analyzed for its combustibility.
If gas is not combustible, it indicates air trapped inside the transformer.
 All instrument should be check for any abnormalities.
 Check winding temperature and oil temperature readings at least once in every shift.
 Check and confirm that the tap position indicators are same in local and remote
indicators.
 Check and confirm that none of the alarms is ON.
 Ensure that cooler power supply isolator is ON.
 Ensure that cooler control is in AUTO.
 Ensure that pumps and fans are running smoothly as temperature dictates. Of the
temperature is below the ON setting neither the pump nor fan should be running.
 Observe the rise in temperature of oil and winding temperature indicators.
 While temperature is rising, confirm that fans and pumps are switched on automatically
at the preset temperatures.
 While temperature is falling, observe that the pumps and fans are switched off at preset
temperatures.

7.4 Routine/periodic inspection schedule for Transformer:

Sl. No. Items to be inspected Frequency

1 Load current Hourly

2 Terminal Voltage Hourly

3 Ambient Temperature Hourly

4 Winding Temperature Hourly

5 Oil Temperature Hourly

6 Tap Position Daily

7 Air cell conservator Daily

8 Oil level in conservator Daily

9 Oil level in Bushings Daily

10 Oil level in OLTC Conservator Daily

 11 Oil level in breather cup Daily

12 Connections Monthly

13 Dust deposits and physical damages to bushing Monthly

14 Air passage and colour of silica gel in breather Quarterly

15 Cable boxes, gasket joints, gauges, etc. Quarterly

16 Dielectric strength f transformer oil Half yearly

17 Moisture content of transformer oil Half yearly

18 Dissolved gas analysis of transformer oil Half yearly

19 Resistivity of transformer oil Half yearly

20 Insulation resistance of windings Yearly

21 Tan delta and capacitance of condenser bushings Yearly

22 Operation of relays and their circuits Yearly

23 Surface paint 2~3 Years

Table 7. 2: Inspection during the operation

 SECTION A:

OPERATION MANUAL

CHAPTER 8
CHAPTER 8: STATION AUXILIARY
TRANSFORMERS

8.1 Station Auxiliary Transformer, 5MVA, 220 kV/33kV

8.1.1 Introduction

General
The Transformer is connected between 220kV and 33kV system, which is effectively earthed, and
is suitable for bi-directional power flow. The Transformer is rated for 5MVA under OFWF cooling
respectively.
Core and Winding
The magnetic circuit is of three limbsNon-Step-Lap construction, each limb being mitered jointed
with the top and bottom yokes. The laminations are made of high grade, non-ageing cold rolled
grain oriented steel. The limbs and yokes laminations are firmly clamped together by Breen belts
along with the yoke clamp.
The windings are arranged on the core limbs in a concentric manner. For mechanical rigidity
under short circuit, the winding has been wound on a rigid cylinder made of pre-compressed
pressboard. The HV winding is placed over the LV winding and HVT winding is placed over HV
winding after placement of adequate insulation. The 220kV line lead emerges from the TOP of HV
winding stack. The HV windings are wound by adopting intershielded disc type of winding which
gives excellent voltage gradation under impulse. Oil ducts are so arranged to provide a maximum
circulation of oil to each and every part of the winding and therefore eliminates occurrence of
any “hot-spot”.
Core and windings together with the insulation are dried and processed under vacuum. Windings
are sized to correct dimension and are firmly clamped under pressure.
No Load Tap Changer
Make: “TELK”
Type: Off Circuit Tap Changer
The Transformer is provided with taps in series of HV windings to vary HV voltage from -2x2.5% to
+2x2.5% in 4 steps of each 2.5% each. The tapping arrangement is linear type.

8.1.2 Transformer Rating:

MVA : 5 MVA
Type of Cooling : OFWF
Frequency : 50Hz
Voltage Ratio (No Load)/Connections:
HV : 220kV/Star
LV : 33kV/zigzag
Phase : Three
Vector group : YNzn11
Rated Current (Amperes)
HV : 13.14
LV : 87.58
Insulation Level:
HV : LI 950 AC 395
HVN : LI 170 AC 140
LV : LI 170 AC 70

8.1.3 Operation

The Operation instruction for charging the transformer for the first time are mentioned below:

 After the inspection and pre-commissioning tests are successfully completed the
transformer can be energized at no load.
 Oil soaking/settling during of 1-2 days for transformers up to 245kV class and 3 days for
400kV and above classes are recommended after completion of hot oil circulation and
before energizing.
 Excessive vibration if any on any part of transformer shall be located and rectified.
 Transformer shall be observed for any abnormality.
 If any gas is collected inside the Buchholz relay, it shall be analyzed for its combustibility.
If gas is not combustible, it indicates air trapped inside the transformer.
 All instruments should be checked for any abnormal indication.
 Check winding temperature and oil temperature readings at least once in every shift.
 Check and confirm that the tap position indicators are same in local and remote
indicators.
 Check and confirm that none of the alarms are indicated.
 Ensure that the cooler power supply isolator is ON.
 Ensure that the cooler control is in AUTO.
 Ensure that the pumps and fans are running smoothly as temperature indicates. If the
temperature is below the ON setting neither the pump nor the fan should be running.
 After watching the operation of the transformer at no load for 24 hours and confirming
that everything is normal, the transformer shall be taken on load.
 Observe the rise of temperature of oil and winding temperature indicators.
 While temperature is rising, confirm that the fans and pumps are witched on
automatically at the preset temperatures.
  While the temperature is falling, observe that the pumps and fans are switched off at
preset temperature.

8.1.4 Routine/periodic inspection schedule for Transformer:

Sl. No. Items to be inspected Frequency

1 Load current Hourly

2 Terminal Voltage Hourly

3 Ambient Temperature Hourly

4 Winding Temperature Hourly

5 Oil Temperature Hourly

6 Tap Position Daily

7 Air cell conservator Daily

8 Oil level in conservator Daily

9 Oil level in Bushings Daily

10 Oil level in OLTC Conservator Daily

11 Oil level in breather cup Daily

12 Connections Monthly

13 Dust deposits and physical damages to bushing Monthly

14 Air passage and colour of silica gel in breather Quarterly

15 Cable boxes, gasket joints, gauges, etc. Quarterly

16 Dielectric strength f transformer oil Half yearly

17 Moisture content of transformer oil Half yearly

18 Dissolved gas analysis of transformer oil Half yearly

19 Resistivity of transformer oil Half yearly

20 Insulation resistance of windings Yearly

21 Tan delta and capacitance of condenser bushings Yearly

 SECTION A:

OPERATION MANUAL

CHAPTER 9

22 Operation of relays and their circuits Yearly

23 Surface paint 2~3 Years

Table 8. 1: Inspection during the operation

CHAPTER 9:220kVGAS INSULATED SWITCHGEAR

9.1 Introduction

The main switching operations of the generating units, auxiliary transformer and an outgoing
feeder are carried out on the Gas insulated switchgear (GIS). It consists of 4 bays: 2 incoming
bays for the 2 generating units through their respective generator transformer banks, 1 bay for
outgoing 220kV feeder/cable and an auxiliary transformer bay.

9.2 Technical Data of 220 kV Gas Insulated Switchgear

Make ALSTOM Grid/Aix Les Bains/ France

Type B105

Rated voltage (Ur) 245 kV

System frequency (Fr) 50 Hz

Normal current (Ir) ratingBusbars and Bays 2000 A

Short-time withstand current (Ik)/ Duration (tk) 40 kA/ 1 Sec.

Peak withstand current (Ip) 100 kA

Rated Lightning impulse withstand voltage (Up 1050 kV

Rated one-minute power frequency withstand voltage

460 kV
(Ud)

Rated Auxiliary Voltage (Ua) 110 V DC

 GIS SF6 Gas Pressure (Filling/Alarm/Minimum @ 20⁰C)
6.3/5.8/5.5 bar
Pre/Pae/Pme

Total mass of SF6 Gas Contained in the GIS Installation

8kg
(m)

Table 9. 1: Technical specification of 220kV Gas Insulated Switchgear

9.3 Operation

The operation of SF6 gas insulated switchgear can be operated locally (open/close control switch
in bay module) or from remote (remote/local control transfer switch from control room control
system).

9.3.1 SF6 Circuit Breaker

The SF6 insulated B105-CB Circuit Breaker is of single pressure type with one breaking element
per pole.
The three horizontal circuit breaker poles with their driving mechanism form a whole. The driving
mechanism is of single pole type and CB enclosure serves as an attachment base for the driving
mechanism and the structure.
The whole module is filled with SF6
gas at 6.3 bars @ 20 ⁰C. SF6 gas is
used for both insulation and arc
quenching. The tripping and closing
of the circuit breakers will be blocked
when the SF6 gas density drops
below a minimum permissible level.
The density of SF6 gas in different
compartments (GO) are monitored by
density switch which is fitted with shielded protection system that enables it to resist extreme
temperatures and external aggressions switch with two alarm levels.
The first stage alarm is set well before any dangerous condition is reached and second stage shall
initiate breaker operation blocking.
For the unacceptable over pressure there is bursting disc installed at an appropriate location on
each gas compartment to protect the enclosures of the GIS. They are metal discs equipped with a
discharge section 110 mm in diameter for the substation and 210 mm for the circuit breaker. The
circuit breaker can be operated locally (open/close control switch in local control panel) or from
remote.
The breaker controls shall operate from the two independent 110V DC systems with both the trip
coils connected. The CBs of the incoming bays, feeder bay and auxiliary transformer bay are of
2000A.

9.3.2 Disconnecting Switch

The function of the disconnecting switch is to isolate different parts of the electrical circuits. It
can establish or cut off loop currents and capacitive charging currents on parts of the substation
being switched ON or OFF.
The disconnect switch consists of three separate poles, connected by an external rod to a manual
or electrical operating mechanism. To perform the disconnect switch function, each pole
compromises a moving contact situated within the disconnector enclosure and a fixed contact
situated within the insulator of the right enclosure or the adjacent cross chamber. A visual
indicator connected to the transmission shaft by mechanical means enables checking of the
disconnector’s open/closed position.
The B105 type disconnector operating mechanism actuates disconnectors and earthing switches
of the B105 SF6 switchgear in three poles. It is attached to the mechanism housing of one pole. In
the case of three pole operating mechanism, the other two poles are operated via push-pull
linkages. The position indicator is mounted on the housing of one pole and is mechanically
coupled with the linkages.

9.3.3 Maintenance Earth Switch

The purpose of maintenance earthing switch is to earth de-energized SF6 switch gear sections.
The maintenance earthing switches are operated in three poles with motor operating mechanism
B105 which is mounted on one pole and connected to the other poles with linkages. It consists of
mechanism housing with shaft, lever and links for motion transmission to contact pin. Tulip
contact screwed into mechanism housing establishes the current connection to contact pin and
counter contact tulip is mounted in the electrode of a disconnector of a connecting element.
Make or break operations in service are handled electrically by the motor operating mechanism
via the control system, if no auxiliary voltage is available the earthing switch can also be actuated
manually with the crank.

9.3.4 High-Speed Earth Switch (HSES)

The High-speed earth switches are used for the short circuit proof earthing of high voltage lines
and cables connected to SF6 switchgear and of switchgear sections. Generally, they are used as
earthing switches for feeders but can be applied anywhere else in the substations according to
requirements and they are designed to close on short circuits and to switch induced currents.
It consists of mechanism housing with shaft, lever and links for motion transmission to contact
pin. Tulip contact screwed into mechanism housing establishes the current connection to contact
pin. Counter contact tulip is mounted in the electrode of a disconnector or a connecting element.

9.3.5 Daily Checklist for Operation:

Sl.No. Description Incomer-1 Incomer-2 Auxiliary Out Going

 transformer Feeder

1 Status of Units
/feeder (in service        
/ standby /PTW)

2 Any alarms
       
indication?

3 Is DC (A& B)
       
healthy?

4 Are both trip

       
circuits healthy?

5 Any relays found

       
operated?

6 Any alarms in
       
annunfascia?

Visual/
Physical/Peripher
7
al check of the    
components for
anything unusual

8 CB Counter
                 
Reading

Table 9. 2: Daily Checklist

 SECTION A:

OPERATION MANUAL

CHAPTER 10

CHAPTER 10: 220 kV POT HEAD YARD

10.1 Introduction

Switch yard is the point at which the

220 kV XLPE insulated cable terminates
and get connected to the two overhead
transmission lines.

10.2Isolator with earth switches

The isolators have three poles which

are of Horizontal Centre Break (HCB)
type, one arm with male contact and
other with female. It is a set of
mechanical device for providing
isolation of equipment and feeder from
the power network.
There is electrical interlocking between
isolator and earth switch operation that
isolator will not close unless earth Switch is opened.
A diagonal rod connects both the rotary pedestals of each column ensuring simultaneous
operation of both the columns.
The three phases of the isolator are connected by
gang operating linkages for simultaneous three
phase operation.
Isolators operate in 3 phase gang operated
powered by electric motor. It can also be operated
manually by hand lever mechanism provided in the
operating box in yard.
 Of the total four sets of isolators, only the main incomer towhich 220KV, XLPE cable terminated
is incorporated to ALSTOM’s control system. It can be operated remotely from control room
with the display of its status. Rests are to be operated from the operating box at yard.
 There are no switching activities in operating earth switch. It is always operated manually.

10.2.1Technical Details of Isolator

Details Specification

Type Horizontal Centre Break (HCB), one arm with male contact and
other with female contact.

Make S&S Pvt. Ltd.

Serial Number 2D849-222-4

Operation Motorized and also can be operated manually. 3 phase gang

operated

Motor Rating 0.37KW

Thermal over load setting 1.1Amps

Table 10. 1: Technical specification of Isolator

10.3 Lightning Arrester

10.3.1 Technical Details of Lightning Arrester

Details Specification

Model No. ZAQ

Type Gapless, METOVAR

Make OBLUM Electrical Industries Pvt.Ltd., Hyderabad

Rated Voltage 198 kV

Rated frequency 48-62HZ

LD discharge class 3

Discharge current 10 KA
MCOB 56 kV

Pressure relief class 40 KA rms

Table 10. 2: Technical specification of Lightning Arrester

10.4 Operation

The operation of the isolators and earth switches can be operated locally only. However, we will
be able to see the position indications of earth switch and isolators in Control System.
 SECTION A:

OPERATION MANUAL

CHAPTER 11

CHAPTER 11:AUXILIARY SUPPLY SYSTEM

11.1 Introduction

Here at Dagachhu Hydro Power plant, we have three sources to supply the auxiliary power for
the generating units and its auxiliaries. The supply is also extended to outdoor locations such as
Diversion Weir, Desilter, Surge Shaft, Chhurachhu side adit and face 4 side adit.

11.2 Operation

The operation of all the auxiliary supply equipment can be perform either locally (local panels) or
remotely (control System).

11.2.1 Auxiliary Supply from External Source (220kV)

During the initial starting of the Generating Units, we can either supply the Generating Units’
auxiliaries through external source or through the emergency diesel generator installed at Power
house premises. We will discuss the external source first.

11.2.1.1 Charging of 220kV Bus bar at GIS

Preconditions:

 The earth switches (00ADD20GS401) at Pot head yard should be in “open” position.
 The isolators (00ADD20GS301) at Pot head yard should be closed.
 High speed electrical earthing switch (00ADD00GS421) at GIS should be in “open”
position.
 Electrical earthing switch (00ADD00GS411 and 00ADD00GS401) at GIS should be in
“open” position.
 Electrical disconnector switch (00ADD00GS311) at GIS should be closed.
 220kV Station Transformer Circuit Breaker should be open.
Charging:

Step Activity

1 Ask Tsirang Substation to extend the 220kV supply through 220kV Dagachhu-Tsirang line.
 2 After getting the 220kV supply till GIS Circuit Breaker end, close the circuit breaker
(00ADD00GS100) at GIS. Now there should be 220kV supply at 220kV Bus bar.

11.2.1.2 Charging of 33kV Power Cavern (20BBA00GH001)

Preconditions:

 220kV Station Transformer bus disconnector (20ADD00GS301) should be closed and

220kV Station Transformer earthing switch (20ADD00GS401) should be Open.
 400V Emergency Diesel Generator circuit breaker should be Open.
Charging:

Step Activity

1 Close the 220kV Station Transformer circuit breaker (20ADD00GS100) after charging the
220kV bus bar. Now the 220/33kV Station Transformer will be charged.

2 Close the 33kV Station Transformer circuit breaker (20BBA00GS111). Now the Power
Cavern 33 kV bus will be charged.

11.2.1.3 Charging of Power Cavern Main Distribution Board (20BFA00GH001)

Preconditions:

 33kV Power Cavern Main Distribution Board should be charged

Charging:

Step Activity

1 After charging the Power Cavern 33kV, either close 33kV Auxiliary Transformer 1 circuit
breaker (20BBA00GS121) to charge the 800kVA Auxiliary Transformer 1 or 33kV Auxiliary
Transformer 2 circuit breaker (20BBA00GS141) to charge 800kVA Auxiliary Transformer
2.

2 Close the 400V Auxiliary Transformer incomer 1 Circuit Breaker (20BFA00SG101) if 33kV
Auxiliary Transformer 1 circuit breaker (20BBA00GS121) is closed and close 400V Auxiliary
Transformer incomer 2 circuit breaker (20BFA00GS102) if 33kV Auxiliary Transformer 2
circuit breaker (20BBA00GS141) is closed.
Note: The sub-distribution boards and motor control cabinets circuit breaker are already closed, so
after charging the Power Cavern 400V Main Distribution the sub-distribution boards and MCC panels
connected from this board should also be charged.

11.2.1.4 Charging of 33kV Control Building Main Distribution Board (25BBA00GH001)

Preconditions:

 33kV Power Cavern Main Distribution Board should be charged

 400V Emergency Diesel Generator circuit breaker (25BFA00GS214) should be Open.

Charging:

Step Activity

1 Close the 33kV Tunnel Feeder circuit breaker (20BBA00GS151) at Power Cavern 33kV
Main Distribution Board.

2 Close the 33kV Tunnel Feeder circuit breaker (25BBA00GS111) at Control Building 33 kV
Main Distribution Board. Now the Control Building 33kV Main Distribution Board will be
charged.

Step Activity

1 Close the 33kV Auxiliary Transformer circuit breaker (25BBA00GS121) to charge the
Auxiliary Transformer in Control Building.

2 After Charging the Auxiliary Transformer, close 400V Auxiliary Transformer incomer
circuit breaker (25BFA00GS101) at 400V Control Building Main Distribution Board.

Step Activity

1 Close the 33kV overhead line (OHL) 2 circuit breaker (25BBA00GS151) in 33kV Control
Building Main Distribution Board

2 Close the Dam 400 V incomer circuit breaker (51BFA00GS011) at 400V Main Distribution
Board.

 33kV Control Building Main Distribution Board should be charged

 400V Emergency Diesel Generator circuit breaker (51BFA00GS021) should be Open

  Desilter 400V Dam circuit breaker (52BFA00GS021) should be Open.
Charging:

Step Activity

1 Close the 33kV overhead line (OHL) 2 circuit breaker (25BBA00GS151) in 33kV Control
Building Main Distribution Board

2 Close the Desilter 400 V incomer circuit breaker (52BFA00GS011) at 400V Main
Distribution Board.

11.2.1.8 Charging of 400V Surge Tank Main Distribution Board

Preconditions:

 33kV Control Building Main Distribution Board should be charged

 The 400V Surge Tank Main Distribution Board circuit breaker should be closed as it is not
motorized.
Charging:

Step Activity

1 Close the 33kV overhead line (OHL) 1 circuit breaker (25BBA00GS141) in 33kV Control
Building Main Distribution Board.

Now the Generating Units are ready to start.

11.2.2 Auxiliary Supply from Generating Units.

After starting the Generating Units and synchronizing with the grid, supply the auxiliary supply
through 5MVA Station Transformer from our own Generating Units.

11.2.3 Auxiliary Supply from Emergency Diesel Generators/ Black Start.

The Black Start is an emergency condition when normal sources of power from our 5MVA Station
Transformer and external power supplies from Tsirang (i.e. Supply through 220kV Dagachhu-
Tsirang line as well as 33kV Tsirang-Dagapela-Dagachhu line) are unavailable and the power
required for essential loads for starting of generating unit has to be met from 400kVA DG set
installed at Power House.
Dagachhu Hydropower Corporation Limited has also 160kVA DG set installed at Diversion Weir for
supplying the essential power supply to the various equipment/systems installed at Diversion
Weir and Desilter and 400kVA DG set at Power House for supplying the essential power supply to
the equipment/systems at Power House.

11.2.3.1Extension of Supply from 400kVA DG Set

Preconditions:

 400kVA DG Set position cubicle location should be AUTO.

  400kVA DG position drive location should be REMOTE.

 There should not be any alarms due to possible faults like earth faults, reverse power, etc.

 Diesel Generator Manual Mode should not be selected.

 400V DG set circuit breaker (25BFA00GS214) should be in AUTO.

 400V Auxiliary Transformer incomer circuit breaker (26BFA00GS101) should be in AUTO.

 33kV Control Building Main Distribution board control should be in AUTO

 33kV Power Cavern Main Distribution board control should be in AUTO

 All 400V Main Distribution Board should be in AUTO.

Charging:

Steps Activity

1 Start the 400kVA Emergency Diesel Generator. The 400kVA emergency diesel
generator will be started automatically if above conditions are fulfilled. However, the
DG set can also be started locally or manually through control system. The 400V DG set
circuit breaker (25BFA00GS214) will also close automatic and the 400V Control Building
Main Distribution Board will be charged.

2 Close the 400V DG set circuit breaker (25BFA00GS214) to charge the 400V Control
Building Main Distribution Board. However, the circuit breaker will automatically close if
above preconditions are fulfilled.

3 Open all the 33kV Feeder Circuit Breaker like control building 33kV Auxiliary
Transformer circuit breaker (25BBA00GS121), Tunnel Feeder circuit breaker
(25BBA00GH111), Overhead line 1 circuit breaker (25BBA00GS141), Overhead line 2
circuit breaker (25BBAGS00GS151) and Power Cavern Auxiliary Transformer 1 circuit
breaker (20BBA00GS121) and Power Cavern Auxiliary Transformer 2 circuit breaker
(20BBA00GS141).

4 Make sure that the incomer from 5 MVA Station Transformer 33kV side circuit breaker
(20BBA00GS111) is OPEN. This is very important.

5 Close the 400V Auxiliary Transformer incomer circuit breaker (25BFA00GS101) to charge
the 800kVA Auxiliary Transformer.

6 Close the incomer from Control building Auxiliary Transformer circuit breaker
(25BBA00GS121) and you will have voltage in Control Building 33kV Main Distribution
Board.

7 Close the Control Building Tunnel Feeder CB (25BBA00GH111) and you should get
voltage at Power Cavern 33kV System.

8 Either close 33kV Auxiliary Transformer 1 circuit breaker (20BBA00GS121) to charge the
 800kVA Auxiliary Transformer 1 or 33kV Auxiliary Transformer 2 circuit breaker
(20BBA00GS141) to charge 800kVA Auxiliary Transformer 2.

9 Close the 400V Auxiliary Transformer incomer 1 Circuit Breaker (20BFA00SG101) if 33kV
Auxiliary Transformer 1 circuit breaker (20BBA00GS121) is closed and close 400V
Auxiliary Transformer incomer 2 circuit breaker (20BFA00GS102) if 33kV Auxiliary
Transformer 2 circuit breaker (20BBA00GS141) is closed. Now Power Cavern 400V Main
Distribution Board will be charged.

11.2.3.2 Extension of 160kVA DG set

The essential power supply to the equipment at Diversion Weir and Desilter can be supplied from
160kVA Diesel Generator installed at Diversion Weir.
Preconditions:

 Dam 400 V incomer circuit breaker (51BFA00GS011) should be open.

 Desilter 400 V incomer circuit breaker (52BFA00GS011) should be open.

Steps Activity

1 Start the 160kVA Emergency Diesel Generator. The 400kVA emergency diesel generator
will be started locally or remotely from control room or in Auto.

2 Close the 400V Emergency Diesel Generator circuit breaker (51BFA00GS021). Now the
400V Diversion Weir Main Distribution Board will be charged.

3 Close Dam 400V Desilter circuit breaker (51BFA00GS031).

4 Close Desilter 400V Dam circuit breaker (52BFA00GS021) and now 400V Desilter Main
Distribution board will be charged.

Note: Now the generating units are ready to start. However, only one of the generating unit can be
started because Diesel Generators will be overloaded if both the generating units are started
simultaneously. Start the next unit only after changing the supply to 5MVA Station Transformer.

11.2.3.3 Supply changeover

After starting any one of generating and synchronizing with the grid, auxiliary supply should be
changeover to 5MVA Station Transformer to start the next unit.
Preconditions:

 One Generating Unit should be synchronized to grid.

Changeover:

Steps Activity

1 Close the 220kV Station Transformer circuit breaker (20ADD00GS100). Now the
 SECTION A:

OPERATION MANUAL

CHAPTER 12

220/33kV Station Transformer will be charged.

2 Keeping everything in AUTO mode, manually open the 400V Auxiliary Transformer
incomer circuit breaker and simultaneously close the 33kV Station Transformer circuit
breaker (20BBA00GS111). Now 400kVA DG set will incomer breaker will get open
automatically and subsequently stop the DG set.

3 Close the 400V Auxiliary Transformer incomer circuit breaker. Now everything will be
normal in Power house premises.

4 Close overhead line 1 circuit breaker (25BBA00GS141) to supply the 400V Surge Tank
Main Distribution board.

5 Close overhead line 2 circuit breaker (25BBA00GS151) to supply the 400V Diversion Weir
Main distribution board and 400V Desilter Main distribution board.

6 Stop the 160kVA diesel generator and open the DG set breaker (51BFA00GS021). Also,
open the Dam 400V Desilter circuit breaker (51BFA00GS031) and Desilter 400V Dam
circuit breaker (52BFA00GS021).

7 Close the Dam 400 V incomer circuit breaker (51BFA00GS011) to supply the 400V
Diversion Weir Main distribution board and also close Desilter 400 V incomer circuit
breaker (52BFA00GS011) to supply the 400V Desilter Main Distribution Board.

CHAPTER 12: DIVERSION WEIR AND DESILTER EQUIPMENT

12.1 Diversion Weir Intake Gate

General
All Gates at the Diversion Weir and Intake, which means
 One Intake Gate
 Two Weir Radial Gates and
 Two Weir Flap Gates
are operated hydraulically by means of Hydraulic Cylinders fed by one common Hydraulic Power
Unit for oil supply, located in the Operation and Maintenance building.
The Intake Gate is actuated by means of two double acting Hydraulic Cylinders.
Each of the Weir Radial Gates as well as the Weir Flap Gates are actuated by means of two single
acting Hydraulic Cylinders. All Hydraulic Cylinders are fed by one common Hydraulic Power Unit
located in the Operation and Maintenance building. All parts of the hydraulic hoisting system are
designed and calculated according to EN 19704.

 The intake is equipped with one Slide Gate. This gate is capable toclose the intake against
full flow in case of turbine over speed orpenstock rupture.
 During normal operation, the intake gate is in the opened position.For filling the
penstock, the gate will be lifted into the crack openposition, lifting height approx. 10cm
above the sill.
 The gate is actuated hydraulically by means of two double acting hydraulic cylinders,
connected to the gate.
 For electrical control of the equipment a local control cubicle(=51LNY10 GH001), located
in Operation and Maintenance building isprovided. The local control cubicle is common
for the Intake gate andthe Weir gates.
 Hydraulic control is achieved via a Hydraulic Power Unit. The gateposition is monitored
via a mechanical position indicator; individualpositions are detected by a position
transmitter.
 The gate position is monitored via an integrated measuring system inthe hydraulic
cylinders. Stroke measuring system is of the magneto restrictive type, make “Balluff”
with analog output.

12.1.1 Operation of Intake Gate

General
Operation of the hydraulic equipment will be executed by means of the pushbuttons and the
selector switches of the local control board.
The Intake Gate is operated by two double-acting hydraulic cylinders acting simultaneously on
both sides of the gate.
The cylinders are equipped with an integrated position measuring system to ensure simultaneous
operation of the two hydraulic cylinders.
The hydraulic circuit for the two cylinders of the Intake Gate hoist is provided with 3/2-way
poppet valve AA111 (-Y01) and 2-way flow control valve+ rectifier sandwich plate NG6 AA011 of the
servomotor left side AS010 and 3/2-way poppet valve AA112 (-Y01) and 2-way flow control valve+
rectifier sandwich plate NG6 AA012 of the servomotor right side AS020 and together the main
directional valve AA110 (-Y01 and –Y02) which, in conjunction with the integrated piston
measuring system CG010-B01 of the servomotor left side and CG020-B01 of the servomotor right
side, are synchronizing the motion of the hydraulic cylinders and ensure levelled raising and
lowering of the gate.

12.1.1.1 Opening of Intake Gate

Preconditions:

 Intake gate in closed position

 Mode selector switch –S13 in LOCAL position
 Either mode selector switch –S11 or –S12 in AUTO position
 No relevant fault indicated at the alarm list of the touch panel –A02
By pressing the illuminated push button –S14/-H14 one of the two pump groups AP001 or AP002
is switched on. The illuminated push button –S14/- H14 flashes.
The solenoid –Y02 of main directional valve AA110 is energized.
The hydraulic pump KP001 for pump group AP001 or KP002 for pump group AP002 is delivering
oil without pressure via
 check valve AA701 for pump group AP001 or
 check valve AA702 for pump group AP002,
 opened pressure relief valve AA301,
 pre-stressed check valve AA705 and
 return line filter AT001
 back to the oil reservoir BB001.
After a programmed period, which corresponds to the motor run-up time of 3,0s, the pressure
relief valve AA301 is closed by energizing the pilot operation valve AA101-Y01. Pressurized oil is
delivered now via
 check valve AA701 for pump group AP001 or
 check valve AA702 for pump group AP002,
 check valve AA703,
 shut off valve AA503,
 pressure piping BR001,
 main directional valve AA110,
 over-center valve AA010,
 3/2-way poppet valves AA111 and AA112 (de-energized by simultaneous lifting of the
 hydraulic cylinders AS010 and AS020),
 2-way flow control valve+ rectifier sandwich plate NG6 AA011 and AA012,
 pressure piping BR011 and BR012,
 shut off valves AA510 and AA520 into,
 the lower part below the piston of hydraulic cylinders AS010 and AS020.
Due to this discharge of the pumps, the piston rods of the hydraulic cylinders as well as the
Intake Gate connected to is going to be lifted. The oil above the piston of the hydraulic cylinders
is displaced via
 pressure piping BR021 and BR022,
 main directional valve AA110,
 piping BR002,
 pre-stressed check valve AA705 and
 return line filter AT001
 back to the oil reservoir BB001.
The Intake Gate is lifted with a speed of approx. 0,3m/min until the limit switch CG002-S01
FILLING POSITION is reached. The limit switch CG002-S01 is adjusted to stop the Intake Gate 10cm
above the sill beam to enable filling of the headrace in case of unbalanced pressure up- and
downstream of the Intake Gate.
In addition, a time delay is implemented in the software to stop the Gate in case of failure the
limit switch CG002-S01. The time delay is programmed in a way to stop the Gate shortly after
reaching the filling position. As far as the limit switch CG002-S01 is reached, the pilot operation
valve AA101-Y01 of pressure relief valve AA301 is de-energized. With a delay of 1,5s the main
directional valve AA110-Y02 is de-energized as well. The electric motor –M01 or –M02 is switched
off 2,0s delayed. In the filling position the signal lamp –H13 is illuminated.
Balanced pressure will be not detected physically. A time delay is implemented in the software.
This time delay is the time which is required to fill the headrace completely. If the time delay is
not elapsed, the OPEN push button –S14 is blocked. If the time delay is elapsed, the gate can be
further lifted. Elapsed time is indicated at the touch panel –A02.
By pressing the illuminated push button –S14/-H14 one of the two pumpgroups AP001 or AP002 is
switched on. The illuminated push button –S14/-H14 flashes.The solenoid –Y02 of main directional
valve AA110 is energized.The hydraulic pump KP001 for pump group AP001 or KP002 for
pumpgroup AP002 is delivering oil without pressure via
 check valve AA701 for pump group AP001 or
 check valve AA702 for pump group AP002,
 opened pressure relief valve AA301,
 pre-stressed check valve AA705 and
 return line filter AT001
  back to the oil reservoir BB001.
After a programmed period, which corresponds to the motor run-up time of 3,0s, the pressure
relief valve AA301 is closed by energizing the pilot operation valve AA101-Y01. Pressurized oil is
delivered now via
 check valve AA701 for pump group AP001 or
 check valve AA702 for pump group AP002,
 check valve AA703,
 shut off valve AA503,
 pressure piping BR001,
 main directional valve AA110,
 over-center valve AA010,
 3/2-way poppet valves AA111 and AA112 (de-energized by simultaneous lifting of the
hydraulic cylinders AS010 and AS020),
 2-way flow control valve+ rectifier sandwich plate NG6 AA011 and AA012,
 pressure piping BR011 and BR012,
 shut off valves AA510 and AA520 into,
 the lower part below the piston of hydraulic cylinders AS010 and AS020.
Due to this discharge of the pumps, the piston rods of the hydraulic cylinders as well as the
Intake Gate connected to is going to be lifted. The oil above the piston of the hydraulic cylinders
is displaced via
 pressure piping BR021 and BR022,
 main directional valve AA110,
 piping BR002,
 pre-stressed check valve AA705 and
 return line filter AT001
 back to the oil reservoir BB001.
The Intake Gate is lifted with a speed of approx. 0,3m/min until the limit switch CG001-S01 GATE
OPENED is reached or the “Stop” command is initiated. As far the limit switch CG001-S01 is
reached, the pilot operation valve AA101-Y01 of pressure relief valve AA301 is de-energized. 1,5s
delayed the solenoid –Y02 of main directional valve AA110 is de-energized and the electric motor
–M01 or –M02 is switched off 2,0s delayed. In the opened position the illuminated push button –
S14/-H14 is illuminated permanently. In the opened position of the Intake Gate an automatic
leakage control is active.
In case of unbalanced lifting of the intake gate due to different friction the synchronization
controller will stop the hydraulic cylinder, which is faster by energizing the relevant
synchronization valve AA111-Y01 for hydraulic cylinder AS010 or AA112-Y01 for hydraulic cylinder
AS020. Maximum allowable deviation between the two hydraulic cylinders will be 25mm. This
value is adjustable at the touch screen –A02 in between a certain range.

12.1.1.2Closing of Intake gate

Preconditions:

 Intake gate in opened position

 Mode selector switch –S13 in LOCAL position
 Either mode selector switch –S11 or –S12 in AUTO position
 No relevant fault indicated at the alarm list of the touch panel –A02
By pressing the illuminated push button –S15/-H15, the two pump groups AP001 and AP002 are
switched on stepwise. The illuminated push button – S15/-H15 flashes.
The solenoid –Y01 of main directional valve AA110 is energized. The hydraulic pumps KP001 for
pump group AP001 as well as KP002 for pump group AP002 are delivering oil without pressure
via
 check valve AA701 for pump group AP001 and
 check valve AA702 for pump group AP002,
 opened pressure relief valve AA301
 pre-stressed check valve AA705 and
 return line filter AT001
 back to the oil reservoir BB001.
After a programmed period, which corresponds to the motor run-up time of3,0s, the pressure
relief valve AA301 is closed by energizing the pilotoperation valve AA101-Y01.Pressurized oil is
delivered now via
 check valve AA701 for pump group AP001 and
 check valve AA702 for pump group AP002,
 check valve AA703,
 shut off valve AA503,
 pressure piping BR001,
 main directional valve AA110 (solenoid –Y01),
 pressure piping BR021 and BR022 into
 the upper part above the piston of hydraulic cylinders AS010 andAS020.
Due to this discharge of the pumps, the piston rods of the hydrauliccylinders as well as the Intake
Gate connected to is going to be lowered.The oil beneath the piston of the hydraulic cylinder is
displaced via
 shut off valves AA510 and AA520,
 pressure piping BR011 and BR012,
  2- way flow control valve+ rectifier sandwich plate NG6 AA011 and AA012,
 3/2-way poppet valves AA111 and AA112 (de-energized by simultaneous lowering of the
hydraulic cylinders AS010 and AS020),
 the opened over-center valve AA010,
 main directional valve AA110 (solenoid –Y01),
 pressure piping BR002
 pre-stressed check valve AA705 and
 return line filter AT001
 back into the oil reservoir BB001.
The Intake Gate is lowered with a speed of approx. 0,3m/min until the limit switch CG003-S01
GATE CLOSED as well as the maximum permissible lowering pressure (detected by pressure
transducer CP001-B01 with limit value created in the software) is reached or the “Stop” command
is initiated.
As far the limit switch CG003-S01 and the maximum permissible lowering pressure is reached, the
pilot operation valve AA101-Y01 of pressure relief valve AA301 is de-energized.
1,5s delayed the solenoid –Y01 of main directional valve AA110 is de-energized and the electric
motors –M01 and –M02 are switched off 2,0s delayed.
In the closed position the illuminated push button –S15/-H15 is illuminated permanently. In case of
unbalanced lowering of the intake gate due to different friction the synchronization controller
will stop the hydraulic cylinder, which is faster by energizing the relevant synchronization valve
AA111-Y01 for hydraulic cylinder AS010 or AA112-Y01 for hydraulic cylinder AS020.

12.1.1.3 Gate droop control (leakage recuperation)

For the control of the opened position a leakage control is provided.

In case one of the hydraulic cylinder extracts due to oil leakages the automatic recuperation is
activated for each hydraulic cylinder separately.
The position signal of the hydraulic cylinder left side given by the integrated piston measuring
system CG010-B01 and the hydraulic cylinder right side given by the integrated piston measuring
system CG020-B01 is processed in the PLC-system via the counting module, i.e. this signal
represents the actual value for the leakage control.
The leakage control functions in such a way, that in case the gate stops in the opened position,
the actual value of the position is stored and now represents the nominal value (set point).
If the one of the hydraulic cylinders is extracting more than 20mm due to oil leakage, the
hydraulic cylinder is lifted into its original position. This means that the motor pump will be
started, the solenoid -Y01 of the 3/2-way poppet valves AA111 respectively AA112 will be energized
and shortly afterwards the normal lifting operation will be initiated.
During recuperation, the operation will be indicated at the Touch Panel –A02.
Furthermore, an alarm will be indicated.
However, should one or both hydraulic cylinders continue to lower equal or more than 50mm, an
alarm will be indicated on the Touch Panel. Lifting is interrupted due to unbalanced lifting of the
gate and an alarm is triggered.
If in addition the hydraulic cylinder does not reach its original position within a present period
(20s) after the leakage control has been activated an alarm is indicated too.
The number of responses of the leakage recuperations can be read off for each hydraulic cylinder
on the screen.

12.1.2 Operation of Intake Gate without control voltage (or PLC fault)

If the control voltage of the valves or the power supply of the PLC fails, the hydraulic system can
be operated manually. That means, all valves have to be actuated by means of their manual
actuating advices and the electric motors have to be switched on manually via the appertaining
selector switch.
During manual operation of the Gate, the pressure gauges have to be monitored very carefully. If
the oil pressure exceeds

 155bar during opening at pressure gauge 51LPX10 CP300 and

 60bar during lowering at pressure gauge 51LPX10 CP300,
the operation has to be stopped due to unusual high oil pressure. The high pressure in the
hydraulic system may be caused by

 blocking of Gate or
 the Gate reached the opened or closed position or a failure occurred at the hydraulic
system
Furthermore, it has to be mentioned that the pressure during operation should not fall below
15bar. Low pressure during operation may be caused by

 a pipe is broken or
 a failure occurred at the hydraulic system

12.1.2.1 Raising of Gate

The electric motors can be switched on directly by the selector switches motor pump #1 (51LPX10
AP001-M01) selector switch –S11 and
motor pump #2 (51LPX10 AP002-M02) selector switch –S12.
These switches have the positions AUTO – OFF – MANUAL. To switch on the motor pumps, the
selector switches have to be switched in position MANUAL.
Note:For operation, only one pump has to be switched on!
The normally solenoid operated main directional valve 51LPB10 AA110 has to be actuated
manually by means of the manual actuation devices attached to the solenoid –Y02. Due to this
actuation, the main directional valve is shifted into position 3, lifting position. After this, the
pressure relief valve AA301 has to be actuated manually by means of the manual actuation
devices attached to the solenoid –Y01 of the valve.
If the pressure relief valve is actuated, the Gate starts raising. To stop the raising motion, switch
off the pumps or remove the manual actuation of the pressure relief valve and remove the
actuation of directional valve AA110.
Caution: During this operation, the limit switches, the pressure transducer, the oil level
switch as well as the position indication are not active as the PLC is overridden. By this,
increased attention is necessary!

12.1.2.2 Lowering of Gate

The electric motors can be switched on directly by the selector switches motor pump #1 (51LPX10
AP001-M01) selector switch –S11 and
motor pump #2 (51LPX10 AP002-M02) selector switch –S12.
These switches have the positions AUTO – OFF – MANUAL. To switch on the motor pumps, the
selector switches have to be switched in position MANUAL.
Note: For operation, only one pump has to be switched on!
The normally solenoid operated main directional valve 51LPB10 AA110 has to be actuated
manually by means of the manual actuation devices attached to the solenoid –Y01. Due to this
actuation, the main directional valve is shifted into position 2, lowering position.
After this, the pressure relief valve AA301 has to be actuated manually by means of the manual
actuation devices attached to the solenoid –Y01 of the valve.
If the pressure relief valve is actuated, the Gate starts lowering. To stop the lowering motion,
switch off the pumps or remove the manual actuation of the pressure relief valve and remove the
actuation of directional valve AA110.
Caution: During this operation, the limit switches, the pressure transducer, the oil level
switch as well as the position indication are not active as the PLC is overridden. By this,
increased attention is necessary!

12.1.3 Operation of Intake Gate without power supply

12.1.3.1 Opening of the Gate

Turn the motor pump selector switches –S11 / -S12 into “OFF” position.
In this position the selected motor pump is switched off.
For maintenance purposes, etc. the Intake Gate may be raised by operated the manual pump
KP003.
The shut-off valve 51LNX10 AA501has to be closed.
The normally solenoid operated main directional valve 51LPB10 AA110 has to be actuated
manually by means of the manual actuation devices attached to the solenoid –Y02. Due to this
actuation, the main directional valve is shifted into position 3, lifting position.
Actuate hand pump KP003.
The gate starts lifting.
 Caution: During this operation, the limit switches, the pressure transducer, the oil level
switch as well as the position indication are not active as the PLC is overridden. By this,
increased attention is necessary!

12.1.3.2 Closing of the Gate

Turn the motor pump selector switches –S11 / -S12 into “OFF” position.
In this position the selected motor pump is switched off.
For maintenance purposes, etc. the Intake Gate may be lowered by operated the manual pump
KP003.
The shut-off valve 51LNX10 AA501has to be closed.
The normally solenoid operated main directional valve 51LPB10 AA110 has to be actuated
manually by means of the manual actuation devices attached to the solenoid –Y01. Due to this
actuation, the main directional valve is shifted into position 2, lowering position.
Actuate hand pump KP003.
The gate starts lowering.
To stop the lowering motion, remove the manual actuation of directional valve AA110.
Caution: During this operation, the limit switches, the pressure transducer, the oil level
switch as well as the position indication are not active as the PLC is overridden. By this,
increased attention is necessary!

12.2 Diversion Weir Gates

General
All Gates at the Diversion Weir and Intake, which means
 One Intake Gate
 Two Weir Radial Gates and
 Two Weir Flap Gates
are operated hydraulically by means of Hydraulic Cylinders fed by one common Hydraulic Power
Unit for oil supply, located in the Operation and Maintenance building.
The Intake Gate is actuated by means of two double acting Hydraulic Cylinders.
The Weir Radial Gates is actuated by means of two single acting Hydraulic Cylinders. Each of the
two Weir Flap Gates is actuated by means of one single acting Hydraulic Cylinder. All Hydraulic
Cylinders are fed by one common Hydraulic Power Unit located in the Operation and
Maintenance building. All parts of the hydraulic hoisting system are designed and calculated
according to EN 19704.

 The Diversion Weir structure includes 2 Weir bays each with a clear width of 9,1 m. Each
Weir bay is equipped with a radial gate. The radial gate is driven by 2 hydraulic cylinders.
 According to the design specifications the max. water level is at EL.843.30m. The sill
beam of the radial gate is located at EL. 824.633m. Hence a water pressure of 18,667m
rests on the closed gate.
  The position of the Weir Radial and Weir Flap Gate is monitored via a gravity pendulum
transducer measuring the turning angle of the gates. Within the software of the
transducer a linearization is implemented to convert the turning angle into a linear
opening signal. This linear opening signal is transmitted to the local cubicles.
 The Weir Radial Gate can be dogged in its fully opened position for inspection or
maintenance. In the fully opened position, both dogging devices can be moved manually
from the storage position into the dogging position.
 For electrical control of the equipment a local control cubicle (=51LNY10 GH001), located
in Operation and Maintenance building is provided. The local control cubicle is common
for the Intake gate and the Weir gates.

12.2.1 Operation

Operation of the hydraulic equipment will be executed by means of the pushbuttons and the
selector switches of the local control board and also through Control System at Control room.
Notice: It is not foreseen to operate Diversion Weir 1 and 2 Gates simultaneously. It is only foreseen
to open both flap gates at one time.

12.2.1.1 Opening of Radial Gate 1 =51LNC11

Preconditions:

 Radial gate in closed or any intermediate position

 Mode selector switch –S23 in LOCAL position

 Either mode selector switch –S21 or –S22 in AUTO position

 No relevant fault indicated at the alarm list of the touch panel –A02
By pressing the illuminated push button –S24/-H24 one of the two pump groups AP001 or AP002
is switched on.
The hydraulic pump KP001 or KP002 is delivering oil without pressure via:
 check valve AA701 for motor pump AP001 or
 check valve AA702 for motor pump AP002,
 opened pressure relief valve AA301
 pre-stressed check valve AA705 and
 return line filter AT001
 back to the oil reservoir BB001.
By starting the pump groups, the solenoid –Y02 of 4/3-way valve AA112 will be energized as well.
After a programmed period, which corresponds to the motor run-up time of 3,0s, the pressure
relief valve AA301 is closed by energizing the pilot operation valve AA101-Y01.
Pressurized oil is delivered now via
 check valve AA701 respectively AA702,
  check valve AA703,
 the shut off valve AA510,
 pressure piping BR001,
 the shut off valve AA511,
 the main directional valve AA112,
 check valve AA711,
 the pressure piping BR001,
 the branch piping BR011/BR021
 shut off valve AA513/AA523,
 shut off valve AA514/AA524,
 check valve AA710/AA720 and
 shut off valve AA510/AA520
into the lower part of the two servomotors AS010 and AS020. The Gate is starting to lift.
Synchronization of the two servomotors is achieved via symmetrical arrangement of the
hydraulic piping.
The oil above the piston of the hydraulic cylinders is displaced via
 shut off valve AA516/AA526,
 shut off valve AA515/AA525,
 the branch piping BR012/BR022,
 the return piping BR002,
 pre-stressed check valve AA705 and
 return line filter AT001 back into the
 oil reservoir BB001.
The Weir Radial Gate is lifted with a speed of approx. 0,3m/min until the limit switch CG001-GW2
GATE OPENED is reached or the “Stop” command is initiated.
Caution:Observe the minimum opening height of 300mm! Opening heights lower than
300mm may cause damage of the structure. For emergency cases the Gate can be
stopped if the STOP button is pressed for more than 5 seconds.
As far the limit switch CG001-GW2 is reached or the “Stop” command is triggered, the pilot
operation valve AA101-Y01 of pressure relief valve AA301 is de-energized.
1,5s delayed the solenoid –Y02 of main directional valve AA112 is de-energized and the electric
motor –M01 or –M02 is switched off 2,0s delayed.
In the opened position the illuminated push button –S24/-H24 is illuminated permanently.
In the opened position of the Radial Gate an automatic leakage control is active.
12.2.1.2 Closing of Radial Gate 1 =51LNC11

Preconditions:

 Radial gate in opened or any intermediate position

 Mode selector switch –S23 in LOCAL position
 Either mode selector switch –S21 or –S22 in AUTO position
 Radial Gate unlocked
 No relevant fault indicated at the alarm list of the touch panel –A02
By pressing the illuminated push button –S25/-H25 one of the two pump groups AP001 or AP002
is switched on. The hydraulic pump KP001 or KP002 is delivering oil without pressure via:
 check valve AA701 for motor pump AP001 or
 check valve AA702 for motor pump AP002,
 opened pressure relief valve AA301
 pre-stressed check valve AA705 and
 return line filter AT001
 back to the oil reservoir BB001.
By starting the pump group, the solenoid –Y01 of 4/3-way valve AA112 will be energized as well.
After a programmed period, which corresponds to the motor run-up time of 3,0s, the pressure
relief valve AA301 is closed by energizing the pilot operation valve AA101-Y01.
Pressurized oil is delivered now via
 check valve AA701 respectively AA702,
 check valve AA703,
 the shut off valve AA510,
 pressure piping BR001,
 the shut off valve AA511,
 the main directional valve AA112,
 pilot piping BR003,
 branch piping BR013/BR023,
 shut off valve AA511/AA521,
 shut off valve AA512/AA522 to the
 pilot operation port of pilot operated check valve AA712/AA722
Pilot operation pressure is adjusted at pressure relief valves AA311/AA321. Due to the higher set
point of main pressure relief valve AA301 the pilot operation pressure is stable and the pilot
operated check valve AA712/AA722 is opening.
The oil flow provided by the motor pumps is passing opened pressure relief valves AA311/AA321
and is leading to the bottom side of the hydraulic cylinders to equalize the differential oil volume
(volume of piston rods) to ensure filling of hydraulic cylinders during lowering.
Due to the opened pilot operated check valves AA712/AA722 the Gate is starting lowering. The oil
below the piston is displaced via
 shut-off valve AA510/AA520,
 opened pilot operated check valves AA712/AA722 and
 flow control valves AA012/AA022
into the upper part above the pistons of the hydraulic cylinders AS010 and AS020. The Gate is
closing with a speed of approx. 0.3 m/min until the limit switch CG001-S03 GATE CLOSED is
reached or the “Stop” command is initiated.
Caution: Observe the minimum opening height of 300mm! Opening heights lower than
300mm may cause damage of the structure. For emergency cases the Gate can be
stopped if the STOP button is pressed for more than 5 seconds.
Excessive oil (provided by the running motor pumps) is flowing via
 shut off valve AA516/AA526,
 shut off valve AA515/AA525,
 the branch piping BR012/BR022,
 the return piping BR002,
 pre-stressed check valve AA705 and
 return line filter AT001 back into the
 oil reservoir BB001.
The closed position is detected by means of limit switch CG001–S03, which is activated shortly
before the gate reaches the sill and the falling oil pressure in the hydraulic cylinders, which is
detected by the pressure transducer (CP012-B01). Both signals (limit switch and programmed
pressure value) at one time indicate that the Gate is fully closed.

12.2.1.3 Closing of Flap Gate 1 =51LNC12

Preconditions:

 Flap gate in opened or any intermediate position

 Mode selector switch –S27 in LOCAL position

 Either mode selector switch –S21 or –S22 in AUTO position

 No relevant fault indicated at the alarm list of the touch panel –A02
By pressing the illuminated push button –S29/-H31 one of the two pump groups AP001 or AP002
is switched on.
The hydraulic pump KP001 or KP002 is delivering oil without pressure via:
 check valve AA701 for motor pump AP001 or
  check valve AA702 for motor pump AP002,
 opened pressure relief valve AA301
 pre-stressed check valve AA705 and
 return line filter AT001
 back to the oil reservoir BB001.
By starting the pump groups, the solenoid –Y01 of 3/2-way poppet valve AA110 will be energized
as well.
After a programmed period, which corresponds to the motor run-up time of 3,0s, the pressure
relief valve AA301 is closed by energizing the pilot operation valve AA101-Y01.
Pressurized oil is delivered now via
 check valve AA701 respectively AA702,
 check valve AA703,
 the shut off valve AA510,
 pressure piping BR001,
 the shut off valve AA511,
 3/2-way poppet valve AA110,
 check valve AA710,
 pressure piping BR001,
 shut off valves AA511 and AA512 and
 throttle/check valve AA011
into the lower part of the servomotor AS011. The Gate is starting to lift (close).
The oil above the piston of the hydraulic cylinder is displaced via
 the shut off valve AA514 and AA513,
 return piping BR002,
 pre-stressed check valve AA705 and
 return line filter AT001 back into the
 oil reservoir BB001.
The Weir Flap Gate is lifted (closed) with a speed of approx. 0,34m/min until the limit switch
CG001-GW2 GATE CLOSED is reached or the “Stop” command is initiated.
As far the limit switch CG001-S02 is reached, the pilot operation valve AA101-Y01 of pressure relief
valve AA301 is de-energized.
1,5s delayed the solenoid –Y01 of the 3/2-way poppet valve AA110 is de-energized and the electric
motor –M01 or –M02 is switched off 2,0s delayed.
In the closed position the illuminated push button –S29/-H31 is illuminated permanently.
In the any closed position of the Flap Gate an automatic leakage control is active

12.2.1.4 Opening of Flap Gate

Preconditions:

 Flap gate in closed or any intermediate position

 Mode selector switch –S27 in LOCAL position

 No relevant fault indicated at the alarm list of the touch panel –A02
By pressing the illuminated push button –S28/-H30 the solenoid –Y01 of 3/2- way poppet valve
AA111 will be energized.
Due to the load pressure of the dead weight of the flap gate and the water load the oil below the
piston of the hydraulic cylinder is displaced via
 throttle check valve AA011,
 shut off valves AA512 and AA511 and
 pressure piping BR001,
 shut off valve AA512/AA511,
 3/2-way poppet valve AA111,
 return piping BR002,
 shut off valves AA513 and 514 and
 throttle valve AA011
into the upper part of the servomotor AS011 due to the pre-stressed check valve AA705.
Excessive oil flows via
 return piping BR002,
 pre-stressed check valve AA705 and
 return line filter AT001 back into the
 oil reservoir BB001.
The Gate is starting to open (lowering). The Gate is opening with a speed of approx. 0.34 m/min
until the limit switch CG001-S01 GATE OPENED is reached or the “Stop” command is initiated.
The opened position is detected by means of limit switch CG001–S01, which is activated shortly
before the gate reaches the sill and the falling oil pressure in the hydraulic cylinders, which is
detected by the pressure transducer (CP011-B01). Both signals (limit switch and programmed
pressure value) at one time indicate that the Gate is fully opened.

12.2.1.5 Maintenance Mode of Weir Gates

For adjustments or dogging of a gate a maintenance mode is provided. Maintenance operation of

a gate is only possible via the pendant control =51LNC00 GK001-A01.
12.2.1.5.1 Maintenance operation of one Radial Gate

Preconditions:

 Relevant mode selector switch –S23 respectively -S31 in MAINTENANCE position

 Pendant control =51LNC00 GK001-A01 is plugged-in into relevant socket =51LNC11 GF002-
XS04 respectively =51LNC21 GF002- XS04

 Either mode selector switch –S21 or –S22 in AUTO position

 Relevant Radial Gate unlocked

 No relevant fault indicated at the alarm list of the touch panel –A02
By pressing the push button –S11 at the pendant control the relevant Radial Gate is opened until
the limit switch CG001–S01 GATE FULLY OPENED is reached. Opening procedure is the same as
described in item 6.2.1 “Opening of Weir Radial Gate”.
By pressing the push button –S12 at the pendant control the relevant Radial Gate is closed until
the limit switch CG001–S03 GATE CLOSED is reached or the STOP command by pressing the push
button –S13 at the pendant control is initiated. Closing procedure is the same as described in item
12.2.1.2 “Closing of Weir Radial Gate”.

12.2.1.5.2 Maintenance operation of one Flap Gate

Preconditions:

 Relevant mode selector switch –S27 respectively -S35 in MAINTENANCE position

 Pendant control =51LNC00 GK001-A01 is plugged-in into relevant socket =51LNC12 GF002-
XS04 respectively =51LNC22 GF002- XS04

 Either mode selector switch –S21 or –S22 in AUTO position

 No relevant fault indicated at the alarm list of the touch panel –A02
By pressing the push button –S11 at the pendant control the relevant Flap Gate is opened until
the limit switch CG001–S01 GATE OPENED is reached or the STOP command by pressing the push
button –S13 at the pendant control is initiated.
Opening procedure is the same as described in item 6.2.6 “Opening of Weir Flap Gate”.
By pressing the push button –S12 at the pendant control the relevant Flap Gate is closed until the
limit switch CG001–S02 GATE CLOSED is reached or the STOP command by pressing the push
button –S13 at the pendant control is initiated.
Closing procedure is the same as described in item 12.2.1.3“Closing of Weir Flap Gate”.

12.2.1.6 Operation of the Weir Gates without control voltage (or PLC fault)

If the control voltage of the valves or the power supply of the PLC fails, the hydraulic system can
be operated manually. That means, all valves have to be actuated by means of their manual
actuating advices and the electric motors have to be switched on manually via the appertaining
selector switch.

12.2.1.6.1 Operation of one Radial Gate without control voltage

The electric motors can be switched on directly by the selector switches motor pump #1 (51LNX10
AP001-M01) selector switch –S21 and
motor pump #2 (51LNX10 AP002-M02) selector switch –S22.
These switches have the positions AUTO – OFF – MANUAL. To switch on the motor pumps, the
selector switches have to be switched in position MANUAL.
Note: For operation, only one pump has to be switched on!
The normally solenoid operated main directional valve AA112 has to be actuated manually by
means of the manual actuation devices attached to the solenoid –Y02. Due to this actuation, the
main directional valve is shifted into position 3, lifting position.
After this, the pressure relief valve AA301 has to be actuated manually by means of the manual
actuation devices attached to the solenoid –Y01 of the valve.
If the pressure relief valve is actuated, the Gate starts raising. To stop the raising motion, switch
off the pumps or remove the manual actuation of the pressure relief valve and remove the
actuation of directional valve AA112.

12.2.1.6.2 Closing of one Radial Gate without control voltage

The electric motors can be switched on directly by the selector switches motor pump #1 (51LNX10
AP001-M01) selector switch –S21 and
motor pump #2 (51LNX10 AP002-M02) selector switch –S22.
These switches have the positions AUTO – OFF – MANUAL. To switch on the motor pumps, the
selector switches have to be switched in position MANUAL.
Note: For operation, only one pump has to be switched on!
The normally solenoid operated main directional valve AA112 has to be actuated manually by
means of the manual actuation devices attached to the solenoid –Y01. Due to this actuation, the
main directional valve is shifted into position 2, lowering position.
After this, the pressure relief valve AA301 has to be actuated manually by means of the manual
actuation devices attached to the solenoid –Y01 of the valve.
If the pressure relief valve is actuated, the Gate starts lowering. To stop the lowering motion,
switch off the pumps or remove the manual actuation of the pressure relief valve and remove the
actuation of directional valve AA112

12.2.1.6.3 Closing of one Flap Gate without control voltage

The electric motors can be switched on directly by the selector switches motor pump #1 (51LNX10
AP001-M01) selector switch –S21 and
motor pump #2 (51LNX10 AP002-M02) selector switch –S22.
These switches have the positions AUTO – OFF – MANUAL. To switch on the motor pumps, the
selector switches have to be switched in position MANUAL.
Note: For operation, only one pump has to be switched on!
The normally solenoid operated 3/2-way poppet valve AA110 has to be actuated manually by
means of the manual actuation devices attached to the solenoid –Y01. Due to this actuation, the
3/2-way poppet valve is shifted into lifting position.
After this, the pressure relief valve AA301 has to be actuated manually by means of the manual
actuation devices attached to the solenoid –Y01 of the valve.
If the pressure relief valve is actuated, the Gate starts raising. To stop the raising motion, switch
off the pumps or remove the manual actuation of the pressure relief valve and remove the
actuation of 3/2-way poppet valve AA110.

12.2.1.6.4 Opening of one Flap Gate without control voltage

The normally solenoid operated 3/2-way poppet valve AA111 has to be actuated manually by
means of the manual actuation devices attached to the solenoid –Y01. Due to this actuation, the
3/2-way poppet valve is shifted into lowering position.
To stop the lowering motion, remove the actuation of the 3/2-way poppet valve AA111.

12.2.1.7 Operation of Weir Gates without power supply

If the power supply fails (or in case of locking/unlocking) of the Radial Gates) the hydraulic
system can be operated manually. That means that the manual pump has to be used for lifting.

12.2.1.7.1 Opening of one Radial Gate without power supply

Turn the motor pump selector switches –S21 / -S22 into “OFF” position.
The shut-off valve 51LPX10 AA501has to be opened.
The normally solenoid operated main directional valve AA112 has to be actuated manually by
means of the manual actuation devices attached to the solenoid –Y02. Due to this actuation, the
main directional valve is shifted into position 3, lifting position.
Actuate hand pump KP003. The gate starts lifting.

12.2.1.7.2 Closing of one Radial Gate without power supply

Turn the motor pump selector switches –S21 / -S22 into “OFF” position.
Open shut off valve AA512 at the control manifolds for Weir Gates.
The gate starts lowering. To stop the lowering motion of the gate, close shut off valve AA512.

12.2.1.7.3 Closing of one Flap Gate without power supply

Turn the motor pump selector switches –S21 / -S22 into “OFF” position.
The shut-off valve 51LPX10 AA501has to be opened.
The normally solenoid operated 3/2-way poppet valve AA110 has to be actuated manually by
means of the manual actuation devices attached to the solenoid –Y01. Due to this actuation, the
3/2-way poppet valve is shifted into lifting position.
Actuate hand pump KP003. The gate starts lifting (closing).

12.2.1.7.4 Opening of one Flap Gate without power supply

The normally solenoid operated 3/2-way poppet valve AA111 has to be actuated manually by
means of the manual actuation devices attached to the solenoid –Y01. Due to this actuation, the
3/2-way poppet valve is shifted into lowering position.
The gate starts lowering.
To stop the lowering motion, remove the actuation of the 3/2-way poppet valve AA111.

12.3 Trash rack Cleaning Machine

General
The rake cleaning machine is inserted into the site clearance of the trash rack with the weir
intake.
The removal of the cleaning debris occurs with the sheet folds in a cleaning debris container,
which is connected with the RCM and is carried with it. The container can be decoupled from the
RCM at the end of the running rail and then switched out or emptied.
The system is conceptualized in such a way that it can be operated automatically (without
manning) or manually controlled. However, inspections in intervals of around a week are to be
performed.
The machine is executed as a mobile rake cleaning machine, type RCM-KA-f.
It consists of the following components:
1. Undercarriage with running gear and running rail
2. Platform with wheel house and balance weight
3. Main arm
4. Articulated-arm
5. Cleaning level
6. Hydraulic Unit
7. Electrical switch and control system
8. Cleaning debris container
The running rails consist of stable I-bearers with welded galvanized flat steel, mounted directlyon
the foundation.
The undercarriage basically consists of a manufactured metal sheet made of a base frame with
aconsole mounted on it and both wheel carriers. In the wheel carriers, where the wheel blocks
aremounted, receive the forces which are freed during the cleaning process, in order words they
leadthem over the running rails back into the foundation.
The main arm and articulated-arm are built onto the. Both arms consist of stable hollow
profiles.They can be moved independently of one another with the hydraulic cylinders.
The platform is mounted on the wheel carriers. The wheel house and balance weight are built
onthe platform. In the wheel house, you can find the hydraulic unit as well as the switch and
controlsystems. The local operation of the machine can be found on the wheel house.
The cleaning level is screwed on the lower end of the articulated-arm and gears into the
clearedrake with the tooth blades.
The cleaning debris gripped by the cleaning level is pulled up over the rake and the folds and
thrown in the cleaning debris container.

12.3.1 Touch Panel Control Unit

Generally, all turquoise buttons are for switching between images. With the violet button, the
procedures can be released and numerical values can be changed in yellow colored fields.

12.3.1.1 Start Screen

Figure 12.1: Start Screen

The screen change buttons, on the lower edge of the screen, are for operating a change to the
named image, respectfully.
The start screen appears when the controlling is turned on and is reachable at any time with the
button “start image”.

 Display of system date and time (this time information is also used for alarms).
 Display of the hours of operation (of the hydraulic unit).
12.3.1.2 Operational Display

Figure 12.2: Operational Display

The screen change buttons on the edge of the image operate the change to the named image,
respectfully.

 Display from horizontal (X-) and vertical (Z-) positions, measured from the axis of the
main arm,
 Display of the angle of the main arm to the horizontal,
 Display of the angle of tilt, 0° according to the cleaning position, positive to the left,
negative to the right,
 Display of the cleaning position in mm,
 The range of the values is written beside the displays.
 Display of the hydraulic oil temperature,
 Display of whether or not the hydraulic is running,
 Operating button for the switching to the mode “stop log set”,
 Operating button for the switching in “local automatic “, button changes with active
“local automatic” to the color green (only possible in mode of operation “local”),
 Operating button for the starting of a cleaning cycle in “local automatic”,
 Operating button for rotating in the cleaning cycle in “local automatic”,
 Operating button for the drive of the 4-cleaning position as well as unload position in
“local automatic”. The set point of the positions is displayed below the buttons.

12.3.1.3 Setting

The screen change buttons are in the lower image edge and operate a change to the named
image,
respectively.

 Operator panel for the setting of the speed in manual operation, acts on the knob button
of the control pendant.
 Screen selection for the setting of the lever position
 Screen selection for the meeting of pre-selections
Figure 12.3: Settings

12.3.1.4 Positions

Figure 12.4: Positions

A password with level “User” is required for all input in this image!
The button “BACKWARD” operates a return to the image “settings”.

 operator panels for the input of the cleaning positions. (1/1…2/2)

 Operator panel for the input of the unload position. (Unload)
 Operator panel for the input of the resting positions. (Rest pos.)
 Operator panel for the input of the position over water (Over Water)
 Operator panel for the input of the position base. The cleaning lever can be found on
thebase of the intake before the rake. (Bottom pos.)
 Operator panel for the input of the lower end of the rake (Trash Rack),
  Operator panel for the input of the lever position during the drive (Top pos.)
 3 indication panels of the actual positions. (Act)

12.3.1.5 Pre-selections

Figure 12.5: Pre-selection

The button “BACKWARD” operates a return to the image “setting”.

 Button for the deactivation of the cleaning procedure on the machines 1, 2 and 3. On the
green colored button is the cleaning process allowed!
 2 buttons for the starting of the cleaning cycle of the respective machine.
 4 buttons for the deactivation of single panels. (panel 1/1…panel 2/3)
 4 indication panels for the count of the occurred mistake with the corresponding button
for acknowledgement/(Reset)
 panels for the input of the interval time with indication of the current elapsed time.

12.3.2 Local control

The Track rack cleaning machine can be operated locally using pendent connected to it.

Figure 12.6: Pendent

In the control pendant are 3 nob buttons built on. Activate them in order to swing the articulated
arm in and out, to lift the main arm and lower the machine left and right for driving. Set the
speed which is used in the image “setting”.

12.4 Desilter

12.4.1 Desilter Inlet Gate

The intake gate sits on the entrance of the desilter in order to close it. The gates basically consist
of the table, the reinforcement with the crossbeam as well as thehydraulic cylinders which are
positioned on it, the limit switch unit and the position encoder.
The gate table is a steel construction which consists of a retaining wall and a welded
stiffeninggirder out of I-profiles.
The bearing and guiding pads are made of synthetic material. The sealing occurs on both
sidesand on the front with a double emergency rubber profile. The base sealing occurs with a
flatgasket.
The lifting and lowering occur with two hydraulic cylinders. The table can be locked in the upper
position using two levers.
Limit switches are built on for the detection of the end position table opening and table
closing.The limit switch unit is mounted on the main head.
The activation of the limit switch occurs with the switching cams on a switch rod which is
carriedwith the table.
A rope pull giver is built on the main head for the detection of the position of the table. The
ropeis fastened using a connecting link on the table.
12.4.2 Desilter Flushing Gates
The flushing gates sit on the end of the desilter under the strainer screen in order to be able to
flush the sediment out of the desilter into the flushing canal.
The gates basically consist of the table, the reinforcement with the crossbeam as well as the
hydraulic cylinder which is situated on it and the limit switch unit.
The gate table is a steel construction consisting of a retaining wall and welded on stiffening
girder out of I-profiles.
The bearing and guiding pads are made out of synthetic material. The sealing occurs on both of
the sides and on the front with an emergency rubber profile. The base sealing occurs with a flat
gasket.
The lifting and lowering occurs with a hydraulic cylinder.
The table can be locked in the upper position using two levers.
Limit switches are fitted on for the detection of the end position table opening and table closing.
The limit switch unit is mounted on the main head. The activation of the limit switch occurs with
the switching cams on a switch road with which the table is carried. The flushing of the Desilting
Chambers is given in Annexure 02.
12.4.3 Desilter Outlet Gate

The outlet gates sit on the exit of the desilter in order to close it. The gates basically consist of
the table, reinforcement with the crossbeam as well as the hydraulic cylinder situated on it, the
limit switch unit and the position encoder.
The gate table is a steel construction which consists of a retaining wall and welded on stiffening
girder out of I-profiles.
The bearing and guiding pads are made out of synthetic material. The sealing occurs on both of
the sides and on the front with a double emergency rubber profile. The base sealing occurs with a
flat gasket.
The lifting and lowering occur with a hydraulic cylinder.
The table can be locked in the upper position using two levers.
Limit switches are fitted for the detection of the end position table opening and table closing.
Thelimit switch unit is mounted on the main head.
The activation of the limit switch occurs with the switching cam on the switch rod with which
thetable is carried.
A Seilzuggeber is built on the main head for the detection of the table. The road is fastened using
a connecting link.

12.4.4 Screen Cleaning Machine

The rake cleaning machine inserted to the site clearance of the strainer screen. The rake debris is
transported through the cleaning lever in the rinsing channel and from there flushed out using
the flushing pump in the flushing canal.
The system is conceptualized in such a way that it can be operated automatically, without
occupation. However, inspections within an interval of a week are to be performed.
The machine is a hydraulic rope pull rake cleaning machine, executed with swiveling levers.It
consists of a stable mount with a drive head fixated on it with cleaning lever, steel folds a lever
guides.
Limit switches are fitted on the drive head for the detection of the end position “lever swivel in”
and “lever swivel out”, which can be activated with switch rods on the swivel arm.
The detection of the end position “lever up” and “lever down” occur through a gears-cam-
limitswitch which is mounted on the drive cable of the rope drum.
The monitoring of the stroke rope is realized through the cable pulley, which is activated with
therope breakage of a limit switch.

12.4.5 Sediment Measuring System

Nine gravel scales are mounted in the de-sanding basin. They have the task of monitoring the
debris supply and to lead a flushing cycle when necessary.
The weight of the rubble lying on the rubber membrane is carried over the liquid filling on a
pressure transducer in the steel body. They transfer an electric signal over the cable connection
onto the evaluation unit in the clearance site.

12.4.6 Operation of Desilter Gates

12.4.6.1 Touch Panel Control Unit

The operation can occur on two touch panels. The first is installed in the switch cabinet
Upstream, the other in the switch cabinet Downstream. The operation occurs as far as possible in
the same efficiency. Therefore, only one panel will be described here. Differences between the
individual images will be pointed out extra.
Generally, all gray buttons are for switching between images. With the green button, the
procedures can be released and numerical values can be changed in yellow colored fields.
Start Screen:

Figure 12.7: Start Screen

The arrow keys on the lower image border cause it to turn a page further to the following
described mages.
With the “Alarm” button, the occurring malfunction is displayed in the image, with the
“acknowledge “button you can acknowledge malfunctions.
Desilter Hydraulic system:

Figure 12.8: Desilter Downstream Hydraulic System

Figure 12.9: Desilter Upstream Hydraulic System

Activate the “enable” button in the field of the respective pump in order to choose it. Now
thechosen button flashes bright green.

 Display of the hours of operation of both hydraulic pumps

 Display of the current oil temperature
Operational Display Screen Desilter 1:

Figure 12.10: Operational Display screen Desilter 1

Activate the “MAN” button. Thereby you have switched the mode of operation to manual. This
isdisplayed with a yellow deposit of the button. Now you can move the respective gates with the
buttons “lift” and “lower”. After activating the button, the gates drive into the corresponding
end
position. With the button “stop”, you can stop the movement before reaching the end
position.For the inlet gate, the additional “FL.POS” button is available. This activation of this
button releases astart-up of the flushing position. This is adjustable in the field “FL.POS”.
A bright green coloring of the button displays that the gate is in the corresponding end
position;the blinking of a button displays that the gate is moving in the direction of the end
position.
If one of the pressure switches alludes to an overload monitoring, “overload” appears next to
thecorresponding button.
Activate the “AUTO” button. Now you can start an automatic flushing cycle with the button
“START FLUSHING” in the field.
Activate the button “0” to avoid the operation of the desilter.
Activate the button “settings” in order to attain an image for the automatic start setting.

 Display position of the inlet gate and outlet gate:

Operational Display Screen Desilter 2 and 3:
For the operation of machines 2 and 3, two further, identical images are available for mounting
and for this reason will not be catered to here.
Automatic Start Settings Desilter:
Here the same images for setting for the automatic start of the desilters 1, 2, and 3 are described
by means of Desilter 1.

Figure 12.11: Image Settings Flushing Cycle Release

In this image, you can see the activation of the button “settings” in the operational displays of
the respective desilter.
Activate the button “ON” in order to turn on or off the interval control or rather the sediment
control of the respective machine. The button is yellow for control which is turned on.

Activate the button in order to bring back the previous image.

The following settings can be me in these images:

 The interval time between the automatic flushing cycles:

 The sediment level at which the flushing cycle should be released:

 The duration of the flushing cycle:

 The time lag after balancing the water-level: This time is started after balancing
the water level. After this process, the outlet gate opens.
The following values will be displayed:

 A countdown until the next flushing cycle

 The current sediment level
Display of the Sediment Measurement:

Figure 12.12: Image of the Display of the Sediment Measurement

The following values are displayed in this image:

 The current sediment level of the 3 desilters in the upper area, in the middle and in the lower
area.
Activate the button “calibrate” in the image in order to reach the setting of the probes of the
respective basin.
Sediment Probe Settings:
The identically constructed images are described here for the setting of the probes for desilters 1,
2 and 3.

Figure 12.13: Image Sediment Probe Settings

Activate the button “calibrate” in the image in order to reach the display of the sediment
measurement. This image is designated for initial operation and maintenance purposes. Thus, a
password is necessary in order to retrieve it.
In this image the following values will be displayed:

 The current level in the upper area, in the middle and in the lower area. Please note that it
concerns the water-level. Sand deposited on the sediment scales falsify the display.
 the corrected level values
 and the corrected values for the probes. This can be inserted signed. Lead a flushing cycle
through in order to be sure that there are not any deposits on the sediment scales. Close the
outlet gate and wait until the water-level calms. Measure the water-level and insert the
corrected value in a way that the corrected value agrees with the water-level.

12.4.6.2 Local Control boxes on the Gates

Local control boxes are fitted on all gates.

Figure 12.14: Local Control Boxes on the Gates

Turn the mode of operation on the respective machine on the touch panel to “manual “. Now
youcan operate the machine locally. Activate the button in order to conduct the thereupon
describedmovement (lifting, lowering).
This movement will only be conducted until the end position unless you activate
thecorresponding stop button.

12.4.7 Operation of Screen Cleaning Machine

12.4.7.1 Touch Panel Control Unit

Generally, all gray buttons are for switching between images. With the green button, the
procedures can be released and numerical values can be changed in yellow colored fields.
Start Screen:

Figure 12.15: Start Screen

The arrow keys on the lower image border cause it to turn a page further to the following
described images.

 With the “alarm” button, the occurring malfunction is displayed in the image, with the
button “acknowledge” you can acknowledge malfunctions.
 Display of system date and time (this time information is also used for alarms).
Hydraulic SCM Image:

Figure 12.15: Hydraulic SCM

Activate the button in the field of the respective pump in order to choose it. Now the chosen
button flashes bright green.

 Display of the hours of operation of both hydraulic pumps

 Display of the current oil temperature
Operational Display Screen Cleaning Machine 1:

Figure 12.16: Operational display screen cleaning machine 1

Switch the nob switch on the switch cabinet to “manual “. Now you can move the lever with the
buttons “lift”, “lower”, “swivel out” and “swivel in”. After activation of the button, the lever
drives into the corresponding end position. With the “stop” button, you can stop the movement
before it reaches the end position.
A bright green coloring of the button shows that the lever can be found in the corresponding
endposition; a blinking of the button that the lever is moving in the direction of the end position.
Switch the nob switch on the switch cabinet to “auto “. Now you can start an automatic
cleaningcycle with the button “Start”. Activate the button “stop” in order to break up a running
cleaning cycle.
Activate the button “difference” or “interval” in order to access the difference or rather the
interval control in the image.
Display difference:

 Current level difference before and after the rake

 Status of the lever control:

Difference start lined up

Difference control active,
Display interval:

 Time until the next interval start

 Status of the interval control is the same as described for that of the difference.
Operation Display Screen Cleaning Machine 2 and 3:
Two further images are built on and available for the operation of machines 2 and 3, and thus will
not be further described here.
Image for Difference Control:

Figure 12.17: Image of Difference control

In this image, you can reach the operation displays for the three machines by activating the
button “difference”.
Activate the button “enable” in order to turn on and off the difference control of the respective
machines. When turning on the difference control, the button is left yellow.
In this image, you can see the following values for all 3 machines:

 The level before the raking,

 the level after the raking,
 and the difference that occurs from it.
Exceed the current difference of a machine’s adjusted set point and difference control of this
machine is turned on and a cleaning cycle is released.
Activate the button “calibrate” in order to reach that which can be adjusted in the probes.
Interval Settings:

Figure 12.18: Interval settings image

Activate the button “interval” in the operational display of the 3 machines in order to reach it in
this image.
Input the wished interval time in the panel “SETPOINT “. This works for all 3 machines. This
interval time is restarted after a cleaning cycle of a machine.
The time until the next start of the machine is displayed under “ACTUAL “.
With the buttons “off”, “on” and “cont.”, you can switch the interval controls of the respective
machine out, on or continuous operation. The chosen mode is illustrated through a yellow
deposit of the button.
Flushing Pump:

Figure 12.19: flushing pump settings

In this image, you can set the mode of operation for the flushing pump. The current mode of
operation is displayed with a yellow deposited button.
Activate the button “enable” in order to enable the flushing pump. Now the flushing pump
runsafter every cleaning cycle of the machines and flushing for the time set in the panel
„SETPOINT “.
Activate the button “disable” in order to turn off the flushing pump. Thus, you can avoid
anautomatic running of the flushing pump.
Activate the button “cont.” in order to switch the flushing pump to continuous operation. This
canbe necessary when the rinsing channel is clogged and you need the flushing push for the
support of the manual cleaning.

12.4.7.2 Local control position of machine

Local control boxes are fitted on all 3 rake cleaning machines.

Turn the mode of operation on the respective machine on the touch panel to “manual”. Now you
can operate the machine locally. Activate the button in order to conduct the thereupon
described movement (lifting, lowering). This movement will only be conducted until the end
position unless you activate the corresponding stop button.
Figure 12.20: Local Control Boxes on the Machines
 SECTION A:

OPERATION MANUAL CHAPTER 13:FIREDETECTION AND

CHAPTER 13 PROTECTION SYSTEM

13.1 Introduction:

Hydrant system consist of a large network of pipes both underground and above ground which
feeds to a number of indoor and outdoor hydrant valves located throughout the area as specified
in the scope. These hydrants are located throughout the power station to meet requirements. In
case of fire these hoses shall be coupled to the respective hydrant valves through instantaneous
coupling and jet of water shall be directed on the equipment on fire.
It is always required that in the event of fire in any area, the water shall be available at the seat of
each hydrant valve with sufficient pressure so that, the firefighting operation shall be carried out
by opening the respective hydrant.
Necessary valves are provided on the ring mains for the purpose of isolation and maintenance.
The hydrant posts are installed on the hydrant ring main and these are min.1m above graded
levels.

13.2 Operational Details

The hydrant system has rightly termed as the backbone of entire firefighting system since a well-
designed and well laid installation, effectively fight fires of serious proportions and of all the class
of risk. Piping being buried underground or placed aboveground, it still continues to be in
operation in utility area even when part of effected building structure etc. have collapsed.
Moreover, jet of water effectively screens off the adjoining properties of fire, simultaneously
cooling the risk, affected by the fire to prevent and further spread of fire.
As the efficiency of the hydrant system ultimately depends upon the manner and speed with
which its efforts are directed, squad consisting of watch and ward personnel; departmental
supervisors trained in the operation of the fire service must be maintained in the premises
around the clock.

13.2.1 Spray System

The spray system is used protect plant-equipment structure and machinery against fire that may
involve highly flammable liquids, gases and solids by the application of water by most effective
manner, in the correct quantity and at the right place.
The equipment is permanently installed around the risk and, where practicable, installations
should be automatically controlled for immediate operation in the event of fire certain special
installations are designed with only manual controlled but wherever possible the system is
designed to respond automatically to the heat of a fire, with freedom from human element.

13.2.2 Automatic high velocity water spray system

Ring mains of high velocity water nozzles around the transformer, similarly a ring main charged
with pressurized water and running parallel to the ring main surround the transformer having
detectors Quartzite bulb provided on it. Both these ring mains are connected to the deluge valve.
The detectors are of quartzite bulb type of 79 Deg. fixed temperature setting and high velocity
water nozzles of various spray angles and flows are provided in all the rings so as to cover
transformers surfaces and surrounding floor area. The location of nozzles and detectors are
designed to cover the complete prismatic area of the transformers well as overlap their ranges.
The high velocity water nozzle ring main piping above the deluge valve is of dry pipe and below
deluges valve is charged with pressurized water.
The detectors ring mains are charged through the open high velocity water nozzles with
pressurized water and connected to the deluge valve detection trim. The seat of the deluge valve
holds back the pressurized water below due to the trimming catch. When a fire is sensed by any
of the detectors surrounding the transformers the quartzite bulb of the detectors will get fused.
This will create a pressure drop in the detector line causing the detection trim of the deluge valve
get trimmed and release the valve seat thereby allowing the pressurized water to discharge from
the upper chambers of the deluge valve and spray on to the complete prismatic surface area of
the transformers which is under fire and also to its surrounding ground area through the open
high velocity water nozzles of the ring mains in order to give a total flooding

13.2.3 Operation of deluge valve

Charging
1. During the charging of deluge valve, ensure that the discharge valve for dry line is in closed
position.
2. Charge the detection line by opening the globe valve.
3. Open the suction valve for deluge.
4. Ensure that the pressure is in detection line and suction line.
5. Open the discharge valve.

13.2.4 Auto operation of deluge valve

Under working conditions, the wet/dry detection system is filled with pressurized water by the
spray pipe network. The pressure keeps the deluge valve closed. That means, the water pressure
in the upper chamber deluge valve keeps the valve towards the feed pipe tight. One of the
strategically distributed detectors in the area protected by the deluge valve is exposed to an
arising fire, the glass bulb will burst and the pipe will release the water from the detection
system. The rapidly dropping pressure allows the piston valve now the area protected by the
deluge valve will be completely covered with a fire water spray.

13.2.5 Manual operation

Deluge valve shall be activated by using the manual lever or by breaking the glass of DVCP panel.
Resetting of Deluge valve
 SECTION A:

OPERATION MANUAL The valve towards the feed pipe must be closed. Ensure that the
valve is drained by pushing the knob of the drip check valve. Then
CHAPTER 14
open the inspection cover and clean the internal parts from all dirt
and soil.

CHAPTER 14: DIESEL GENERATORS

14.1 400kVA Diesel Generator

Cummins heavy-duty engines are designed to operate successfully at full throttle under transient
conditions down to peak torque engine speed (RPM). This is consistent with the recommended
operating practices for good fuel economy.
Excessive full throttle operation below peak torque rpm will shorten engine life to overhaul, can
cause serious engine damage, and is considered engine abuse. Peak torque RPM varies from
1,100 RPM, depending upon rated engine speed.

14.1.1 Operation

General
Correct care of your engine will result in longer life, better performance and more economical
operation.

 Follow the daily maintenance check list in Maintenance Guidelines.

 Check the oil pressure indicators, temperature indicators, warning lights and other
gauges daily to make sure they are operational.

14.1.1.1 Starting the Engine

The engine requires clean air and fuel to be supplied to the combustion chambers in proper
quantities at the correct time.
Caution: While staring the engine, do not touch the throttle or throttle lever
Normal Staring Procedure
Warning: Before starting, check to make sure everyone is clear of engine and equipment to prevent
accidents.
If fuel system is equipped with over speed stop, push “Reset” button before attempting to start
engine.
1. On units equipped with air activated prelube device, open air valve until oil pressure is
registered on oil pressure gauge to activate piston in prelube device which will lubricate all
moving parts in engine.
2. Set throttle for idle speed and disengage driven unit.
3. Open manual fuel shut down valve, if so equipped. Electric shut down valves operate as
switch is turned on. A manual override knob provided on forward end of electric shut-down
valve allows valve to be opened in case of electric power failure. To use, turn fully clockwise;
return to “run” position after electric repair.
4. Press starter button or turn switch key to “Start” position and crank the engine till it fires.
5. At the initial start or after oil or filter changes and after engine has run for a few minutes,
shut it down and wait for 15 minutes for oil to drain back into pan. Check engine oil level
again, add oil as necessary to bring oil level to “H” mark on dipstick. The drop in oil level is
due to absorption by oil filters

14.1.1.2 Engine Warm-Up

When the engine is started, it takes a while to get the lubricating oil film re-established between
shafts and bearing and between pistons and liners. The most favorable clearance between
moving parts are obtained only after all engine parts reach normal operating temperature. Avoid
seizing pistons in liners and running dry shafts in dry bearings by bringing the engine up to
operating speed gradually as it warms up.

14.1.1.3 Engine Shut Down

 Allow the engine to idle three to five minutes after a full load operation before shutting it
off. This allows the engine to cool gradually and uniformly.
 Turn the ignition key switch to the OFF position. If the engine fails to stop running, rotate
the manual fuel shutoff thumb screw counter-clockwise to make sure the valve is not
bearing held open by the manual override screw.

14.2 160kVA Diesel Generator

14.2.1 Operation

14.2.1.1 Starting the Engine

Before starting the engine, perform daily maintenance checks.

Caution:To prevent damage to the starter, do not engage the starting motor more than 10 to 12
seconds. Wait 2 minutes between each attempt to start. If the engine does not start after three
attempts, check the fuel supply system. Absence of blur or white exhaust smoke during cranking
indicates that no fuel is being delivered. Move the throttle position to idle as soon as the engine
starts. Engine oil pressure must be indicated on the gauge within 15 seconds after starting.

14.2.1.2 Stopping the engine

Remove the load from the engine. Run the engine few minutes before routine shut down, on no
load.
It will allow the lubricating oil and coolant to carry heat away from the combustion chamber,
bearings, shafts etc. This is especially important for Turbocharged engines.
14.2.1.3 Operating the engine

 Do not operate the engine at full throttle below peak torque engine speed for extended
periods (More than 1 minute) of time.
 Allow the engine to idle 3 to 5 minutes before shutting it off after a full load operation.
 Monitor the oil pressure and coolant temperature gauges frequently. Shut off the engine if oil
pressure or coolant temperature does not meet specifications.
 Continuous operation of the engine with low or high coolant temperature can damage the
engine.
 Most failures give an early warning. Look and listen for changes in performance, sound or
engine appearance that can indicate service or engine repair is needed. Some changes to look
for are as follow:
 Engine misfires
 Vibration
 Unusual engine noise
 Fuel, oil or coolant leakage
 Sudden change in engine operating temperature or oil pressure
 Excessive smoke
 Loss of power
 An increase in oil consumption
 An increase in fuel consumption
 SECTION A:

OPERATION MANUAL

CHAPTER 15

CHAPTER 15: CONTROL SYSTEMS

15.1 Overview

The control and monitoring system is defined to operate the HPP DAGACHHU including the 220kV
switchyard and the dam area from the control room in the power station.
In addition, there are local HMI systems related to the different plant areas which are as follows:

 Unit 1
 Unit 2
 Power Cavern
 Dam
 Desilter
Following equipment is controlled by the control system:
i. Controlled/monitored equipment for each unit:
 Spherical valve
 Turbine and governor
 Generator and excitation
 11 kV bus ducts
 Transformer unit
 Cooling water equipment
 All auxiliary equipment
ii. Controlled/monitored equipment for the general services of the power plant: Electrical
auxiliaries:
 Auxiliary supply systems: 110 V DC, 24 V DC
 230 V, 50 Hz and uninterruptable power supply system (UPS)
 Station services: 33 kV, 11 kV and 400/230 V 50 Hz AC systems
 Emergency diesel generator unit
iii. Mechanical auxiliaries:
 Ventilation and air conditioning
 General compressed air supply
 Fire detection
iv. Hydraulic auxiliaries:
  Water level measurement
 Drainage water system
 Cooling water system
 Bottom outlet valves
 Intake gates
 Valve chambers
 Spillway Gates
v. Controlled/monitored equipment for the switchyards:
 220 kV GIS switchyard
The control and monitoring system enables supervision and control of all controllable
mechanical, hydro-mechanical and electrical equipment of the Dagachhu Hydro Power Plant.

15.1.1 Locations

There are the following main locations within the HPP DAGACHHU facility:

220 220kV Switchyard 00

U1 Unit 1 01

U2 Unit 2 02

PC Power Cavern 20

CB Control Building 25

DAM Dam 51

DESI Desilter 52

SUSH Surge Tank 55

HVAC Heating-Ventilation-Air Conditioning 60, 61, 71

15.1.2 Plant Areas –Automation Cells

The control and monitoring system is divided into the following plant areas. Each plant area has
its own automation cell.

UNIT1 Unit 1

UNIT2 Unit 2

PCCOM Power Cavern Common + 220kV Switchyard

CBCOM Control Building Common + Surge Tank +HVAC

DAM Dam
DESI Desilter

One automation cell is used for each plant area. The automation cells consist of the following
parts:

…HMI local HMI system based on CENTRALOG C10 (not for location CBCOM)

…CL cell controller for the processing of the control functions of the plant area based on
MFC1000

…IO for analogue and digital inputs and outputs the CE1000 is used

For the locations UNIT1, UNIT2, CBCOM and PCCOM there are additional MODBUS connections to
other systems.

15.2 Control Room

The plant will generally be operated from the three operator stations.

Operator station 1 C30 system + 25CKA00 control room

Operator station 2 C30 system + 25CKA00 control room

Operator station CVS system + 20CKA00 power cavern

The CVS station uses the C30 stations as interface to the process. The software functions of the
CVS are based on the CENTRALOC C30 system.
The status of the processes is represented on the visual display units (VDU) in the form of
processdisplays (Mimic views). Elements such as dynamic objects, trends, alarms, event lists,
messages, color changes and flashing symbols are used to draw the attention of the operator to
changes in theprocess and departure from normal and given general information.
The displays will be presented on high-resolution color monitors. This function together with
windowoverlapping capabilities will provide a uniquely powerful operating environment.
Displaying the status of the process and the presentation are done by the following:

 Process displays
 Overview and group displays
 Object displays
 Curve displays
 Alarm and event list
 Status list
The displays are organized in that way that the required information can be found quickly. It is
possible for the operator to view different displays on the two VDUs simultaneously. The
operator is able to control from both VDUs by means of a keyboard and mouse. With dedicated
keys on the keyboard or moving the cursor using the mouse device, the operator is able to select
which VDU is currently active for operation.
The operator station contains only information that is related to the presentation and to manual
control operations. The control functions itself are provided within the cell controllers of the
different plant areas.

15.2.1 Control Room Equipment

Within the control room there is the following equipment for the operation of the Dagachhu
Hydro Power Plant facility:
Computers:
Printers:
Two printers are part of the control system
Control building:

 HP A4 Colour LaserJet CP2025dn

 HP A3/A4 Colour LaserJet 5550n
Power cavern:

 HP A4 Colour LaserJet CP2025dn

The control room allows operation of the entire Dagachhu Hydro Power Plant facility consists of:
C30 Operator Station 1 with the following functions:

 HISTORIAN-S
 OPC-S
 STORAGE-S
 HMI
 HMI-WEB
C30 Operator Station 2 with the following functions:

 HISTORIAN-S
 OPC-S
 STORAGE-S
 HMI
 HMI-WEB
CVS (Central View Station) Operator station with the following functions:

 HMI
The STORAGE-S function enables the storage of the historian data. The HISTORIAN-S function
enables the access to the historian information. The OPC-S enables an OPC-Server on the Station
allowing OPC-Connections. The HMI function enables the Human Machine Interface (HMI) on the
Station to allow the operation of the HPP DAGACHHU facility. The HMI-WEB function enables a
web server on the station to allow remote access to the HMI
Engineering Station:
The engineering of the control system software is done with a CONTROCAD (CCAD) station. The
CCAD station is based on a notebook computer.

15.2.2 Startup of Operating Station

After power up of the Operating Station Windows XP is starting. In addition, the CENTRALOG
software is also started.
After starting of the CENTRALOG the ALSPA HMI will open and the Login is requested. With
successful login, the initial view is started and the Operating Station can be used.

15.3 Local HMI

Local HMI systems utilizing touch screen technology are provided to operate the various plant
areas and units at a local level. The software functions are based on the CENTRALOC C10 system.
For the following plant areas are local HMI systems available:

Unit 1 C10 system +01CJA00 unit 1 control cubicle

Unit 2 C10 system +02CJA00 unit 2 control cubicle

Power Cavern C10 system +20CBA00 common control cubicle

Dam C10 system +51CBD00 dam control cubicle

Desilter C10 system +52CBD01 desilter control cubicle

The local control functions are only used during commissioning, maintenance and
emergencies.The information is limited to the process area where the touch panel is
implemented.
Displaying the status of the process and the presentation are done by the following:

 Process displays
 Overview and group displays
 Object displays
 Curve displays
 Alarm and event list
 Status list
The handling of the operation provided by the local HMI is similar to that of the operator stations
in the control room.

15.3.1 Local HMI Equipment

The Local HMI systems allowing operation of the local plant areas of the HPP DAGACHHU facility
consists of:
C10 Operator Station with the following functions:

 HISTORIAN-S
 OPC-S
 HMI
 HMI-WEB
The HISTORIAN-S function enables the access to the historian information. The OPC-S enables an
OPC-Server on the Station allowing OPC-Connections. The HMI function enables the Human
Machine Interface (HMI) on the Station to allow the operation of the local area of the Dagachhu
Hydro Power Plant facility. The HMI-WEB function enables a web server on the station to allow
remote access to the HMI.

15.3.2 Startup of local HMI

After power up of the Local HMI station Windows XP is starting. In addition, the ALSPA HMI and
the MY-TSOFT program are starting. MY-TSOFT provides a touch screen software keyboard
function.
After starting of the CENTRALOG software the ALSPA HMI will open and the Login is requested.
With successful login, the initial view is started and the local HMI can be used.

15.4 Communication

15.4.1 E8000 – Field Bus

The communication within each automation cell is done via the E8000 Field Network. The
E8000network is based on the Ethernet power link standard.

 Fast Ethernet (100 Mbits/s)

 Deterministic (5ms for data exchange)
 Copper or optical fiber solution
 Bus or Star topology
 Based on Ethernet Power Link technology (EPL), an open standard (IEC standard 61784-2)

15.4.2 S8000-E – Process Bus

The communication between the different automation cells and as well with the control
roomequipment is done via the S8000-E Unit Network. The S8000-E network is based on
Ethernet standard.

 Fast Ethernet 100Mbits/s or 1Gbits/s

  Deterministic with utilization of standard industrial switches (RS20 or RS30 switches from
Hirschmann manufacturer respectively for 100Mbits/s or 1Gbits/s)
 Copper or optical fiber solution
 Bus or ring topology integrating the fault tolerant concept
 Based on standard Ethernet protocol UDP-TCP/IP, with addition of a reliability layer to
ensure that the addressee receives the variables correctly

15.4.3 Site Network-Enterprise Bus

Communication between the control room equipment is done via the Site Network. The Site
Network is based on Ethernet standard.

 Fast Ethernet 100 Mbits/s switched network

  Bus topology as standard
 Simplex
 Copper 10/100Base-TX, maximum operating distance of 100m
 Optical fiber between 2 Ethernet switches, maximum operating distance of 2000m

15.4.4 TCP/IP Site Network Addresses

The addresses of the Site Network equipment are defined as follows:

Short name Description TCP/IP Address

U1_C10 Unit 1 C10 system 10.18.184.51

U2_C10 Unit 2 C10 system 10.18.184.52

COM_C10 Common C10 system 10.18.184.53

SP_C10 Spare C10 system 10.18.184.54

WI_C10 Weir and Intake C10 system 10.18.184.55

DO_C10 Desilter Outlet C10 system 10.18.184.56

OS1_C30 Operator Station 1 C30 system 10.18.184.59

OS2_C30 Operator Station 2 C30 system 10.18.184.60

ES_NB Engineering Notebook 10.18.184.63

CB_PR1 Control Building printer 1 A4 10.18.184.190

CB_PR2 Control Building printer 2 A3 10.18.184.191

PC_PR Power Cavern printer 10.18.184.192

PC_CVS Power Cavern Central View 10.18.184.217

CLK GPS CLOCK 10.18.184.253

TE_COM Telecom system NA

Table 15. 1: Address of Site Network

15.4.5 S8000-E TCP/IP Unit Network Addresses

The addresses of the S8000-E Unit Network equipment are defined as follows:

Short name Description TCP/IP Address

U1CL Unit 1 MFC 195.0.0.1

U2CL Unit 2 MFC 195.0.0.2

PCCL Common Power Cavern MFC 195.0.0.3

CBCL Common Control Building + Surge Tank MFC 195.0.0.4

DACL Weir and Intake MFC 195.0.0.5

DICL Desilter Outlet MFC 195.0.0.6

U1_C10 Unit 1 C10 system 195.0.0.51

U2_C10 Unit 2 C10 system 195.0.0.52

COM_C10 Common C10 system 195.0.0.53

SP_C10 Spare C10 system 195.0.0.54

WI_C10 Weir and Intake C10 system 195.0.0.55

DO_C10 Desilter Outlet C10 system 195.0.0.56

OS1_C30 Operator Station 1 C30 system 195.0.0.59

OS2_C30 Operator Station 2 C30 system 195.0.0.60

ES_NB Engineering Notebook 195.0.0.63

PC_CVS Power Cavern Central view station 195.0.0.217

Table 15. 2: S8000-E Unit Network

15.5 Data Acquisition

15.5.1 Cell Controller - MFC1000

The ALSPA MFC1000 is a real-time Multi-Function Controller of the ALSPA Control System.
Itprovides the following main automation cell functionalities:

 Fast processing of Automation

 Data (opened loop, closed loop)
 I/O Management
 Supervision dialog
 Field networks management
 Redundancy management
 Time stamping events and sampled measurements
 Diagnostic messages
 Centralized cell downloading and settings
 Sequence control
The MFC1000 is available for high-performance applications that require a powerful processor.
These processors, developed specially for mobile computing, offer many advantages for
industrialapplication. They combine a high computing capacity with low power consumption.
The MFC1000 is specially designed to be used without fans (Fanless).
There are six cell controllers for the HPP DAGACHHU facility, one for each cell:

UNIT1 Unit 1 01

UNIT2 Unit 2 02

PCCOM Power Cavern 00, 20

CBCOM Control Building 25, 55, 60, 61, 71

DAM Dam 51

DESI Desilter 52

The cell controller is connected to the S8000-E network and to the E8000 (EPL) field bus of the
automation cell. For the cell controller UNIT1, UNIT2, PCCOM and CBCOM the MODBUS port
isalso used to acquire data from external systems.

15.5.2 Field Controller - CE1000

The ALSPA CE1000 I/Os allows connecting a large range of distributed I/Os modules thanks to
aBus Coupler interface. ALSPA CE1000 distributed I/O provides a large range of best of class
Inputsand Outputs modules like Digital, Analog, Thermocouple, RTD, Counters, …
The distributed CE1000 field controllers are connected with high performance bus couplers over
theE8000 field bus to the MFC1000 cell controller.
ALSPA CE1000 Technology features:

 Modular, flexible and decentralized architectures according to the Plant size

 Compact and highest component density on minimal space
 Hot swap of I/Os modules
 Facilities for I/Os Wiring
 Fast scan time I/O bus (X2X) compatible with DCS constraints and extendable up to 4 rails
each one separated by 100m max.
 High performance Bus Couplers connected by Ethernet Power Link technology to the
ALSPA E8000 Field Bus
In the six automation cells, there are the following field controllers included:
UNIT1

 U1IO Unit 1 I/O

 U1GE Unit 1 Generator
 U1TU Unit 1 Turbine
 U1TC Unit 1 Transformer Cavern
UNIT2

 U2IO Unit 2 I/O

 U2GE Unit 2 Generator
 U2TU Unit 2 Turbine
 U2TC Unit 2 Transformer Cavern
PCCOM

 PCIO Power Cavern I/O

 PCGE Power Cavern Generator
 PCTU Power Cavern Turbine
 TCIO Transformer Cavern I/O
CBCOM

 CBIO Control Building I/O

 SUIO Surge Tank I/O
DAM

 DAMIO Dam I/O

DESI

 DIIO Desilter I/O

15.5.2.1 Analogous Inputs

Transducers are used to measure electrical or mechanical values within the plant. The
transducerscreate 4..20 mA current signals related to the measurements.
The current signals from the plant are connected to the control system by input cards. The input
cards are installed in the cell- or field controllers.
The used cards are of the type X20AI4622. There are 4 inputs on one card with 12 bits resolution.
Within the controllers a range from 0…32767 is used to represent the measurement by means of
variables (model EPL_AI).
There are LED indicators on the module X20AI4622, which provide module and user supply status.
15.5.2.2 Temperature Inputs

PT100 sensors are used to measure temperature values within the plant.
The temperature signals from the PT100 sensors are connected to the control system by input
cards.
The used cards are of the type X20AT4222. There are 4 inputs on one card.
Within the controllers a range from -2000 to 8500 is used to represent a temperature from -200°C
to 850°C by means of variables (EPL_AI). Within the local HMI and the operator station a range of
-50°C to 200°C is used.
There are LED indicators on the module, which provide module and user supply status.

15.5.2.3 Digital Inputs

Digital signals of sensors, switches, circuit breakers, conductors etc. are connected to the control
system by input cards.
DC24V are used to supply the sensors. The DC24V are fed from the DC/DC converter of the
relatedcontroller. Sometimes interposing relays are used.
The used cards are of the type X20DI9371. There are 12 inputs on one card for 24VDC. Within the
controllers the inputs are represented by means of Boolean variables (Model EPL_DI). This
multivariable model transfers the signal and the validity value within the system.
There are LED indicators on the module X20DI9371, which provide module and user supply status.

15.5.2.4 Analog Outputs

The output cards are installed in the field controllers. The card can handle output signals from
0…20mA, 4…20mA, 0…10V, –10V…10V.
The used cards are of the type X20AO4622. There are 4 outputs on one card with 12 bits
resolution.
The following ranges can be used:
mA0…20mA = 0…32767
4…20mA = 6553…32767
V -10V…10V = -32767…32767
0V…10V = 0…32767
It is possible to select for every output one of the two different kinds of signals:
Current (0…20mA)
Voltage (-10V…10V)
There is no difference between 0…20mA and 4…20mA or 0…10V and -10V…10V.
The selection is done by the respective range of the output variable (see above).
-32767…32767 is used to represent the measurement by means of variables (Model EPL_AO).
If the controller fails or the communication is lost, the output is set to 0.
There are LED indicators on the module X20AO4622, which provide module and user supply
status.
15.5.2.5 Digital Outputs

Digital commands or signals are connected from the control system by output cards to control or
supervise different systems.
DC24V are used to supply the output card. The DC24V are feed from the DC/DC converter of the
related controller. The output card provides for each channel DC24V and 0VDC. Therefore, the
card is foreseen for the activation of interpose relay.
The used cards are of the type X20DO9322and X20DO8332. There are 12 outputs with 24VDC for
X20DO9322and 8 outputs with 24VDC for X20DO8332. The X20DO8332is used on the Desilter
only.
Within the controllers the outputs are represented by means of Boolean variables (Model
EPL_DO).
If the controller fails or the communication is lost, the output is set to 0.
There are LED indicators on the module, which provide module and user supply status.
15.5.2.6 Power Supply

The supply module X20PS9400 is used together with an X20 bus controller. It is equipped with a
feed for the bus controller, the X2X Link, and the internal I/O supply.

 Supply for the bus controller, X2X Link, and internal I/O supply
 Feed and bus controller / X2X Link supply electrically isolated
 Redundancy of bus controller / X2X Link supply possible by operating multiple supply
modules simultaneously
 RS232 service interface

15.5.2.7 Bus controller

The X20BC0083 bus controller makes it possible to connect X2X Link I/O nodes to POWERLINK
V1and V2. It is also possible to operate the X2X Link cycle synchronously 1:1 or synchronous to
POWERLINK using a prescaler.
POWERLINK is a standard protocol for Fast Ethernet with true real-time properties.

 POWERLINK V1/V2
  I/O configuration and firmware update via the fieldbus
 Integrated hub for efficient cabling

Usually the bus controller is used together with the power supply X20PS9400 which are the base
of an I/o station. After the power supply all necessary I/O may be placed to fulfill the process
needs.

15.5.2.8 Bus controller Extension 10-Base T HUB

The X20HB2880 standalone hub is equipped with a modular hub expansion. Depending on the
bus base used, one or two additional slots are available. The HB2880 hub expansion module is
equipped with an integrated 2x hub. The Ethernet connections are made using RJ45 connectors.
The module and network status is indicated using LEDs.

 Hub expansion module

 2x Fast Ethernet hub

The X20HB2880 module is connected over the X20BB81 or X20BB80 base with the X20BC0083.
So, it is really a 2 port Ethernet extender.

15.5.2.9 Bus controller Extension 100 FX HUB

The X20HB2881 POWERLINK standalone hub is equipped with modular hub expansion.
Depending on the bus base used, one or two additional slots are available. Take note that
thehardware rev. of the BC8083 and the HB8880 must be ≥F0.
The hub expansion module HB2881 is equipped with two 100 Base-FX ports. The
Ethernetconnection is made using 62.5/125 μm or 50/125 μm glass fiber multimode cable with a
duplex LC connection. The module and network status is indicated using LEDs.

 Hub expansion module

 Two 100 Base-FX hub ports

The X20HB2881 module is connected over the X20BB81 or X20BB80 base with the X20BC0083.
So, it is really a 2 port Ethernet extender.

15.5.2.10 Bus transmitter

The bus transmitter X20BT9100 provides for the seamless expansion of the X20 System. The
stations can be up to 100 m away from each other.

 X2X Link bus transmitter

 For seamless expansion of the system
 Up to 100 m segment lengths
 Feed for internal I/O supply
 Operation only on the slot to the far right
The bus transmitter module X20BT9100 can only be operated with the bus module BM11.If the
feed is being used for internal I/O supply, this potential group cannot be supplied from anyother
module. An I/O module with bus module BM01 should be used to separate the potentialgroup.
15.5.2.11 Bus Receiver

The bus receiver X20BR9300 is used to connect the X20 System to the X2X Link. The module is
equipped with a feed for the X2X Link as well as the internal I/O supply.

 X2X Link bus receiver

 Supply for X2X Link and internal I/O supply
 Electrical isolation of feed and X2X Link supply
 Redundancy of X2X Link supply possible by operating multiple supply modules
 Simultaneously
 Operation only on the slot to the far left

15.5.2.12 Alstom SW X20 License Module

The software license card X20ZF0001-K01 enables the download from the MFC to theX20BC0083
I/O station. It should be every time placed on the end of the I/O station. The reason forthis is the
non-existing board identification in CONTROCAD. So, if an additional I/O card has to
beimplemented, it should be before the X20ZF0001-K01card.
15.5.2.13 Bus Module X20BB80

The X20BB80 bus module is used as a socket for a base module and a power supply module.
Base Module:

 X20BC0083
 X20HB2880
 X20HB2881
Power Supply:

 X20PS9400

15.5.2.14 Bus Module X20BM11

The X20BM11 bus module serves as the base for all 24 VDC X20 I/O modules. The internal I/O
supply is interconnected.

15.5.2.15 Bus Module X20BM01

The X20BM01 bus module is the base for all X20 power supply modules like X20PS9400.

15.6 HMI Operation

15.6.1 HMI Database

The configuration of each CENTRALOG C30/C10 system is defined in the CCAD engineering tool.
Each system has an HMI Database to keep the configuration data.
There are the following databases defined for the Dagachhu Hydro Power Plant:

Short name Description Reference HMI_DB

U1 Unit 1 C10_1 1

U2 Unit 2 C10_2 2

PC Common Power Cavern C10_3 3

SP1 Spare 4

DAM Dam C10_5 5

DESI Desilter C10_6 6

SP2 Spare 7

SP3 Spare 8

CB Common Control Building C30 9

Table 15. 3: Control System Database

15.6.2 Time Server / Time tagging

ALSPA system ensures reliable time tagging through a stable reference time source and the
corrective action. The LANTIME GPS time server (synchronized by GPS) is the synchronization
source of the ALSPA system.
The synchronization and time stamping is realized from the GPS or IRIG-B master clock,
whichelaborates several kinds of synchronizing tops notably 5s tops for the MFC1000 head of
cells. The automation cell is synchronized thanks to its MFC1000 synchronized by hardwired link.
Protocols allowing exchange of time tagged data are IEC 104, IEC 101 and OPC DA. IEC 104 data
can be time-tagged by the MFC for example. Other protocols such as Modbus or Profibus don’t
allow exchanging time tagged data.
Consequently, the Profibus and Modbus data are time tagged at the MFC level. The GPS or IRIG-B
master clock also elaborates time synchronization by network time protocol (NTP) for Control
room stations, display panels through the ALSPA Ethernet Process Bus and for other systems.

15.6.3 Users

The CENTRALOG system is protected against unauthorized access by username and password.
For the ALSPA HMI the following users are configured.
There are three different levels of authorization:
ALSTOM with maximum access level
OPERATOR with medium access level
OBSERVER with minimum access level

Minimum access level : only observation, no commands, set points, acknowledgment,

system operations allowed

Medium access level : only operation, no changes of system parameters

Maximum access level : no limitation

On each C10 system and on the C30 system there is the CAC function. The CENTRALOG
ADMINISTRATION CENTER (CAC) is used for manual starting up and shut down of the system and
for updating the configuration of the system. The CAC is not needed for the operation of the
plant. The CAC is also protected against unauthorized access by a defined username and
password.

15.6.4 LOCAL/REMOTE Switches

There are the following levels for operation:

Level Mode of operation Selection of Mode Remark

2 C30 Control room or CVS Remote Station Software memory in cell controller
Power Cavern Control selectable by local HMI or operator
 station

1 C10 Local HMI: Local HMI Control Software memory in cell controller
selectable by local HMI or operator
U1, U2, PC, DAM, DESI
station

0 Feeder/ MCC/ Device/ Local /Remote Hardware switch

AVR/ GOV/ Gate etc.:

Table 15. 4: Level of Operation

Commands or set points can be activated only if the related selection switches are in the correct
position for the related level of operation.
A selection of local mode on one level blocks the operation of all levels higher than the selected
level.
For example, if the local mode is selected for a feeder, operation of this feeder is not allowed by
the local HMI or the operator station in the control room.
The hardware switches are situated near the equipment. In local mode the commands are
connected hardwired to the devices. These commands work without control and monitoring
system and are used for test and commissioning only.
Commands out of the hardware will be indicated by the feedback of the device only in the
controlsystem. The commands itself are not reported to the event log.
Commands and set points given by the operator station or the local HMI will be indicated within
the related event log. The integration of the different commands and set points of the different
systems will be done at cell controller level.
The selection of operation mode out of the control room or local HMI can be fetched by each
level.

15.6.5 Alarms and Events

Errors, faults and other malfunctions within the equipment or the control system of the HPP
DAGACHHU facility will be reported to the operator’s staff by means of alarms. All alarms are
reported to the control room for indication on the operator stations. In addition, alarms are
indicated to the related local HMI. Some equipment has additional alarm indicators on the
equipment itself.
Alarms are indicated on the different alarm views. Level 1 Alarms are system critical alarms
thatcause a shutdown of the unit. Level 2 Alarms are all other alarms. Each alarm has to be
acknowledged by the operator.
To enable a comfortable operation of the plant there are the following categories or “SETS”,
ofalarms based on the location:

All Set 1

Unit 1 Set 2
 Unit 2 Set 3

Common Set 4

DAM/DESI Set 5

System Set 6

In addition to the alarms, events are reported on the operator stations in the control room and
on the local HMI. Events need no acknowledgment.
Depending on the configuration of the variable the rising or falling signal creates an alarm.
Depending on the configuration of the variable the rising only - respectively the falling only - or
both movements are reported to archive and printer.
Alarm signals may be delayed or blocked by other signals to avoid alarms in case of normal
operation.

15.6.6 Audible Alarms

Each operator station within the control room and each local HMI are equipped with audible
alarm(klaxon). The volume can be controlled by the Windows volume control.
The klaxon of the operator stations is started by each alarm rising within the whole facility.The
klaxon of the different local HMI systems is started by the alarms rising within the
relatedautomation cell.
The related icon of the operator station or local HMI is used to stop the klaxon.
Within the different locations of the HPP DAGACHHU facility there are installed horn devices to
give audible alarm in case of a new alarm rising.
There are the following locations defined:

 Unit 1
 Unit 2
 Power Cavern
 Control Building
 Dam / Desilter
Only the horns of the related location will be started. The common controller of the related
locationcontrols the horn. The horn devices will be stopped after 5 seconds automatically.
The horn of the local HMI area will be started only if the respective Remote Station
Control/LocalHMI Control software-switch is in position Local HMI Control.

15.6.7 Naming of Mimics’

The Mimic name consists of an ID and the name of the system shown on the Mimic.
ID's:

OVE Overview
 U1 Unit 1

U2 Unit 2

PC Power Cavern

DAM Dam

DESI Desilter

SUSH Surge Tank

CB Control Building

Example: PC_33 -> Power Cavern 33 kV

15.7 Mimic Views

Each Cell can be controlled from the C30 Operating Station in the Control room or from the
LocalHMI.
To control a Cell from local via the Local HMI Touch Panel the operator has to select "Local
HMIControl" via the touch screen.
See picture below.

15.7.1 Process symbol description

The pictures below describe the used Touch Panel Process Symbols and their status indications.
Forexample, a green condition means opens in most case (depending on the device), a faulty
conditionis indicated red.

15.7.1.1 Status indication

Status indication of pumps, valves, fans, heating, breakers and disconnectors

Figure 15.1:Status indications
15.7.1.2 Control Window and Synthetic Variable concept

In most of the pictures some CB, DIS, valves, motors, sub systems… are shown. If you touch/click
on the CB one individual control window will appear where it is possible to operate.
Warning:
If you try to operate a local HMI and the "Local HMI Control" is not selected, you are not able to open
the control window. Same applies to the Operating Station if not in "Remote Station Control".
The Synthetic Variable:
ALSPA P320 system brings a new remarkable concept to the operating power plant system. The
socalled synthetic variable is an operative unit that brings to the operator the reason why he
cannot make his desired action.
In other words, thanks to the synthetic variable, the operator knows why his system is
interlocked and he can act in order to unlock the system.
Example:

When the interlocks are active, which means there is one or several signals missing to make the
requested action, a yellow warning symbol appears.
By clicking on this yellow warning symbol, the operator knows what signal is missing. In the
example

here after, the operator cannot switch On the Disconnector because it is not in remote.
Make sure that all the releases are ok then the yellow triangle will turn gray and the drive can be
operated.

15.7.1.3 Control Window for Setpoints

By clicking/touching the setpoint value or the setpoint command button a single setpoint control
window will appear where it is possible to operate.
The operator can use the green arrows to increase or decrease the set point. He can also use the
slide bar to set the desired set point and accept it with the green hock. Another possibility to
enter the desired set point is to click in the white box with the set point value. A calculator
window will appear where the set point can be entered or calculated and confirmed with the
green hock. The requested set point, if the system accepts the value will appear in orange. The
blue value corresponds to the current value.

If the set point is locked the control buttons in the set point window will appear in grey and a red
exclamation mark is shown to the right.

15.7.1.4 General buttons present in all mimics

15.7.1.4.1 Local / Remote window

Use this window to switch from Local (C10 local touch panel) to remote control (Control room
C30)

 The operator cannot make any action in local if the "Remote Station Control" is selected.
 The operator cannot make any action form the control room if the "Local HMI Control" is
selected.
15.7.1.4.2 Emergency Stop Button

The operator has the possibility to access the "Emergency Stop" Button on each mimic to reduce
thedelay between a dangerous situation and the unit shut down. Each unit has its own
"Emergency
Stop" Button. On the overview mimics the "Emergency Stop" Buttons for both units are shown
(seeright picture). On the unit, related mimics only the "Emergency Stop" Button for the
respective unit is shown. After clicking the "Emergency Stop" Button the emergency stop control
window will open.
When pressing the arrow down button and confirming with the green hock, the emergency shut
down for the respective unit starts.
Warning:
It is advising to push the “EMERGENCY STOP” button only in case of Electrical emergencyfailure. It is
advised to avoid the emergency shut down for mechanical emergency failure. A normal shut down
of the unit should be done for mechanical emergencies.

15.7.2 Overview mimics

The mimics are only shown on the Operating Station and the Local HMI of the Power Cavern.
All mimics where it is possible to operate are equipped with a Local/Remote window.
15.7.2.1 220kV Overview

Figure 15.2:220kV Overview

This mimic gives the global overview of the 220kV distribution in the switchyard. Disconnectors,
earth disconnectors and circuit breakers are represented. Software and hardware interlocks are
foreseen between the devices:

 The operator cannot switch ON disconnectors on voltage.

 The operator cannot switch ON CB or disconnector if earth disconnector is ON.
 The operator cannot switch ON the Unit 1 and Unit 2 CB manually. This operation has to
be done with automatic sequence or manually from the Synchrotact itself.
The CB's, disconnectors and earth disconnectors for Unit 1 and Unit 2 can't be operated from this
view, they are for indication only. These switches can only be operated from the respective
unitoverview. Click the respective unit to jump to the unit overview.
For each action on devices software interlocks are shown in the synthetic variables. The actual
Active and Reactive Power, Voltage and Current is displayed for every branch. Exported Active
and Reactive Power are displayed. Idem for imported Power. The Fire System Control for the
Station Transformer is also shown.
15.7.2.2 Overview Control

Figure 15.3:Overview Control

This mimic is the most common mimic to run and control the units of Dagachhu. This mimic
provides the most important information needed to drive the power plant:
− Use the Buttons “UNIT 1”, “UNIT 2” to switch to the Unit Overview mimic and start the Unit if
"READY TO START" is indicated or to change the individual unit setpoints.

 Use the Button "JOINT CONTROL ACTIVATION" to run both units in joint control.
 In joint control the operator can change the global value for water level, voltage and
produced active and reactive power by assigning the set points. Both Units will share the
load.
 The "CONTROL MASTER" indicates which unit is master in joint control (automatic)
 The individual mode, status and setpoints for the units are for indication only. The
individual setpoints, mode and status of the related unit can be set only on the Unit
Overview.
Use the “EMERGENCY STOP” button to initiate an emergency shutdown of the related unit.
Use the “EMERGENCY CLOSE” button to initiate an emergency close of the inlet gate and the
desilter 1-3 outlet gate.
Warning:
Pushing the “EMERGENCY CLOSE” button will also activate the quick shut down for both units!
15.7.2.3 Overview Electrical

Figure 15.4:Overview Electrical

The Mimic contains a global overview of the whole electrical network.
The network is divided by color:

 Green = 220kV
 Brown = 33kV
 Red = 11kV
 White = 400VAC
 Telemagenta (183) = 110VDC
 Telemagenta (185) = 24VDC
No possibility to interact with the circuit breakers represented in the squares. Only their status
isavailable.
The circuit breaker ON is displayed in the color of its respective network. When the CB is OFF, it is
represented in black. If the square is gray the indication is invalid.
Use the “EMERGENCY STOP” button to initiate an emergency shutdown of the related unit.
15.7.2.4 Overview Heating / Ventilation / Air Conditioning

Figure 15.6:Overview Heating/ Ventilation and Air Conditioning

The Mimic contains a global overview of the Heating / Ventilation / Air Conditioning system. The
status of the fans is displayed. To switch the fan on/off or to switch the mode of the fan to
auto/manual click the respective fan and select in the pop-up control window the desired action.
15.7.2.5 Overview Hydraulic

Figure 15.7:Overview Hydraulic

The mimic shows the hydraulic overview of the whole power plant Dagachhu.
Dynamic Levels, Pressure, Flows and Valve or Gate status (open/closed or position) is displayed in
the mimic. The operator cannot interact with the valves or gates.
He can only press the “EMERGENCY CLOSE” button.
Pressing the “EMERGENCY CLOSE” button will initiate an emergency close of the inlet gate and
the desilter 1-3 outlet gates.
From the screen the operator has the possibility to jump to the mimics of the different hydraulic
parts of the plant like Dam, Desilter or the Units.
Warning:
Pushing the “EMERGENCY CLOSE” button will also activate the quick shut down for both units!
15.7.2.6 Overview System

Figure 15.8:Overview System

On this mimic the whole power plant network of the control system is shown. This contains all
cell and field controllers, C10 Local HMI's and the C30 operating station. There are indications for
the status of each Hirschman switch.
The IP address for the S8000 Network is shown on each device. The status of the links of the
controllers and HMI's is displayed in colour:

 Green = communication okay

 Red = communication broken
 Grey = invalid signal
The S8000 Network is composed of a Ring for redundancy reasons.
Alarms appear for a communication failure between controllers and HMI's. The GPS clock is red
and an alarm occurs if the system fails.
Each cell controller has three status lamps. The first lamp indicates a failure of the controller, the
second lamp the status of the controller (running/stopped) and the third lamp shows the
presence of a module fault in the field controllers linked to the cell controller. There is also a
status indication for the Modbus TX/FX converter. With the HORN button the horn can be
activated or deactivated.

15.7.3 Unit Mimics

The mimics are only shown on the Operating Station and the Local HMI of the Unit.
All unit mimics have an “EMERGENCY STOP” button to initiate an emergency shutdown of the
related unit and a Local/Remote window.

15.7.3.1 Unit 110V DC

Figure 15.9:Unit 110V DC

This mimic gives an overview over the 110V DC distribution board for the unit. Only the both main
fuses are indicated. There is no indication for the other fuses.
The over or under voltage of the both bus bars are also shown.
Use the “MAIN DISTRIBUTION” button to view the upstream POWER CAVERN 110V
MAINDISTRIBUTION window.
15.7.3.2 Unit 400V Distribution

Figure 15.10:Unit 400V Distribution

This mimic gives an overview over the two 400V distribution panels for the unit. All shown fuses
are for indication only. The "U AVLBL" indicates if voltage is on the busbar.
The square shows if the busbar MCB for the voltage measurement is tripped.
Use the “PC 400V MAIN DISTRIBUTION” button to view the upstream POWER CAVERN 400V
MAIN DISTRIBUTION window.
15.7.3.3 Unit Cooling Water System

Figure 15.11:Unit Cooling Water System

This Mimic shows the cooling water system of the Unit.

 Green pipes represent the cooling water system.

 Blue pipes represent the high-pressure air system.
The cooling water system per unit is composed of 2 pumps, operable from the display.
The pumps can be switched to automatic or manual operation and in manual operation they can
be turned on and off.
The cooling water valve for the governor can also be switched to automatic or manual operation
and in manual operation it can be turned on and off.
Both pumps have a pressure indication and flow meters are displayed for each branch.
The operator can visualize if:

 “P” pressure is present or absent

 “F” flow is present or absent
From the screen the operator has the possibility to jump to the mimics of the different parts of
the unit like Generator, Turbine, Main Transformer, Governor System and Station Transformer.
15.3.3.4Unit ESD (Emergency Shutdown)

Figure 15.12:Unit Emergency Shutdown

This mimic gives an overview of the on-standing emergency shutdown reasons and the progress
ofthe emergency shutdown sequence.
If an emergency trip is on-standing and is not acknowledged by the operator a red blinking
square appears. The emergency shutdown sequence for the unit starts.
When the operator acknowledges the on-standing emergency trip the square stops blinking but
stays red. If the emergency trip is no more on-standing the square turns yellow and the operator
needs to acknowledge this again, so that the square turns black.
The headings of the different sections allow to jump to the mimic of the respective part of the
unit.
15.7.3.5 Unit Generator

Figure 15.13:Unit Generator

This mimic displays the Generator for the Unit. Brown pipes represent the oil system. Green pipes
represent the cooling water system. Blue pipes represent the high-pressure air system.
The temperature indications for the stator windings, stator core, bearings and air are available.
The cooling for the oil of the upper guide bearing, lower guide bearing and the cooling for the
generator windings are displayed. The shaft insulation is monitored by a resistance
measurement.
The operator can switch the mode to AUTO/MANUAL and turn ON/OFF in MANUAL:

 the both high-pressure pumps

 the generator heating
 the oil vapour extractor pump
 the valve for the generator rotor lifting device / carbon brake
 the carbon brake dust suction pump
 the carbon brake dust suction valve and the carbon dust suction valve
 the dome lamp
The operator can visualise if:

 “DP” differential pressure alarm is on standing

 “L” level Very Low, Low, High or Very High is on standing
 “P” pressure is present or absent
  “F” flow is present or absent

15.7.3.6 Unit Main Inlet Valve

Figure 15.14:Unit Main Inlet Valve

This Mimic shows the spherical valve system.

 Brown pipes represent the oil system originated from the Governor System.
 Green pipes represent the water system.
The pressure before and after spherical valve is displayed. If the pressure is not equalized, the
pressure alarm is displayed and the opening of the spherical valve will not be permitted.
The Bypass Valve, Service Seal Valve and Spherical Valve can be switched to AUTO/MANUAL
mode and in manual mode they can be OPENED or CLOSED.
The spherical valve positions are shown by digital inputs. From fully close 0°, 30°, 98° to 100° fully
open position.
The presence or absence of water before, in and after the spherical valve is also displayed.
It is possible to switch to the Turbine/Governor view.
The operator can visualize if:

 “DP” differential pressure alarm is on standing

 “P” pressure is present or absent
15.7.3.7 Unit Main Transformer

Figure 15.15:Unit Main Transformer

This mimic gives an overview of the Main Transformer consisting of three single transformers,
one for each phase.
The cooling water, oil system and the alarm board is shown for each transformer.

 Brown pipes represent the oil system.

 Green pipes represent the cooling water system.
The two oil pumps per transformer have a hardware Local/Remote and a hardware main pump
selection switch.
From the Operating Station and the Local HMI it's possible to switch the oil pumps to
AUTO/MANUAL mode and in manual mode to turn them ON/OFF.
The Fire System Control for each Transformer is also shown.
15.7.3.8 Unit Overview

Figure 15.16:Unit Overview

This mimic provides the most important information needed to drive the Unit.
It's divided into five sections:

 Unit Control (upper left side)

 Excitation including the Regulation Control (lower left side)
 Electrical Overview of the Unit (center)
 Synchronisation (upper right side)
 Governor including the Regulation Control and the Additional Functions (lower left side)
Unit Control:
The Unit Status window shows the actual unit status. The Start, Stop and Preconditions button
opens the mimic of the Start Sequence, Stop Sequence or the Prestart Conditions.
Caution: The Start or Stop button doesn't start or stop the Unit! This is done by selecting the
operating mode with the "GEN.OP/SPIN.RES/ENERG.HV.LINE/STOP" button.
To Start the Unit the desired operating mode

 Generator Operation (GE)

 Spinning Reserve (SN)
 Energize High Voltage Line (LE)
has to be selected and if the Prestart Conditions are met the Unit will start up. There is no
separate
START button!
To Stop the Unit the operating mode

 Stop (ST)
has to be selected.
It's possible to switch from Generator Operation to Spinning Reserve or from Spinning Reserve
to Generator Operation.
The Unit Control Mode window shows the actual unit mode. There are three possible modes:

 Step-by-Step
 Automatic
 Joint

The Joint Mode can only be activated from the Control Overview.
The "AUTOMATIC/STEP/NEXT STEP" button activates the Automatic or Step-by-Step mode for
the Unit. In the Step-by-Step mode, it's possible to switch manually to the next step in the start
or stop sequence.
Excitation:
Use the “EXCITATION” button to turn ON/OFF manually the EXCITATION or to switch to
AUTO/MANUAL mode. The area below shows the status of the EXCITATION.
Use the “Q / 11KV U / IE CONTROL” button to choose manually if Excitation will run in Voltage
(VOLT), Current (EXCI) or Reactive Power (REA) Control mode.

In the Excitation Regulation area use the U (Voltage), IE (Current) or Q (Reactive Power) Set
point
Change button to assign the respective set point. The change of the set point is authorized only if
the right mode is active, otherwise it will be shown grayed out.
For the "Energize High Voltage Line" mode the button "VOLTAGE UP/DOWN COMMAND" is used
to increase or decrease the voltage. In other operating modes, it's shown grayed out.
Electrical Overview:
This part shows the Electric Overview of the Unit. Disconnectors, earth disconnectors and circuit
breakers are represented and can be turned to AUTO/MANUAL mode or switched ON/OFF.
Software and hardware interlocks are foreseen between the devices.
The unit circuit breaker cannot be switched on directly; the final ON command is released by the
Synchronization.
The neutral point earth switch for the main transformer can be turned to AUTO/MANUAL mode
or switched ON/OFF.
The line voltage and frequency is shown on top. For the Unit, the excitation voltage and current
as
well as the Unit voltage, current, frequency, cos phi, speed and active/reactive power output is
shown.
If the Unit is tripped the “DEBLOCK” button gets yellow and the unit start is prohibited. The
“DEBLOCK” button is used to reset the Unit after a Trip. This is only possible if the Trip is not
active anymore. If the reset of the Unit is successful, the “DEBLOCK” button gets grey and the
start of the unit is permitted.
The electrical breaking switches and the excitation supply switches can also be operated from
this overview.
Synchronization:
This area shows the status of the synchronization.
Governor:
Use the “GOVERNOR” button to turn ON/OFF manually the GOVERNOR or to switch to
AUTO/MANUAL mode. The area below shows the status of the GOVERNOR.
Use the “P / N / F / L CONTROL” button to choose manually if the Governor will run in Power PC),
Speed (NC), Flow (FC) or Level (LC) Control mode.

In the Governor Regulation area use the P (Power), F (Flow) or L (Level) Set point Change button
to assign the respective set point. The change of the set point is authorized only if the right mode
isactive, otherwise it will be shown grayed out.
In Speed Control mode no Set point can be assigned, the Frequency is kept constantly at 50 Hz.
In the Governor, Additional Functions area, the "LOAD TAKE UP" and the "NOZZLE FREEZING"
can be switched ON and OFF. The Governor "PRIMARY CONTROL" can be turned ON/OFF or
switched to AUTO/MANUAL mode.

15.7.3.9 Unit Prestart Conditions (1 - 4)

Figure 15.17 (a):Unit Prestart Condition 1

Figure 15.17 (b):Unit Prestart Condition 2

Figure 15.17 (c):Unit Prestart Condition 3

Figure 15.17 (d):Unit Prestart Condition 4
These four mimics show the necessary prestart conditions. All of them have to be green to be
able tostart the Unit. The "MTR OVERRULE" button can be used if non-transformer earth switch
is ON.

15.7.3.10 Unit QSD (Quick Shutdown)

Figure 15.18 (a): Unit Quick Shutdown 1

Figure 15.18 (b): Unit Quick Shutdown 2
This mimic gives an overview of the on-standing quick shutdown reasons and the progress of the
quick shutdown sequence.
If a quick shutdown is on-standing and is not acknowledged by the operator a red blinking square
appears. The quick shutdown sequence for the unit starts.
When the operator acknowledges the on-standing quick shutdown the square stops blinking but
stays red. If the quick shutdown is no more on-standing the square turns yellow and the operator
needs to acknowledge this again, so that the square turns black.
The headings of the different sections allow to jump to the mimic of the respective part of the
unit.
15.7.3.11 Unit Start sequence

Figure 15.19:Unit Start Sequence

The start sequence is shown in this view. Unit run measurements like Speed, Active Power,
ReactivePower and Voltage are displayed. The Unit Control is also displayed (see 15.7.3.8. Unit
Overview).
The operator can start the unit from STANDSTILL to SPINNING RESERVE, ENERGIZE HIGH
VOLTAGE LINE or to GENERATOR OPERATION. Additionally, he can start the unit from SPINNING
RESERVE to GENERATOR OPERATION.
The start sequence will not go through a step if the conditions are not fulfilled. If the horizontal
baris still red, click on the question mark aside to see what are the conditions to fulfill to go to the
nextstep. If the bar is green, the conditions are fulfilled and the start sequence proceed to the
next step in Automatic mode. Click on the “Next Step” button to go to the next step if the Unit is
in Step-by-Step mode.
Warning: If the Start Sequence is in automatic mode and the step is activated longer than the Step
Timeout, the Unit trips. If the Start Sequence is longer than 600 seconds active, the Unit trips.

15.7.3.12 Unit Stop Sequence

Figure 15.20:Stop Sequence

The Stop Sequence is shown in this view. Unit run measurements like Speed, Active Power,
ReactivePower and Voltage are displayed. The Unit Control is also displayed (see 15.7.3.8 Unit
Overview).
Warning:If an Emergency or Quick Shutdown occurs, the Stop Sequence is started and the Unit is
switched to Automatic mode.
The operator can stop the unit from GENERATOR OPERATION, ENERGIZE HIGH VOLTAGE LINE or
SPINNING RESERVE to STANDSTILL or from GENERATOR OPERATION to SPINNING RESERVE.
The stop sequence will not go through a step if the conditions are not fulfilled. If the horizontal
bar is still red, click on the question mark aside to see what are the conditions to be fulfilled to go
to thenext step. If the bar is green, the conditions are fulfilled and the stop sequence proceed to
the nextstep in Automatic mode. Click on the “Next Step” button to go to the next step if the
Unit is in Step-by- Step mode.
Warning: If the Stop Sequence is in automatic mode and the step is activated longer than the Step
Timeout, the Unit trips. If the Stop Sequence is longer than 600 seconds active, the Unit trips.

15.7.3.13 Unit System

Figure 15.21:Unit System

This view shows the part of the Control System for the Unit. This contains the cell and field
controller and the C10 Local HMI. There is also an indication for the status of the Hirschman
switch.
This view is for indication only.
15.7.3.14 Unit Turbine

Figure 15.22: Unit Turbine

This mimic shows the Turbine of the Unit including the Governor.

 Brown pipes represent the oil system originated from the Governor System.
 Green pipes represent the water and cooling water system.
 Blue pipes represent the high-pressure air system.
The bearing vibration indication and bearing oil system with temperature indication is
represented.The turbine speed, nozzles and deflectors position, distributor and penstock
pressure is shown.
From the Governor, the Start/Stop valve, the Shutdown valve, the Jet Brake valve and the
Pressure Tank Isolation valve can be switched to Auto/Manual mode and in Manual Mode
Opened/Closed.
The two Governor Pumps can be switched to Auto/Manual mode and in Manual mode turned
On/Off. In addition, the main Governor Pump for the automatic mode can be selected. The
governor oil tank with temperature, level and oil in water alarms is displayed.
In the oil circulation system, the circulation pump can be switched to Auto/Manual mode and in
Manual mode turned On/Off. The cooling water valve and the heating valve of the oil
circulationsystem can be switched to Auto/Manual mode and in Manual Mode Opened/Closed.
The pressure tank has a pressure indication and level and pressure alarms.
The air make-up valve for the pressure tank can be switched to Auto/Manual mode and in Manual
Mode Opened/Closed.
It is possible to switch to the Main Inlet Valve, Cooling Water System, Air Supply and Generator
view.
The operator can visualize if:

 “DP” differential pressure alarm is on standing

 “L” level Very Low, Low, High or Very High is on standing
 “T” temperature Very Low, Low, High or Very High is on standing
 “P” pressure is High, Low, present or absent
 “F” flow is Very Low, present or absent

15.7.4 Power Cavern Mimics

The mimics are only shown on the Operating Station and the Local HMI of the Power Cavern. All
power cavern mimics have a Local/Remote window

15.7.4.1 Power Cavern 110V Common Distribution

Figure 15.23:Power Cavern 110V DC Common Distribution

This mimic gives an overview over the 110V common distribution board. Only the both main
fusesare indicated. There is no indication for the other fuses.
The over or under voltage of the both busbars is also shown.
Use the “MAIN DISTRIBUTION” button to view the upstream POWER CAVERN 110V
MAINDISTRIBUTION window.

15.7.4.2 Power Cavern 110V Main Distribution

Figure 15.24:Power Cavern 110V Main Distribution

This mimic gives an overview over the 110V main distribution board.
The Distribution board feeds the Unit 1, Unit 2 and Common 110V DC sub distribution boards.
Both rectifiers represented on both incomings provide 110V DC from the 400V AC source. The
rectifiers have indications for low voltage on the supply side and for a common fault. The
incomings are equipped with a voltage, current and fault indication after the rectifiers.
Batteries back up are also represented including their voltage and current indication.
Use the “400/230V AC COMMON SUB DISTRIBUTION" button to view the upstream 400V AC sub
distribution mimic.
It is possible to switch to the downstream Unit 1 110V DC, Unit 2 110V DC, Power Cavern 110V
Common and Power Cavern 110V Transformer distribution panel view.
All displayed fuses are for indication only.
15.7.4.3 Power Cavern 110V Transformer Distribution

Figure 15.25:Power Cavern 110V Transformer Distribution

This mimic gives an overview over the 110V transformer distribution board. Only the both main
fuses are indicated. There is no indication for the other fuses.
The over or under voltage of the both busbars is also shown.
Use the “MAIN DISTRIBUTION” button to view the upstream POWER CAVERN 110V MAIN
DISTRIBUTION window.
15.7.4.4 Power Cavern 33kV

Figure 15.26:Power Cavern 33kV

This mimic gives the global overview of the 33kV distribution in the power cavern.
Earth Switches and Circuit Breakers are represented. Software and hardware interlocks are
foreseen between the devices.
The Circuit Breaker, Earth Switch, Voltage and Current for each branch is displayed.

 Station Transformer
 both Power Cavern 400V supplies
 connection to Control Building
For the busbar the voltage and frequency is indicated.
The CBs are operable from the display and can be turned to AUTO/MANUAL mode or switched
ON/OFF. The status of the hardware Local/Remote switch for each CB is also displayed.
Warning:Each earth switch is not operable from the display and will not be switched off
automatically when its respective CB is Open for security reason. Even if CB is OFF, there is a
possibility to supply the line from downstream. The earth disconnector has to be switched ON
manually with precaution.
For each action on devices software interlocks are shown in the synthetic variables.
It's possible to select one of the two 400V supplies as the desired supply source for the
automatic AUXILIARY SUPPLY SWITCH OVER.
It's also possible to allow to separate the 33kV control building connection for the automatic
AUXILIARY SUPPLY SWITCH OVER.
Warning:For the automatic AUXILIARY SUPPLY SWITCH OVER all Circuit Breakers have to be in AUTO
mode. Otherwise an AUXILIARY SUPPLY SWITCH OVER alarm will be displayed.
The AUXILIARY SUPPLY SWITCH OVER can be switched to AUTO/MANUAL mode. The question
mark aside shows the conditions that have to be fullfilled to successfully switch to AUTO mode. If
the AUXILIARY SUPPLY SWITCH OVER was switched to AUTO mode successfully the AUTO
indication turns green.
The Fire System Control and the Standstill Cooling Selection for the Station Transformer is also
shown.
It is possible to switch to the Overview 220kV and to the Control Building 33kV view and to the
downstream Power Cavern 400V Distribution view and also to the Station Transformer view.

15.7.4.5 Power Cavern 400V Main Distribution

Figure 15.27:Power cavern 400V Main Distribution

This mimic gives an overview of the power cavern 400V AC main distribution supplied by two
33kV sources and one alternative 950V, 100kVA tunnel emergency link to the control building.
The two supplies from the 33kV have a voltage and current indication and the associated
transformers have a temperature and status indication. It's possible to select one of the two as
the desired supply source for the automatic AUXILIARY SUPPLY SWITCH OVER.
The alternative tunnel emergency link has a current indication for all three phases and the
associated transformer has a winding temperature indication for all three phases.
It is possible to switch the three incoming Circuit Breakers to AUTO/MANUAL mode or to turn
them in MANUAL mode ON/OFF. The Circuit Breakers have a control voltage fault indication.
Warning: For the automatic AUXILIARY SUPPLY SWITCH OVER all three incoming Circuit Breakers
have to be in AUTO mode. Otherwise an AUXILIARY SUPPLY SWITCH OVER alarm will be displayed.
The AUXILIARY SUPPLY SWITCH OVER can be switched to AUTO/MANUAL mode. The question
mark aside shows the conditions that have to be fulfilled to successfully switch to AUTO mode. If
the AUXILIARY SUPPLY SWITCH OVER was switched to AUTO mode successfully the AUTO
indication turns green.
The Circuit Breakers for the supply of the Unit and Common distribution panels can be switched
toAUTO/MANUAL mode or in MANUAL mode turned ON/OFF. All Circuit Breakers have a control
voltage fault indication.
All branches have a current indication for all three phases and the bus bar has a voltage
indication.
Using the buttons "NORMAL LIGHT" and "ESSENTIAL LIGHT" it's possible to switch the lights
toAUTO/MANUAL mode or in MANUAL mode to turn them ON/OFF. The mini circuit breaker for
the light and heating is also indicated.
For the bus bar and the three transformers the electrical protection status is shown (MICOM
WATCHDOG).
It is possible to switch to the upstream Power Cavern 33kV view and to the downstream views of
the Unit 1 400V Distribution, the Unit 2 400V Distribution and the Power Cavern 400V Sub
Distribution 1,2 and 3. In addition it's possible to switch to the Control Building 400V Distribution
view.
15.7.4.6 Power Cavern 400V Sub-distribution 1

Figure 15.28:Power cavern 400V Sub-distribution 1

This mimic gives an overview over the 400V sub distribution panel 1. The voltage available and
themini circuit breaker for the voltmeter are displayed for both bus bars.
All displayed fuses are for indication only.
Use the “400V MAIN DISTRB.” button to view the upstream POWER CAVERN 400V MAIN
DISTRIBUTION window.
15.7.4.7 Power Cavern 400V Sub-distribution 2

Figure 15.29:Power Cavern 400V Sub-distribution 2

This mimic gives an overview over the 400V sub distribution panel 2. The voltage available and
themini circuit breaker for the voltmeter are displayed for the bus bar.
All displayed fuses are for indication only.
Use the “400V MAIN DISTRB.” button to view the upstream POWER CAVERN 400V MAIN
DISTRIBUTION window.
15.7.4.8 Power Cavern 400V Sub-distribution 3

Figure 15.30:Power cavern 400V Sub-distribution 3

This mimic gives an overview over the 400V sub distribution panel 3. The voltage available and
themini circuit breaker for the voltmeter are displayed for both bus bars.
All displayed fuses are for indication only.
Use the “400V MAIN DISTRB.” button to view the upstream POWER CAVERN 400V MAIN
DISTRIBUTION window.
Use the “BATTERY CHARGER” button to view the downstream POWER CAVERN 110V MAIN
DISTRIBUTION window.
15.7.4.9 Power Cavern Air Supply

Figure 15.31:Power cavern Air Supply

The mimic displays the Compressed Air System.
The system is composed of two compressor pumps and a High-Pressure Tank, which brings high
pressure air for the Generator Brake and the Governor Tank.
The actual air pressure in the High-Pressure Tank and the high and low pressure alarms are
displayed.
The two compressor pumps can be switched to AUTO/MANUAL mode or turned ON/OFF. The
selected main compressor for automatic mode is indicated.
The main compressor pump for automatic mode can be chosen with the "SELECT MAIN
COMPRESSOR" button.
It's possible to switch to the Unit Generator or Turbine view. The operator can visualize if:

 “P” Pressure is Low or High

15.7.4.10 Power Cavern System

Figure 15.32:Power cavern System

This view shows the part of the Control System for the Power Cavern. This contains the cell and
field controller and the C10 Local HMI. There is also an indication for the status of the Hirschman
switch. This view is for indication only.
15.7.4.11 Power Cavern Station Transformer

Figure 15.33:Power cavern station transformer

This mimic gives an overview of the Station Transformer.
The cooling water, oil system, alarm board and winding temperature is shown for the
transformer.

 Brown pipes represent the oil system.

 Green pipes represent the cooling water system.
The two oil pumps for the transformer have a hardware Local/Remote and a hardware main
pump selection switch.
From the Operating Station and the Local HMI it's possible to switch both oil pumps to
AUTO/MANUAL mode and in manual mode to turn them ON/OFF.
The Cooling Water Valve for Unit 1 or Unit 2 can be switched to AUTO/MANUAL mode and in
manual mode turned OPENED/CLOSED.
The Fire System Control and the Standstill Cooling Selection for the Station Transformer is also
shown. From this view, it's possible to switch to the Unit Cooling Water view.
15.7.5 Dam/Desilter Mimics
The mimics are only shown on the Operating Station and the Local HMI's of the Dam and Desilter.
All Dam/Desilter mimics have a Local/Remote window, which works a little different to the other
Local/Remote window, due to the fact that three stations are involved.
To operate from the Operating Station, the "Remote Station Control" on the Operating Station
has to be selected. The both Local HMI's will indicate "Remote Station Control" and it's not
possible to control from them.
To operate from one of the local HMI's the "Local HMI Control" has to be selected on the desired
Local HMI. On the other Local HMI, the "Remote Station Control" will be indicated and it's not
possible to operate. On the Operating Station the "Local HMI Control" will be indicated and its
not
possible to operate from the Operating Station.

15.7.5.1 Dam 400V Distribution

Figure 15.34:Dam 400V Distribution

This mimic shows the 400V Distribution of the Dam. It consists of the 33kV main supply from the
Control Building and the Emergency Diesel supply. A connection from the 400V busbar to the
Desilter and Local 400V Distribution is available. A rectifier supplies 24V DC from the 400V AC.
Alternatively the 24V DC can be supplied by the Battery.
The Circuit Breakers for the

 33kV Supply
 Emergency Diesel Supply
 Desilter Connection
 Local Connection
can be turned to AUTO/MANUAL mode or switched ON/OFF. The 24V DC control voltage for this
circuit breakers are also indicated.
The electrical protection for the 33kV supply transformer (MICOM) and the lights/heating MCB
isindicated. The high/low voltage alarm for the 33kV supply and the voltage available for the 400V
busbar is also shown.
All displayed fuses are for indication only.
The status of the 24V DC supply is indicated.
The Emergency Diesel Generator can be turned to AUTO/MANUAL mode and switched ON/OFF.
The status panel shows the status of the Emergency Diesel Generator. The current of the
EmergencyDiesel Generator is also indicated.
From this view, it's possible to switch to the Control Building 33kV and to the Desilter 400V
Distribution view.

15.7.5.2 Dam Hydro

Figure 15.35:Dam Hydro

This mimic shows the hydraulic overview of the Dam and Intake. It consists of the Trash rack,
theIntake with the Intake Gate and the Weir with the Radial and Flap Gates.
The Head Water Level, the Trash Rack Pressure Too-High and the Trash Rack Cleaning Machine
fault are indicated.
Intake Gate:
For the Intake Gate the hardware Remote status, the 1st and 2nd Hydraulic fault, the Electric fault
and the Watchdog fault are displayed. The filling position reached is also indicated. The Intake
Gate can be turned to AUTO/MANUAL mode and in manual mode OPENED/CLOSED.
Radial and Flap Gate:
For every Radial and Flap Gate the hardware Remote status, the Hydraulic or Electric fault and
theactual gate position is shown. The Gates can be turned to AUTO/MANUAL mode and in
manual mode OPENED/CLOSED/STOPED.

A general Weir Hydraulic fault is indicated at the bottom.

For each action on devices software interlocks are shown in the synthetic variables. Pressing the
“EMERGENCY CLOSE” button will initiate an emergency close of the inlet gate and the desilter 1
to 3 outlet gates.
Warning:
Pushing the “EMERGENCY CLOSE” button will also activate the quick shut down for both units! From
the screen the operator has the possibility to jump to the mimic of the desilter hydraulic.
15.7.5.3 Dam System

Figure 15.36:Dam System

This view shows the part of the Control System for the Dam. This contains the cell and field
controller, the S7 link and the C10 Local HMI. There is also an indication for the status of the
Hirschman switch.
This view is for indication only.
15.7.5.4 Desilter 400V Distribution

Figure 15.37:Desilter 400V Distribution

This mimic shows the 400V Distribution of the Desilter. It consists of the 33kV main supply from
the Control Building and the emergency supply through the connection to the Dam 400V
Distribution. A connection from the 400V bus bar to the Spare 400V Distribution is available. A
rectifier supplies 24V DC from the 400V AC. Alternatively the 24V DC can be supplied by the
Battery.
The Circuit Breakers for the

 33kV Supply
 Spare
can be turned to AUTO/MANUAL mode or switched ON/OFF. The 24V DC control voltage for this
circuit breakers are also indicated.
The electrical protection for the 33kV supply transformer (MICOM) and the lights/heating MCB is
indicated. The high/low voltage alarm for the 33kV supply and the voltage available for the 400V
busbar is also shown.
All displayed fuses are for indication only.
The status of the 24V DC supply is indicated.
From this view, it's possible to switch to the Control Building 33kV and to the Dam 400V
Distribution view.
15.7.5.5 Desilter Hydro

Figure 15.38:Desilter Hydro

This mimic shows the hydraulic overview of the Desilter. It consists of the three desilter lines
withWater level and AUTO mode indication and a Channel Flushing Gate with fault indication.
Each Desilter line has an Inlet Gate with position and fault indication, a Gravel meter indication, a
Flushing Gate with fault indication, a Trash Rack Cleaning Machine with status indication and an
Outlet Gate with fault indication. The level and flow to the Units is also shown.
The Flushing and Outlet Gates can be switched to AUTO/MANUAL mode and in manual mode
OPENED/CLOSED.
For each action on the Gates software interlocks are shown in the synthetic variables.
Pressing the “EMERGENCY CLOSE” button will initiate an emergency close of the inlet gate and
the desilter 1-3 outlet gates.
Warning:
Pushing the “EMERGENCY CLOSE” button will also activate the quick shut down for both units!
From the screen the operator has the possibility to jump to the mimic of the Dam Hydraulic or
Overview Hydraulic.
15.7.5.6 Desilter System

Figure 15.39:Desilter System

Controller, the S7 link and the C10 Local HMI. There is also an indication for the status of the
Hirschman switch.
This view is for indication only.
15.7.5.7 Surge Tank 400V Distribution

Figure 15.40:Surge tank 400V Distribution

This mimic shows the 400V Distribution of the Surge Tank. It consists of the 33kV main supply
fromthe Control Building and a rectifier supplying 24V DC from the 400V AC. Alternatively the 24V
DC can be supplied by the Battery.
The circuit breaker for the incoming 33kV supply and the lights/heating MCB is indicated. The
high/low voltage alarm for the 33kV supply is also shown.
All displayed fuses are for indication only.
The status of the 24V DC supply and the status of the AC/DC Converter is indicated. From this
view, it's possible to switch to the Control Building 33kV view.
15.7.6 Control Building Mimics

These mimics are only shown on the Operating Station.

15.7.6.1 Control Building 110V Distribution

Figure 15.41:Control Building 110V Distribution

This mimic gives an overview over the Control Building 110V distribution.
The rectifier represented on the incoming provide 110V DC from the 400V AC source. The rectifier
has indications for low voltage on the supply side and for a common fault.
The incoming is equipped with a voltage, current and fault indication after the rectifier. Battery
backup is also represented including voltage and current indication. Use the “400/230V AC
COMMON SUB DISTRIBUTION" button to view the upstream 400V AC distribution mimic. All
displayed fuses are for indication only.
15.7.6.2 Control Building 33kV

Figure 15.42:Control Building 33kV

This mimic gives the global overview of the 33kV distribution in the control building.
It consists of four branches:

 Power Cavern Connection

 Control Building 400V supply
 Surge Shaft supply
 Dam, Desilter and Local Side Adit. Supply
All branches are equipped with Earth Switches and Circuit Breakers. Software and hardware
interlocks are foreseen between the devices. The actual Voltage and Current is displayed for
every branch and for the bus bar the voltage and frequency is indicated.
Exported Active and Reactive Power is also displayed for every branch. Idem for imported Power.
The CBs are operable from the display and can be turned to AUTO/MANUAL mode or
switchedON/OFF. The status of the hardware Local/Remote switch for each CB is also displayed.
Warning:Each earth switch is not operable from the display and will not be switched off
automatically when its respective CB is Open for security reason. Even if CB is OFF, there is a
possibility to supply the line from downstream. The earth disconnector has to be switched ON
manually with precaution.
For each action on devices software interlocks are shown in the synthetic variables.
It's possible to allow to separate the 33kV power cavern connection for the automatic
AUXILIARYSUPPLY SWITCH OVER.
Warning:For the automatic AUXILIARY SUPPLY SWITCH OVER all Circuit Breakers have to be in AUTO
mode. Otherwise an AUXILIARY SUPPLY SWITCH OVER alarm will be displayed.
The AUXILIARY SUPPLY SWITCH OVER can be switched to AUTO/MANUAL mode. The question
mark aside shows the conditions that have to be fulfilled to successfully switch to AUTO mode. If
the AUXILIARY SUPPLY SWITCH OVER was switched to AUTO mode successfully the AUTO
indication turns green.
It is possible to switch to the Power Cavern 33kV view, to the downstream Control Building
400VDistribution view, to the Surge Shaft 400V Distribution view and to the Desilter 400V
Distribution view.

15.7.6.3 Control Building 400V Distribution

Figure 15.43:Control Building 400V Distribution

This mimic gives an overview of the control building 400V AC distribution supplied by the 33kV
source, one alternative 950V, 100kVA tunnel emergency link to the power cavern or by the
emergency diesel.
The supply from the 33kV has a voltage and current indication. The alternative tunnel
emergencylink has a current indication for all three phases and the associated transformer has a
winding temperature indication for all three phases. The emergency diesel supply has a current
indication for all three phases and a voltage fault indication.
It is possible to switch the three incoming Circuit Breakers to AUTO/MANUAL mode or to turn
them in MANUAL mode ON/OFF. The Circuit Breakers have a control voltage fault indication.
Warning:For the automatic AUXILIARY SUPPLY SWITCH OVER all three incoming Circuit Breakers
have to be in AUTO mode. Otherwise an AUXILIARY SUPPLY SWITCH OVER alarm will be displayed.
The AUXILIARY SUPPLY SWITCH OVER can be switched to AUTO/MANUAL mode. The question
mark aside shows the conditions that have to be fulfilled to successfully switch to AUTO mode. If
the AUXILIARY SUPPLY SWITCH OVER was switched to AUTO mode successfully the AUTO
indication turns green.
The Circuit Breakers for the Sub distributions can be switched to AUTO/MANUAL mode or in
MANUAL mode turned ON/OFF. All Circuit Breakers have a control voltage fault indication. All
Sub distributions have a current indication for all three phases and the bus bar has a voltage
indication.
All displayed fuses are for indication only.
Using the buttons "NORMAL LIGHT" and "ESSENTIAL LIGHT" it's possible to switch the lights to
AUTO/MANUAL mode or in MANUAL mode to turn them ON/OFF. The mini circuit breaker for the
light and heating is also indicated.
For the bus bar, the two transformers and the emergency diesel generator the electrical
protectionstatus is shown (MICOM WATCHDOG).
The Emergency Diesel Generator can be turned in AUTO/MANUAL mode and in manual
modeswitched ON/OFF. The Emergency Diesel has a status and fault indication board.
Additionally, the Emergency Diesel operating mode is also shown.
It is possible to switch to the upstream Control Building 33kV view and to the downstream view
ofthe Control Building 110V Distribution. In addition, it's possible to switch to the Power Cavern
400V Main Distribution view.

15.8 400V Auxiliary Switchover

For the 400V auxiliary supply of the HPP DAGACHHU power station see single line diagram
AUZ024286.
There are two 400V bus bars (+20BFA00 and +25BFA00) with coupling circuit
breaker(20BFA00GS120 and 25BFA00GS120). The coupling of both 400V bus bars is limited by
100kVA.
The power cavern 400V section is connected over 2 auxiliary transformers (+20BFT10
or+20BFT20) with the power cavern section of the 33kV bus bar +20BBA00. The control
building400V section is connected over 1 auxiliary transformer (+25BFT10) with the control
building section of the 33kV bus bar +25BBA00.
Both 33kV bus bars can be coupled by 20BBA00GS151 and 25BBA00GS111.The power cavern
section of the 33kV bus bar +20BBA00 is supplied by one transformer+20BBT00 from the 220kV
switchyard. The control building section of the 33kV bus bar +25BBA00 can also be supplied by
the 33kV line over 25BBA00GH141.
The 33kV feeder 25BBA00GH151 distribute the energy from the control building 33kV bus bar to
auxiliaries which are outside the power house (dam, desilter, side adit,…).
In addition, the supply of the control building 400V bus bar +25BBA00 can be provided from
incoming feeder 25BFA00GS112 of the diesel unit.

15.8.1 Interlocking

At the same time, all incoming CB can feed the 400V bus bars.

 +20BBA00GS121
 +20BBA00GS141
 +25BBA00GS121
 +25BFA00GS112
The coupling CB can be closed, if at least one side of the 400V is without voltage.
In emergency cases the coupling between the two 400V bus bar can be closed. But the limit on
theenergy supply is 100kVA.
The outgoing circuit breakers on the 400V side can be switch on or off if there is no fault on
thefeeder without any interlocking.

15.8.2 Control Function

Each circuit breaker is equipped with a Local/Remote switch and On/Off control buttons for
manual operation within the distribution panel. The hardwired interlocking of the circuit breakers
is always activated.
Local operation of the feeders is only possible if the Local/Remote switch is in Local position.
Thisposition deactivates the automatic switchover.

15.8.3 Incoming Feeders and Diesel

The circuit breakers of both 400V bus bars are controlled from the common controllers.
Operation is possible from the Power Cavern Local HMI and from the Operator Stations in the
control room. Within the control system the Remote Station Control/Local HMI Control software
switch of the Dagachhu Hydro Power Plant is used.
Within the control system there is an Automatic/Manual software-switch for each of the feeding
circuit breakers to enable the automatic switchover and On/Off control buttons to operate the
circuitbreakers on touch screen respectively on operator station.
Manual operation enables manual On and Off commands, if the interlocking release the
command.

15.8.4 Diesel Unit

The circuit breaker of the coupling and the diesel unit are controlled by the control system of
thediesel unit.
There are the following modes of operation:

Off Diesel switched off

Hand Diesel start and circuit breaker operation manually

 Automatic Automatic start up and operation of the related circuit breakers in
case of loss of supply of priority service
After return of supply automatic operation of the related circuit
breaker and automatic stop of the diesel

Parallel Operation operation of diesel parallel with net supply

Test start of the diesel with selecting this mode

operation of the related circuit breakers manually
after this mode, automatic mode has to be selected
to switch back to normal operation and stop the diesel

The selection of the mode is possible at the diesel unit only. A ready signal is provided by the
diesel if operation is possible.

15.8.5 Automatic switchover

Automatic function takes care for the correct feeding of the bus bar depending on the different
situations of supply.

15.8.6 Automatic switchover topologies

The normal operation is divided into 4 different types of 220kV / 33kV / 400V topology

 Supply from 220kV

 Supply from external 33kV
 Supply from DG Auxiliary
 Supply for every 33kV bus bar separately (open bus bar coupling)
No automatic switch for different topologies than the above explained will be supplied.
The operator itself can handle other topologies in manual mode.

15.8.7 Priority of the Auxiliary Supply

By default, the auxiliary is taken over from the 220kV by the auxiliary transformer +20BBT00
which feeds the 33kV power cavern section. From there the auxiliary transformers
+20BFT10/+20BFT20 or +25BFT10 take the energy to supply the 400V bus bars.

 Supply from 220kV highest priority

 Supply from external 33kV medium priority
 Supply from DG Auxiliary lowest priority
 Supply for every 33kV bus bar separately (open bus bar coupling)emergency supply
Under voltage:
If the under-voltage relay of the 220kV auxiliary feeder shows that there is a fault of supply, or
theauxiliary feeder from the 220kV to 33kV trips, the related circuit breaker is switched
Off+20BBA00GS111 and the diesel generator take over the auxiliary supply.
If the fault is located in the 33kV supply feeder +20BBA00GS121 incl. transformer the supply
istaken over by the parallel +20BBA00GS141 33kV supply.
After a trip of a circuit breaker by over current no new switch ON command will be send until the
trip is acknowledged.

15.8.8 Emergency Supply

For emergency supply the operation mode of the diesel unit has to be in automatic and the
system has to be ready.
Recovery after emergency supply:
If one of the 33kV feeders reports voltage O.K. the related circuit breaker is switched on.
With voltage O.K. on the normal service bus bar, incoming feeder of the diesel unit will be
switchedoff and the coupling circuit breaker will be switched on. After a delay for cooling the
diesel will bestopped.

15.8.9 Manual Operation

An automatic / manual switch supervises the 400V auxiliary supply switch over automatic. If one
of the CB which is included in the switch over is set to manual control of operation, the complete
switch over will be set to manual. By setting the general switch over selection switch again to
automatic mode, all CB which are included in the switch over will be transfer also to automatic
mode of operation.
If the CB is in manual mode on and off commands can be activated and executed according the
interlocking.

15.8.10 Alarm

Alarms will be generated if there is an automatic switch over and if a section of the bus bar is
without voltage. If the switch over cannot be successfully fulfilled, an alarm signal will be
generated by the program and the switch over will be set to manual.
 SECTION A:

OPERATION MANUAL

CHAPTER 16

CHAPTER 16: ISLANDED MODE OF OPERATION

16.1. Introduction

The Generating Units of Dagachhu Hydro Power Corporation Limited is designed to feed the
station auxiliary supplies even during the time of grid failures. The Unit circuit breakers will not
open during the transmission line faults or grid failures, instead it will continue to feed the station
auxiliary supply or other substation if there are no faults in that particular substation and its
feeders. This mode of operation is called the “Islanded Mode of Operation” and during this
mode, governor mode of control will automatically switch over to the Speed Control mode and
all the nozzles will open according to the generation.

16.2 Operation procedures

During the Islanded Mode of Operation, our generator will feed the station through our 5MVA
station transformer. The operation procedure for the operators during the time of Islanded
Mode of Generation are given below:

16.2.1 Failure of 220kV Dagachhu-Tsirang line.

First of all, check why the Unit has switched to Islanded Mode of Operation? And check whether
our line CB is in OPEN/CLOSE position at both ends. If our 220kV has opened at either end and
unit is in Islanded Mode of Operation follow the following procedure:
i) Make a call to nearest substation i.e. Tsirang Dhajay Substation or National Load Dispatch
Centre (NLDC) and confirm the cause of interruption and duration of
malfunction/interruption.
ii) And in the meantime, check whether the auxiliaries are working or not and if it is not
working, manually ON the auxiliaries from the control system. If it is not getting ON from
control system, you have to locally put ON or if this too is not working you have to inform
the Maintenance Team.
iii) Open our 220kV Line CB if it has not opened during the time of system interruption. But note
that we will open the CB only if 220kV line CB at the Tsirang end has opened.
iv) Call and inform the relevant head of the Units/Divisions (Head, Operation & Maintenance
Division, Head, Operation Unit and Head, Maintenance Unit).
v) Upon receiving the confirmation of normalization of the grid from Tsirang Dhajay
Substation, make them extend the line from Tsirang end.
vi) Confirm whether we are receiving the rated line voltages or not. Also, confirm whether our
line is free of fault by checking the whether the line is sustaining more than 5 minutes or not.
vii) Now If the line is sustaining more than 5 minutes, change our unit control to Spinning
Reserve (SN) and we will have black out.
viii) Close the 220kV line circuit breaker (00ADD00GS100) manually from control system and if it
is not closing from control system, go to the Power Cavern common panel (20CJA10GH001)
and locally close the line CB by changing the selection key to manual mode. Now you will
have voltage in the 220kV Bus.
ix) Close the 5MVA Station Transformer circuit breaker at 220kV Side after getting the bus
voltage and bus frequency.
x) Now close the station service transformer CB (20BBA00GS111) from power cavern 33kV
mimic in control system. Note that you will close only if this CB is open.
xi) Check the Auxiliary Transformer 1 CB (20BBA00GS121) and Auxiliary Transformer 2 CB
(20BBA00GS141). Note that either one of the Auxiliary Transformer’s CB should be closed.
Close either one of the Auxiliary Transformer CB if neither one is in closed position.
xii) Now check the subsequent CB at Power cavern 400V Main Distribution panel
(20BFA00GH001). Note that the 400V CB (20BFA00101) should be closed only if the Auxiliary
Transformer 1 CB (20BBA00GS121) is closed and 400V CB (20BFA00102) should be closed
only if the Auxiliary Transformer 2 CB (20BBA00GS141) is closed.
xiii) Now by this time you will have power supply to all auxiliaries in power cavern but you should
put ON the illumination though the normal light command window (20SLA00GS101_FP).
xiv) Check the auxiliaries like pumps and flaps of the Generating Unit and give ON command
from control system if the auxiliaries have stopped working. Some of the auxiliaries needed
to be checked are Main Transformer oil circulating pumps, cooling water pumps, governor
oil pumps, governor oil circulating pumps, oil vapor extraction system pump, carbon dust
suction device flap, etc.
xv) Check the 33kV power supply for control building, and check whether the control building
400V CB (25BFA00GS101) is OPEN/CLOSED? Close the breaker if it is in OPEN position.
xvi) Now go to Unit Overview Mimic and change the Unit control back to Generator Operation
(GE) Mode and note the time of Unit synchronization with the grid.

16.2.2Failures of other transmission line except our line

Our Generating Units will automatically go to Islanded Mode of Operation whenever there are
failures of grid or line fault at transmission lines. If the Unit goes to Islanded Mode of Operation
with our 220kV line still healthy you should follow the following procedures:
xvii) Call the National Load Dispatch Centre and Tsirang Dhajay Substation and confirm the cause
and duration of interruption. Also, make calls to relevant substations.
xviii)Upon getting the confirmation from the concerned substation regarding the normalization
of the system, check whether our Unit is still in Islanded Mode of Operation of not. If it is still
in Islanded Mode of Operation call and confirm again.
xix) And if our Unit is not in Islanded Mode of Operation, change the Governor regulation control
to Power Set point mode and increase the power and check whether it is increasing or not.
If it is increasing keep the Generation as per the schedule and grid frequency.
 SECTION A:

OPERATION MANUAL

CHAPTER 17

CHAPTER 17: GENERATION SCHEDULING

AND SYSTEM COORDINATION

The effective operation of the Power plant requires the understanding of the system to which
the plant is connected to. DHPC generating units are connected to both eastern and western grid
of Bhutan. The Transmission network in Bhutan is owned by Bhutan Power Corporation Limited
(BPC). The Eastern Region Load Dispatch Center (ERLDC) is an apex body in the region entrusted
to ensure integrated operation of the power system in the Eastern Region, India. The body
directs the safe and efficient operation of the bulk power transmission, interconnection
operation, and security and performance analysis.
DHPC is linked with numbers of Sub-stations and neighboring generating stations. For the safe
and smooth operation, proper coordination among these stations is very important.

17.1 Generation Scheduling

Dagachhu Hydro Power Plant is in ABT (Availability Based Tariff) based power system wherein,
we have to schedule our generation for next 24 hours in advance as DC (Deliverable Capability) to
dispatch Centre i.e. National Load Dispatch Centre (NLDC) at Thimphu, Bhutan. Our scheduling
should reach to business partner TPTCL latest by 10:00 hours (BST) through National Load
Dispatch Centre (NLDC), Thimphu as per the form 4.5 of Annexure 04.
Dagachhu, represented by TPTCL is into the power market under “Short Term Open Access Bi-
lateral Day-ahead Transaction”.
As per Power Purchase Agreement (PPA), Generation planning should be daily, monthly and
quarterly (every three months). Twenty hour (24) hours in advance for daily, not later than 15
days for monthly and not later than 30 days for quarterly.
The following instructions and guide lines shall provide the Control Room operators to effectively
manage the generation forecasting.
a) Ensure that the communication facilities connecting Control Room and various Sub-stations
and BPSO/NLDC are functioning perfectly at all times.
b) Predict the next day’s availability based on status of units and on historical data (previous
inflow) and send the ex-bus schedule as per the form 4.5 of Annexure 04.
c) The daily generation forecast/ ex-bus schedule shall be conveyed to BPSO/ NLDC latest by
10:00 hour, daily.
d) The variations in generation from schedule arising due to unforeseen events shall be
communicated to BPSO/NLDC and TPTCL on real time basis for change in schedule.
e) In case of any of unscheduled outage of a generating units or feeders, the shift In-charge
shall inform BPSO/NLDC of any change in availability, with valid reasons.
f) The planned outage of Units shall be informed to BPSO/NLDC well in advance for
approval/concurrence.
g) For the management of the grid, BPSO/ NLDC conduct the System Coordination Committee
(SCC) meeting and Protection Coordination Committee (PCC) meetings inBhutan on regular
basis. The minutes of each meeting is circulated to all the stake-holders for follow up and
compliance.

17.2 Message

Message is a systematic method of communication to facilitate exchange of information among

the stake-holders, for coordination of operation and to ensure high level of safety and reliability
in operations of the power system. Message is documented in a standard format duly signed by
the sender.

17.2.1 Purpose of Message

Message communication is required for the following events and activities:

i. Requesting for planned/Ad-Hoc/Emergency shutdown of equipment.
ii. Schedule Declaration.
iii. Emergency load shedding due to unforeseen natural calamities.
iv. Obtaining final switch off and charging clearances.
v. Installation of new equipment in the system.
vi. Any exchange of information related to grid.
vii. Management of work permits (under certain condition).

17.2.2 Scope of application

Message communication covers the following entities:

i. The Grid owner
ii. The National Load Dispatch Center
iii. Transmission and Distribution Operators
iv. Generating stations

17.2.3 Type of Messages

Message could be in one of the followings forms:

i. Telephonic message
ii. Fax message
iii. Electronic message

17.2.4 Message Procedure

i. If the nature of the work is planned, the notification shall be made well in advance allowing
the stake-holders to prepare for the opportunity shutdowns.
ii. If the shutdown is unplanned and necessitated by the conditions of the equipment,
notification shall depend on the severity and critically of the equipment in service.

17.3 Planned Outages Management

BPSO/NLDC, Thimphu is responsible for approving the schedule of outages planned by the
constituent stakeholders. A systematic procedure shall be followed for taking the equipment
under shutdown for the maintenance.
Sometimes the equipment shutdown may be necessitated by unexpected faults which results in
unplanned outage and demands an immediate action by the site engineers. All such outages shall
be immediately informed to BPSO/ NLDC.
The following guidelines shall apply to the management of planned outages.

a) Planned outage program shall be put up for shutdown approval from BPSO in advance. The
shutdown proposal shall be prepared as per the form 4.4 of Annexure 04.
b) The Shift In-charge control room shall ensure that a written shutdown approval is received a
few days or a day ahead of the proposed date of shutdown.
c) On the shutdown day, final switch off clearance for feeders or final shutdown clearance shall
again be obtained from BPSO/ NLDC before taking up the shutdown operations.
d) Until and unless the written message of final switch off clearance is not received, the
shutdown of equipment shall not be initiated.
e) At the time of shutdown, proper interaction and coordination among the duty stations is very
important.
f) Similarly, the unplanned shutdowns, which are not emergent in nature, required to be
attended urgently shall be put up for approval.
g) Once the equipment is cleared for bringing back into service, notification shall be given to
BPSO/NLDC. The equipment shall be normalized through proper coordination with the
corresponding duty stations.

17.4 Coordination of System Operation

The exchange of information or coordination of actions among the interconnected sub-stations

shall be required for the safe and smooth operation. The following guidelines apply to the
coordination of system operation.
a) Communications and notifications regarding data exchange and information are important
for proper coordination. Shutdown and normalization of equipment requires proper
coordination within the stations.
b) The contingency plan developed/adopted in common shall be followed. The contingency plan
shall form an integral part of system management and shall be accordingly used as routine
guidelines.
c) In certain contingencies, difficulty may arise in synchronizing BHP units with the grid. CHP and
BHP Control Room operators on duty need a good coordination in such times for early
restoration.
d) In case of tripping of outgoing feeders, the test charging of feeders shall be carried out
before declaring the feeders faulty.
 SECTION A:

OPERATION MANUAL

CAPTER 19

CHAPTER 18: ENERGY METERING AND

METER READING

18.1 Energy Metering

As per metering philosophy, energy meters of uniform technical specifications are provided on
feeder side. One as main and other as check meter. As standardized, ERLDC recommended us to
install L&T make SEM (Special Energy Meter). Desired by ERLDC standard, we have also installed
Standby meters of similar make and specifications on LV side of Generator Transformers.
On both sides of Generator Transformers, one each of power logic series and L&T make energy
meters are installed so that energy and losses are accounted properly cross checking each other.

18.2 Energy Meter Reading

Energy Meter Readings are to be taken with due diligence. The final energy meter reading of
Generators for the day is done @ 24:00 hrs. and realized actual generation achieved for the day.
Actual generation may vary from scheduled generation depending upon unforeseen outages and
inflow
Operation personnel should cross-check the correctness of energy meter readings in a way of
keeping following check points in mind while energy updating @ 24:00 hours daily:

 Seeing that energy achieved by main energy meter and its corresponding check energy
meter is within permissible limit of percentage error.
 Percentage error should be within + - 0.6% as per grid code for meters’ accuracy class of
0.2.
 If the difference is beyond permissible limit, matter to be reported to concerned officer
in-charge without delay.
 Energy generated should be always more than energy exported in normal conditions.
 Energy meters are getting counter overflow (re-set) after having run upto certain values.
To get cumulative energy, number of counter overflown should be kept tracing.
 Ensure that energy meter is running/recording energy during round checks.
Based on actual generation achieved, Daily Generation Report (DGR) in the format provided by
DGPC is prepared and sent daily.
The power from Dagachhu is deemed delivered to consumers after deducting 2% losses within
Bhutan system through export meters of CHP and THP.
JEMR (Joint Energy Meter Reading) is taken @ 12:30 Hrs.(BST) on every 1 st date of the month in
presence of DHPC, BPC and DGPC- Basochhu.
As per Bhutan Electricity Authority, Bhutan Grid Code 28.03.2008, the results of JEMR should be
within permissible percentage error of + - 0.6% between main energy meter and its corresponding
check energy meter of accuracy class of 0.2. If percentage error exceeds limit, then meters
should be taken out for joint calibration.
The report is sent especially to Chhukha Hydropower Plant and Tala Hydropower Plant to deduct
Dagachhu power from their total export meters.
 SECTION A:

OPERATION MANUAL

CHAPTER 20

CHAPTER 19: BILING AND PAYMENT

19.1 Billing

As per PPA signed between DHPC and TPTCL, India, DHPC shall raise monthly bill to TPTCL for
supply of electricity for the particular month on or before 3 rd day of each month. The billing is
convened in the format developed in line with PPA wherein, there are total energy exported, 2%
rebate from the billed amount and amount payable for the month.
The monthly bill should be supported by following supporting documents:

 Daily schedules declared as DC (Deliverable Capability) should have been authenticated

by BPSO,NLDC, Thimphu. The same be duly signed and stamped by DHPC, Head,
Operation Unit as well.
 Detailed summary statement of energy scheduled at delivery point and energy available
at delivery point.
Any differences between scheduled energy and available energy at delivery point will be resolved
based on energy statement released by REA, ERPC, Kolkata.

19.2 Payment

Payment for the bill becomes due on the 10th day of the bill dated. If due date falls on Sunday or
Government holiday, due date shifts to next working day as per PPA. If TPTCL makes full payment
within 10 days from the delivery of bill, rebate of 2% is allowed. The payment is @ INR 2.90/unit.
The tariff escalation will be @ 2% per year as agreed in PPA. The energy bill of Dagachhu Hydro
Power Corporation Limited in given in Annexure O5.
 SECTION A:

OPERATION MANUAL

CHAPTER 21

CHAPTER 20: DATA KEEPING AND

REPORTING

For the safe operation of Power Plant, monitoring the parameters of generating units and their
auxiliaries is of outmost importance. In every shift, routines checks shall be performed on various
equipment for abnormalities.

20.1 Shift Change Over

It is necessary for operators to know the status and conditions of equipment under their
jurisdiction. It is equally important to know the status of the subs-stations and generators to
which Dagachhu is connected. The status information has to be collected from various locations
from time to time. These data, some of which need not be logged, are required to operate the
station efficiently and safely. The Shift In-charge and the Shift staff shall perform the following
checks and collect the information right after assumption of the charge of the shift.
B) On changeover of the shift, shift in charge shall collect the weather conditions at Dagana
through weather man deputed by Department of Hydro-Met Services, MOEA and status of
the power house, Diversion Weir, Desilter and switchyards along with the signing of the
handing and taking over register.
C) The operators shall check all the equipment parameters (oil and water pressures,
temperatures) and equipment conditions and record on hourly basis.
D) The operators shall go inside the power cavern for the inspection right after taking the taking
over the shift.
E) The operators shall check the condition of all the equipment which ever necessary in every
shift.
F) The Operators shall obtain the status of the grid (whether we are connected to Eastern grid
or to West grid) through System operators right after taking over the shift.

20.2 Data Recording

a) The equipment parameters such as load, currents, active and reactive power, temperatures,
and energy meter readings for Units and Feeders shall be recorded hourly.
b) The energy meter recording of feeders at every 24:00 hours.
c) The Daily Data Report of the Plant shall be prepared from the hourly data recorded as per the
4.1 of Annexure o4.
d) The Daily Data Report shall be submitted via e-mail to the Chief Executive Officer and O&M
Department, DGPC at 10.00 hrs. of the following day.
e) Daily Plant availability data shall be submitted via e-mail to PSCC, TPC and Chief Executive
Officer, DHPC as per form 4.3 of Annexure o4.
f) The monthly data to Royal Monetary Authority (RMA) and Department of Hydro Power
Service shall be submitted by Head, Operation Unit as per the form 4.4 of Annexure 04.
g) The Energy Generation and Consumption report shall be submitted to O&M Department,
DGPC as per the form 4.7 of Annexure 04.
h) Any abnormalities observed on equipment, parameters and actions taken by the staff shall be
clearly reflected with time in the defect register at Control Room.
i) Every tripping report/Event information report shall be prepared right after the event and
submitted to the Chief Executive Officer and BPSO.

20.3 Production Incentive System (PIS) Data Preparation

 The monthly Production Incentive payout for DHPC is derived considering the following
instruction.
a) Measurement of Performance (Monthly Generation Achieved)
i. The monthly generation of energy shall be compared with the energy equivalent of utilizable
river inflow for the month, adjusted for the availability of machines and losses due to
outages.
ii. Inflows shall be logged on an hourly basis and over a 24-hour period, daily average inflow
shall be computed.
iii. River inflow (in m3/s) equal to or below that of the maximum generating capacityof the Plant
shall be taken as the “Utilizable Inflow” that shall be utilized for generation of power.
iv. Over a month, the total energy equivalent of all the daily utilization inflows shall be obtained.
v. From the monthly energy equivalent, losses due to machines under planned shutdown when
some part of the inflow is required to be spilled and any losses in generation due to outages
which are not within the control of Operators shall be deducted to arrive at the monthly
generation target.
vi. The formula given below shall be thus used for fixing the monthly generation target.

Monthly Generation Target = (Total energy equivalent for the month given by utilizable
inflow) – (Uncontrollable losses) – (losses due to machine non-availability due to planned
shutdown)

vii. The actual generation achieved in a month will then be computed as a percentage of the
target generation and performance of the plant shall be determined.
viii. Uncontrollable losses shall mean loss in generation due to faults in grid and transmission,
abnormal flooding of river necessitating shutdown of plant and other natural calamities and
uncontrollable factors. Losses due to forced outages arising from within the plant shall not
be deducted.
ix. Losses due to non-availability of machines shall arise only if machines are already under
shutdown for planned works when the inflow rises beyond the generation of the other
machines in service and water has to be spilled. Depending on the urgency, planned
shutdown of a machine shall be deferred by some reasonable period if inflow is high enough
and requires the machine to be in operation.
x. Schedules for planned works for any year shall be finalized and approved at the beginning of
the year.
xi. In the summer months, the maximum generation capacity shall be 126 MW.

b) Performance Rating and Award of Monthly Incentive

i. For the non-lean months from April to October, the monthly generation achieved shall be
compared with the target generation and the performance rating shall be given as defined in
the Table 20.1. As per the performance rating, the eligibility of incentive as a percentage of
basic pay for Non-Production Group (NPG) and Production Group (PG) shall be defined as per
the Table 20.1.

Monthly Generation as the % of Performance Rating Incentive as % of basic Pay

Monthly Generation Target NPG PG

≥ 99 % Excellent 18 % 20 %

≥ 98 % but < 99 % Very Good 15 % 17 %

< 98 % No Incentive shall be awarded for performance below 98 %

Table 20.1:Monthly Production Incentive for the Peak Months

ii. For the lean months from November to March, the monthly generation achieved shall be
compared with the target generation and the performance rating shall be given as defined in
the Table 20.2. As per the performance rating the eligibility of incentive as a percentage of
basic pay for Non-Production Group (NPG) and Production Group (PG) shall be defined as per
the Table 20.2.

Monthly Generation as the % of Performance Rating Incentive as % of basic Pay

Monthly Generation Target
NPG PG

≥ 99 % Very Good 15 % 17 %

< 99 % No Incentive shall be awarded for performance below 98 %

Table 20.2:Monthly Production Incentive for the Lean Months

 SECTION A:

OPERATION MANUAL

CHAPTER 23 CHAPTER 21: IP CAMERA MANAGEMENT

21.1 Introduction

IP Camera system plays vital role in achieving continuous monitoring of various

equipment/systems installed at different locations of Dagachhu Hydropower Corporation
Limited. It also helps in recording the important activities carried out in different location of the
plant.
The IP camera system uses the fiber optic cable laid in numerous site of the Power Plant for its
communication. The Main Server for IP camera system is installed in Main Control room with hard
disc capacity of 2TB.
DHPC IP Camera system comprises of fourteen (14) cameras out of which twelve (12) cameras are
capable of panning, tilting and zooming (PTZ) and two (2) are fixed type and focus only on one
particular view.
The PTZ cameras are installed at outdoor location such as Diversion Weir, Desilter, Surgeshaft
and Chhurachhu side Adit and indoor location such as Main Access Tunnel, Emergency Exit
Tunnel, Control Building, Transformer Cavern, Power house Machine Hall, Generator Floor,
Turbine Floor and GIS Floor. The fixed cameras are installed at GIS staircase and GIS floor.

21.2 Indigo Vision Control Center

Control Center allows users to manage IP Cameras, sites, video recordings and the recording
schedule. In Control Center, a site can include cameras from many different geographical
locations and networks.
Control Center enables user accounts to be organized into user groups. Access permissions for
cameras and other objects can be applied to user groups so that all users in the group inherit the
same permissions, eliminating the need to set up permissions for each user account. User groups
can have full administrator, restricted administrator or no administrator rights. Control Center
users can be linked to Windows user accounts. This means that users can have the same login
and password for Windows and Control Center.
Control Center’s diagnostic tools allow you to monitor the health of all devices in your site. This
means that you can ensure that each device is functioning as expected.
For NVRs, Control Center alerts the user when a disk, redundant power supply or network
connection fails; it also displays status information. Control Center displays NVR disk usage
information for each camera which has recordings on that NVR. Information such as recording
start and stop times, total recording time and total recording size and rate is displayed for each
camera and recording.

21.3 Users and user groups

Here at Dagachhu we have two levels of users. Administrator user has full accessibility over the
Indigo Control Center and the operator user is restricted accessibility.

21.4 Operation

21.4.1 How to add camera in IndigoVision control centre software.

i. Open IndigoVision control center software.

ii. Click on setup option.
iii. Right click on site name (DHPC Power House) and click on add devices as shown in
screenshot in figure 1.
iv. Enter device details like name and IP address (e.g. Machine hall 1, 192.168.0.52) of camera and
click ok and shown in figure 2. Camera will be added to the software.

Figure 21.1: Step to add devices

Figure 21.2: Name of device and IP address setting

21.4.2 Camera setting:

21.4.2.1 Camera encoder setting:

IP camera system uses Encoder 1 for Live viewing and Encoder 2 for Recording video.

 Open IndigoVision control center software and click on setup option.

Figure 21.3: Configuration of camera

 Select the camera and click configure to login inside the camera using password
"powerdhpc" as shown in figure 3.

 Select encoder 1 and change the resolution as per requirement SIF, 2SIF and 4SIF as
shown in figure 4.
Figure 21.4: setting of resolution

 Click on submit to take effect of the required changes. Then click encoder 2 and make the
same setting as encoder 1.
The SIF and 2SIF are normal and medium resolution (Image quality) setting respectively, 4SIF is
for high resolution, so we select 4SIF for both the encoders.

21.4.2.2 Camera time setting:

Camera time has to be synchronized with GPS to get real time video recordings.

 Login the camera in IndigoVision control center software.

 Click on Date & Time configuration and select Network time protocol.

 Type server IP address (192.168.0.51) and choose the time zone as (GMT +06:00) Astana,
Dhaka for our system and submit.
Figure 21.5: Date and Time configuration

21.4.2.3 Set login password for Camera:

 First login to camera to be assign password in control center software and click on Network
security configuration option.

Figure 21.6: Network security configuration password

Under Network Security configuration type password and then submit.
21.4.2.4 Set camera for video recording:

Setting for video recording must be done after adding camera in the system because it will only
display the video without recording the video in the system server. So the settings are done as
follows:
i. Open IndigoVision control center software and click on setup menu.
ii. Select added camera and click on recording schedule as shown in figure 6.

Figure 21.7: Setting of recording schedule

Figure 21.8: Setting of recording schedule for new job

iii. Right click on empty space and click new recording job as shown in figure 7.
iv. Then small tab will pop up in the screen. Select recording time option All the time (24/7) or
we can choose our own schedule for recording as shown in screenshot below and click on ok,
camera will start recording as per the setting. All the DHPC IP camera’s recording schedule
are in 24/7.

Figure 21.9: Setting of recording times

21.4.3 Export recorded video to external drive:

i. Open IndigoVision control center software and click on playback option as shown in figure 9.

Figure 21.10: Playback of recorded videos

ii. Drag the camera and drop to right side empty screen.
iii. Click on export and protect option as shown in figure 10.

Figure 21.11: Exporting the video for archiving

iv. Tab will pop up, select time period i.e. date and time (from & to) you want to export the
recordings.
Figure 21.12:Export and protect recording
v. Browse the file location you want to save the recording and click ok to start exporting video
files.

21.4.4 Create sequence for camera automatic rotation:

i. Open IndigoVision control center software and click on setup option.

ii. Right click on site (DHPC power house) name and select new sequence.
Figure 21.13: Creating sequence for automatic rotation

iii. Type camera name you would like to create sequence and click ok as shown in figure 13.
Figure 21.14: Creating sequence

iv. Right click on left side empty screen and select add cameras as shown in figure 14.
Figure 15.15: Adding cameras for creating new sequence

v. From the list of cameras select camera name you want to create sequences, then click ok.
Note: If you want to create 3 sequences to the camera, you have to add same camera 3 times inside
the sequence (Repeat the above procedure).
Figure 21.16: Creating the additional sequence

vi. Then double click on Preset Position and select preset 1 (Camera focusing position),
preset 2 for next sequence and so on.
Figure 15.17:Setting the preset position for creating sequence

vii.Then again double click on Dwell Time to set the preset time.
viii. Set Dwell Time as per your requirement (5,10…..seconds) and click ok.
Figure 21.18: Setting of dwell time for sequence

ix. Now click to Live option and drag the same camera to lift side screen as shown below. Click
on Switch between normal and edit preset modes button shown below and select the preset
position i.e. preset 1.
Figure 21.19: Setting of additional pan for the sequence

x. Now click on the camera screen (PTZ option) and set the camera focusing position for preset
1 and save it.

xi. Select preset 2 for next sequence and also change the camera focusing position, again save
it. Repeat the procedure for as many sequences as you want.

xii. After allocating final sequence to the camera, select the same camera from the list shown in
setup menu. Right click on the camera and click on view in pan to start the sequences,
camera will start to rotate automatically in the given preset position and record.
Figure 21.20: Selecting the camera for view in Pane

21.4.5 Network Video Recorder (NVR):

Figure 21.22: Network Video Recorder

Network video recorder (NVR- AS 3000) 3000 series provides a powerful and integratedrecording
and playback system for video from cameras. NVR contain four (4) 500 GB disks, disks 0 & 3 for
 SECTION A:

OPERATION MANUAL primary pair, disks 1 & 2 for secondary pair. Primary pair for
current recorded videos storage and secondary pair is for
CHAPTER 25
21.4.6 Archiving

The Shift In-charge/operators should always archive important file

for future references in external drives such as DVDs or CDs. One
must export the important files to a folder to archive as IP camera recordings and storing system
is FIFO (first-in and first-out), meaning that the oldest recordings are stored first and get deleted
first whenever there are new recordings based on the hard disk capacity of the IP Camera system
server. The important files include recordings on following occasions:
(i) Whenever there are visitors: It’s important to export and archive the recordings whenever
there are visitors as some visitors may take the tools and devices from the Sites and some
may be of threat to the security of the equipment/ systems installed at various locations of
the Plant.
(ii) Whenever there are Important Maintenance Activities: Recordings during important
maintenance activities will serve as references for the next maintenance period for
particular equipment/ system/ functional location.
(iii) Whenever there are Malfunction or breakdown of the equipment/ system: Recordings
during the breakdown/malfunctions of particular equipment will serve as
evidences/references for future purposes.
(iv) Whenever there are suspicious people at Site vicinity: The particular people may be a threat
to security of the equipment/systems installed at different locations of our Plant.

CHAPTER 22: VENTILATION SYSTEM

22.1 Introduction

Heating Ventilating and Air Conditioning (HVAC) system in Underground Power House is one of
the most important factors for maintaining thermal comfort and acceptable indoor air quality.
Ventilation system is also the process of exchanging or replacing air in any space for temperature
control, removal of excessive moisture, unpleasant smells, heat, smoke and dust. The ventilation
and Air conditioning of the underground hydropower station is not only associated with the
health of personal working inside the power house, but also with equipment’s natural working.
It has direct effect on the efficiency of workers and running machine. Dagachhu Hydro Power
Corporation Limited underground power house has 15 numbers of mechanical ventilation fans
installed at different locations.

22.2 Overview of HVAC system

Figure 1.1: Overall Mimic layout of DHPCL power house ventilation System

The mechanical ventilation fans rated capacity, quantity & location are tabulated as below:
Sl.
Capacity(kW) Qty. Location Purpose
No.

1 45 3 Emergency Exit Tunnel To supply fresh air to

(71SAA00GS001,2,3) underground power house.

2 at Transformer cavern
(71SAA00GS006, & 7).
2 30 4 3 nos. are smoke exhaust during
1 at Machine hall at EET fire inside power cavern.
top. (71SAA00GS008)
(Exhaust fan)
1 at Machine Hall at EET
side. (71SAA00GS005) To supply fresh air

3 15 2 Main access tunnel Exhaust

(60SAA00GS001 & 2)

4 18.5 2 Main access tunnel Exhaust

(60SAA00GS003 & 4)

5 1.5 2 Bus duct tunnel To supply fresh air

(61SAA00GS001 & 2)

6 9.3 1 Gas Insulated Sub-station To supply fresh air

(71SAA00GS004)

7 3.7 1 Machine Hall To distributes fresh air to

(20SAA00GS001) generator and turbine floor.

Table 1.1:Rating and locations of Ventilation Fans

22.3 Evacuation of smoke during fire inside power cavern

Generally, transformer is considered as the active source of fire in Electric Power Plant. If the fire
starts from transformers, the firefighting system will trigger automatically and water will spray
over it to extinguish and control the fire before spreading to other equipment’s. Since
transformer is located underground cavern, smoke will accumulate easily.
Hence, designer has taken care of smoke evacuation in such way that firefighting systems Deluge
Valve (DV) operates when input signal trigger from either smoke detector or electrical fault
(PRD/Buchholz relay), then, transformer on fire alarm appears in fire control penal at control
building and in control system as well. Any of the transformer’s deluge valve is activated, the
control relay K1, K2, K3, K4 energize and gives start command to smoke exhaust fan, 30kW
(71SAA00GS005, 006 & 008) and automatically stop all other air supply fans.

22.4 Operation procedure for power cavern ventilation system

Based on the ventilating system operation practiced by other Power Plant, the ventilation system
is allocated into winter and summer condition. We have to consider that heat generation from
the running machine at peak load and outside metrological condition.
Hence, it’s important to study the underground power house temperature, humidity and air
circulation system in the plant. Based on these parameters we have to run the ventilating fans
accordingly and set the procedure.

22.4.1 In winter season, run the following mechanical ventilation:

 Any of the 45 kW fan (71SAA00GS001, 2 &3)

 3.7 kW fan (20SAA00GS001)
 9.3 kW fan (71SAA00GS004)
 Any of the 15 kW fan (60SAA00GS003 & 60SAA00GS004)

22.4.2 In summer season

 Run 2 nos. 45 kW fan (71SAA00GS001 and 71SAA00GS002)

 30 kW fan (71SAA00GS005)
 3.7 kW fan (20SAA00GS001)
 9.3 kW fan (71SAA00GS004)
 Any of the 15 kW and 18.5 kW fan (60SAA00GS003 &4, & 60SAA00GS001 & 2)
 Both 1.5 kW fans (61SAA00GS001 and 61SAA00GS002)
 ANNEXURE: OPERATION MANUAL

ANNEXURE
(OPERATION MANUAL)
 SECTION A:

OPERATION MANUAL Annexure 0 1: Procedure for filling and de-watering

ANNEXURE 01 of Water Conducting System

1.1 Filling of Water Conducting System

The filling of the entire water conductor system shall be through the intake. A discharge of about
0.5 - 1.0 m3/sec is to be maintained by suitably lifting the intake gate. The filling rate can vary
between the above given limit, though in all subsequent paras, a filling rate of 0.5 m 3/sec is
mentioned. The probable extent of opening of the intake gate for this purpose, under various
heads are indicated in Table 1. During the filling of the water conductor system, the reservoir level
should not exceed El 843.30 m. The rise in reservoir water level should be regulated by operating
the spillway radial gates. The filling and testing of the various components of the water
conductor system may be divided into various stages and carried out in the order indicated
below.

Sl.No. Water Level Assumed Height of Head over upper Discharge (m3/sec)
(m) opening (m) nappe profile (m)

1 843.30 0.014 3.941 0.50

2 843.00 0.015 3.640 0.50

3 842.50 0.016 3.139 0.50

4 842.00 0.017 2.638 0.50

5 841.50 0.019 2.136 0.50

6 841.00 0.022 1.633 0.50

Table 1.1:Showing the opening heights of intake gate and corresponding discharges

1.1.1 Stage 1 - Filling of the Reservoir

i) Close one radial gate and regulate other radial gate in such a way that the filling rate is not
more than 0.5m/hour upto EL 835.00 m
ii) After reaching water level at EL835 m, close the intake gate and flap gates and continue
filling up the reservoir at 0.5m/hour up to EL 843.30 m
iii) Regulate using the flap gates and radial gates and maintain the level at EL 843.30 m

1.1.2 Stage 2 – Filling up of the WCS upto Desilter Inlet Gate): Volume (approx.) = 14,000
m3

In this stage, the WCS will be filled up to the desilter inlet gate up to El 841.0 m in the following
manner:
i) Close all the three desilter inlet gates. Keep all the desilter flushing gates open.
ii) Start filling the open channel system by allowing 0.5 m 3/sec by regulating the intake gate
according to the opening height as indicated in table 1.1.

1.1.3 Stage 3 - (Filling up of Desilter): Volume (approx.) = 26,100 m3

Desilter shall be partially filled in this stage upto the sill level of the outlet gate (i.e. El 837.90 m.
Filling of the desilter shall be done one after another.
i) Close the desilter flushing gate of desilter-1 and open the corresponding inlet gate so that 0.5
m3/sec flows through it based on the gate opening given in table 1.2, keeping the other two
inlet gates closed.
ii) Keep raising the desilter inlet gate at a slow rate till it is fully open. Thereafter, start filling the
desilter by allowing 0.5 m3/sec by regulating the intake gate. Let water fill up to El 837.90 m.
iii) Likewise, deilster-2 and desilter-3 can be filled up one after another.

Sl. Water Level Assumed Height of Head over upper Discharge (m3/sec)
No. (m) Opening (m) nappe profile (m)

1 841.10 0.012 6.038 0.50

2 840.50 0.013 5.437 0.50

3 840.00 0.013 4.937 0.50

4 839.50 0.014 4.436 0.50

5 839.00 0.015 3.935 0.50

6 838.50 0.016 3.434 0.50

7 838.00 0.017 2.933 0.50

8 837.50 0.019 2.431 0.50

Table 1.2:Showing the opening heights of the Inlet gate and its corresponding discharges

1.1.4 Stage – 4 (Filling up of HRT up to El 803.75 m i.e. invert at Surge Shaft):

Approximate Volume = 47,600 m3

In this stage, the HRT shall be partially filled up to an elevation corresponding to the invert level
of HRT at surge shaft and the valves provided at side adit shall be tested.
i) Close all the desilter flushing gates. Desilter inlet and outlet gates should be open at this time.
ii) The side adit access door should be properly closed.
iii) Keep both the valves (i.e., HRT drain valve and gravel flushing valve) at side adit open.
iv) Start filling the HRT by allowing 0.5 m3/sec by regulating the intake gate.
v) After some time, water will be coming out of the lower pipe i.e. the gravel flushing pipe
provided at side adit. Allow flow of water through this pipe until the water is clean. When it is
 observed that the water coming out is clean, the valve on the gravel flushing pipe shall be
fully closed.
vi) Again, after some time, it will observe that water will be coming out of the upper pipe i.e. the
drainage pipe provided at side adit. Allow flow of water through this pipe forabout 10
minutes and close it fully.
vii) Continue filling the HRT at the rate of 0.5 m 3/sec until water in the HRT reaches El 803.75 m.
viii) When the water level reaches El 803.75 m in the HRT, stop filling for 24 hours and check the
following:
1. Leakage at the desilter flushing gate, valves at side adit and side adit accessdoor.
2. Leakage at the ATH junction.
3. Any marked decrease in pressure measurement at pressure gauges installed near the
HRT drain and gravel flushing valves at side adit.
4. The HRC hill slope.
5. The hill slopes near Face-1 particularly the first 600 m of HRT-North.
6. The hill slope near ATH and surge shaft.
7. Monitor the water table in the wells, streams and springs along the tunnel alignment
especially in the valley portions and report.

1.1.5 Stage – 5 (Filling up of the pressure shaft): Approximate Volume = 3,000 m3

The pressure shaft shall be filled up in the following three stages:

1.1.5.1 Stage – 5A (Filling up of the pressure shaft up to El 637.00 m)

i) Close the Main Inlet Valve (MIV) provided in the power house.
ii) Keep the penstock drainage pipe open.
iii) Start filling the pressure shaft by allowing 0.5 m3/sec by regulating the intake gate.
iv) Close the penstock drainage pipe after allowing water to flow though it for about 10 minutes.
v) Close the intake when water in the pressure shaft reaches El 637.00 m (water level to be
ascertained with the help of water pressure gauge installed in MIV) and stop filling for 24
hours and check the following:
a) The entire check list under Para 1.4.
b) Any marked decrease in the pressure measurement at MIV.
c) Any sign of distress near the Powerhouse hill slope.
d) Any leakage of the MIV seals.
e) Observe readings of all the geotechnical instruments installed in Powerhouse and
Transformer caverns

1.1.5.2 Stage – 5B (Filling up of the pressure shaft up to El 737.00 m)

i) Continue filling the pressure shaft by allowing 0.5 m 3/sec through the intake gate.
ii) Close the intake when water in the pressure shaft reaches El 737.00 m and stop filling for 24
hours and check the entire list given in Para 1.5.1.

1.1.5.3 Stage – 5C (Filling up of the pressure shaft up to El 803.75 m)

i) Similarly, continue filling the pressure shaft by allowing 0.5 m 3/sec through the intake gate.
ii) Close the intake when water in the pressure shaft reaches El 803.75 m and stop filling for 24
hours and check the entire list given in Para 1.5.1.
iii) Special attention should be given to observe leakage through the cavity formation in
pressure shaft between El 754 m to El 774 m.

1.1.6 Stage – 6 (Filling up of the balance HRT and Surge Shaft): Approximate Volume =
92,150 m3

The balance HRT and surge shaft shall be filled up in the following four stages:

1.1.6.1 Stage – 6A (Filling up of the HRT and surge shaft up to El 815.00 m)

i) Start filling the balance HRT and surge shaft by allowing 0.5 m 3/sec through theintake gate.
ii) Close the intake when water in the surge shaft reaches El 815.00 m and stop fillingfor 24
hours and check the entire list given in Para 1.5.3.

1.1.6.2 Stage – 6B (Filling up of the HRT and surge shaft upto El 825.00 m)

i) Continue filling the WCS by allowing 0.5 m3/sec through the intake gate.
ii) Close the intake when water in the surge shaft reaches El 825.00 m and stop fillingfor 24
hours and check the entire list given in Para 1.5.3.

1.1.6.3 Stage – 6C (Filling up of the HRT and surge shaft upto El 835.00 m)

i) Continue filling the WCS by allowing 0.5 m3/sec through the intake gate.
ii) Close the intake when water in the surge shaft reaches El 835.00 m and stop fillingfor 24
hours and check the entire list given in Para 1.5.3.

1.1.6.4 Stage – 6D (Filling up of the HRT and surge shaft upto El 841.0 m)

i) Continue filling the WCS by allowing 0.5 m3/sec through the intake gate.
ii) Close the intake gate when water in the surge shaft reaches El 841.0 m and stop filling for 24
hours and check the entire list given in Para 1.5.3.

1.2 Emptying of Water Conducting System

Emptying of the WCS may be required in case of emergency or maintenance and repair. Since,
the WCS consists of various sections, emptying may be required only for a particular section or
whole of it depending on the nature of emergency or inspection/repair.
The following are the possible scenarios while emptying the WCS:
i) Case-1: Emptying of the WCS up to desilter outlet gate
ii) Case-2: Emptying of the desilter only
iii) Case-3: Emptying of the WCS downstream of desilter but not pressure shaft
iv) Case-4: Emptying of the pressure shaft only
v) Case-5: Emptying of the whole WCS
The procedure for emptying the WCS in each of the above case is described below. In each of the
case, before any of the described activity is begun, it is assumed that the turbine is standstill and
the MIV is fully closed.

1.2.1 Case-1: Emptying of the WCS up to desilter inlet gate

i) Close the intake gate and desilter outlet gates to isolate the section between them.
ii) Start opening the desilter flushing gate slowly and allow passage of water at the rate of 0.5
m3/sec.
iii) There can be two variants in this case i.e. emptying of the WCS upstream of the desilter or
including the desilter depending on the requirement. In the first case, empty water from the
desilter up to the desired level, say El 834.00 m. In the second case empty whole of the water
from the desilter.

1.2.2 Case-2: Emptying of the desilter only

i) Close the desilter inlet and outlet gates for that desilter which is required to be emptied. This
will hydraulically isolate the particular desilter.
ii) Start opening the desilter flushing gate slowly and allow passage of water at the rate of 0.5
m3/sec until all the water is drained.

1.2.3 Case-3: Emptying of the WCS downstream of desilter but not pressure shaft

i) Close all the desilter inlet gates.

ii) Open the two drain valves provided near the downstream abutment of Churachhu bridge to
drain any water that may exist between the steel liner and concrete casing at the side adit.
Observe the flow pattern. Initially, the flow rate might be slightly higher but it should be
almost steady/constant thereafter.
iii) After the flow in the above-mentioned drain pipes has steadied or stopped altogether
regulate the HRT drainage valve provided inside the valve house at side adit, so that
approximately 0.5 m3/sec of water passes. The following steps shall be followed while
emptying:
a) Empty up to El 835.00 m and hold for 24 hours.
b) Empty up to El 825.00 m and hold for 24 hours.
c) Empty up to El 815.00 m and hold for 24 hours
d) Empty up to El 805.00 m and hold for 24 hours
e) Continue emptying until the whole HRT is empty. It should be noted that water will be
there in the pressure shaft up to El 803.75 m.

1.2.4 Case-4: Emptying of the pressure shaft only

Follow the steps (i) through (iii)-(d) described in Case-3. After that follow the steps givenbelow. It
is to be noted that from here on emptying will be through the penstockdrainage valve provided
near the MIV.
For the penstock dewatering a two-valve arrangement is foreseen right before the MIV as shown
below:
Figure 1.1:Drawing showing the dewatering valves of Penstock
Pos. 1 – Wedge Gate Valve DN100, PN63 – is directly mounted on MIV-inlet pipe. This valve is a
kind of maintenance valve and shall NOT be used for regulating purpose.
Pos. 2 – Globe Valve DN100, PN63 – is mounted right after the wedge gate valve and can be used
for regulating purpose as well as for opening/closing under full pressure.
Important:
For discharging water of the penstock, first the wedge gate valve (pos. 1) has to be opened and
afterwards the globe valve (pos. 2) has to be opened.
When discharging needs to be stopped, first the globe valve (pos. 2) has to be closed and afterwards
the wedge gate valve (pos. 1) has to be closed.
The discharged water shall not contain hard and abrasive particles as this could damage the seating
surfaces and bring about untightens!!
The main step are as follows:
a) Continue emptying the part HRT and surge shaft up to El 795.00m by operating the
penstock drainage pipe provided near the MIV so that flow rate is approximately 0.5
m3/sec and hold for 24 hours.
b) Continue emptying up to El 750.00 and hold for 12 hours.
c) Continue emptying up to El 700.00 and hold for 12 hours.
d) Continue emptying up to El 650.00 and hold for 12 hours.
e) Continue emptying up to El 600.00 and hold for 12 hours.
f) Continue emptying up to El 560.00 and hold for 12 hours.
g) Continue emptying until whole of the water from the pressure shaft is drained.
1.2.5 Case-5: Emptying of the whole WCS

This is a combination of Case-1, Case-3 and Case-4 described above and they shall be
followed in that order only.

1.2.6 Check list while emptying of WCS

During the process of emptying or during the hold period, the following shall be checked
andreported.
i) Any sign of distress on hill slope all along the WCS in general.
ii) Any sign of distress on hill slope near Face-1 particularly the first 600 m of HRTNorth.
iii) Any sign of distress on the hill slope near ATH and surge shaft.
iv) Monitor the water table in the wells, streams and springs along the tunnel alignment
especially in the valley portions and report.
 SECTION A:

OPERATION MANUAL Annexure 0 2: Silt Flushing of Desilting Chamber

ANNEXURE 02

2.1 Introduction

Flushing of the Desilter can becarried out either in Auto and Manual Mode.

2.2 Auto Mode

In this mode, it can be either be based on time or in height of the gravel deposits. The setting has
to be done at the cubicle +52LPAGH002 (Andrtiz Panel).

2.2.1 Time Based

This mode based on the time interval set by the operator at the touch screen at cubicle
+52LPAGH002 and is shown in figure 1 and the setting can be done as below:
i. Punch the required time in set point in hours,
ii. Give the flushing time in minutes,
iii. Check the Time Control by clicking it on the ON button and will become green after
selecting,
iv. Put the setting of Desilter in AUTO Mode,
v. Follow the same process for Desilter 2 and 3 too.
The Desilting Chamber will start flushing when the actual time reaches the set point.

Figure 2.1:Showing the touch panel to set the time for triggering the flushing
2.2.2 Gravel Based

This is based on the actual deposits of sand / gravel in the chamber and operator can set up the
height of gravel at which the flushing can happen and is shown below:
i. Punch the height of the gravel in cm to trigger the flushing in Trigger Flushing box,
ii. Give the flushing time in minutes (this is the duration if flushing),
iii. Check the Gravel Control by clicking it on the ON button and will become green after
selecting,
iv. Put the setting of Desilter in AUTO Mode,
v. Follow the same process for Desilter 2 and 3 too.
The Desilter Chamber will start flushing when the actual gravel height reaches the set value.

Figure 2.2:Showing the setting up of the auto flushing in gravel based

2.3 Manual Mode

Other the automatic mode, the flushing can be done in manual mode locally or through remote
from Control System.

2.3.1 Local Mode

For this mode of operation, we don’t need to set up anything in the touch panel as it purely
depends on the operators and the step are as follows:
i. Select the touch panel in Manual Mode,
ii. Lower the Desilting Chamber Gates i.e. Inlet and Outlet Gate,
iii. When both Inlet and Outlet gate are fully closed, open the flushing gate of that particular
chamber 10 cm (Use stop watch and 15 seconds corresponds to 10 cm opening),
iv. After 30 minutes, open the flushing gate another 10 cm (15 seconds),
 v. After another 30 minutes, open the flushing gate fully,
vi. When the flushing gate is fully opened, open the Inlet Gate of the Chamber to its flushing
position i.e. 8 cm and let it flush all the sand and gravels from that chamber,
vii. Close the flushing gate fully after completion of flushing of the sand and gravel from that
chamber,
viii. After fully closing the flushing gate, fill the chamber by keeping the Inlet gate opened in
its flushing position i.e. 8 cm until the water level of that chamber equals the water level
of other Desilter or Desilter Outlet water level,
ix. After reaching the water level of that chamber same as that of Desilter Outlet, wait for
five minutes and start opening the Inlet and Outlet gate fully,
x. When both the gates are fully open, but the Desilter in Auto Mode.

2.3.2 Manually from Control System (remote operation)

The flushing of the Desilter can also be carried out from the control room at Power House
through the Control System. For this mode of operation, the Desilter should be in Auto Mode and
the flushing time should be pre-set up in the touch panel and can be carried out by clicking it on
the flushing button shown in figure 3:

Figure 2.3:Showing how to flush the Desilter through Control System.

 SECTION A:

OPERATION MANUAL Annexure 0 3: Reservoir Scouring Procedure

ANNEXURE 03

3.1 Precondition:

a) The shift in-charge shall shutdown the Unit at after consultation with the System operator
and the Scouring Team at Diversion Weir.
b) Maintenance staff shall go to Diversion Weir with adequate tools and relevant safety gadgets.
c) Maintenance Unit shall depute an operator at Chhurachhu side adit to monitor the pressure
readings.

3.2 Scouring sequence and activities

a) Scouring Team shall fully close the Weir Intake gate after getting confirmation from Shift in-
charge that the Generating Units are at stand still. However, the operator at Power house will
constantly monitor the Headrace channel (HRC) level and note the readings hourly.
b) The operator at Chhurachhu side adit will measure the water pressure readings at Chhurachu
upon getting instruction from Scouring Team.
c) The Scouring Team will also note the readings of Head Water Level, Desilter water levels, HRC
water level, Surge Tank level, Penstock pressures and the river inflow after closing the intake
gate.
d) Scouring Team shall fully open the Weir Flap Gates.
e) Scouring Team shall open the Radial Gates one by one at its minimum opening i.e. 30 cm.The
Scouring Team shall gradually increase the opening of the Radial Gatesaccording to
procedure given in Annexure 01.
f) The Scouring Team will start the scouring activities after fully opening the radial gates. The
scouring duration will depend on the amount of the silt deposits and the river inflow during
the time of scouring.
g) Scouring Team may either build up or deplete the water level of the Weir to adequately flush
the sand and silt deposits according to the Annexure o1.

3.3 Normalization:

a) After completion of scouring, Team shall fully close one Radial Gate and fill the reservoir by
regulating the other gate.
b) The rate of filling will be accordance with the procedure given in Annexure 01.
c) After water level reaching its normal operating level of EL 841.00 m, the team shall take the
readings from different locations of the power plant like head water level, Desilter water
levels, HRC water level, Surge tank water level, penstock pressure and river inflow,
d) The operator at Chhurachhu will also measure and note the water pressure at Chhurachhu
after getting instruction from Team Scouring.
e) Scouring Team will fully open the intake gate.
f) Up on normalizing the water conductor system, the Scouring Team shall communicate with
the shift in-charge at Power house and accordingly the start the generating Units.
g) The Shift in-charge will start and synchronize the generating unit after getting proper
approvals from the National Load Dispatch Center (NLDC).
 SECTION A:

OPERATION MANUAL Annexure 0 4: Data Formats

ANNEXURE 04

4.1 Daily Power Plant Performance Report:

DAILY POWER PLANT PERFORMANCE REPORT OF DHPC

  Date:  

1 Generation/Import:    

B Daily Generation Achieved (MU)  

C Daily Scheduled Generation (MU)  

D Import (MU)  

2 Energy Export/Sale:    

A Ex Bus schedule (MU)  

Export to TPTC (after 2% losses

B  
within Bhutan)

Actual cumulative Generation till date for the month

1    
(MU)

Scheduled cumulative Generation till date for the

2    
month (MU)

Actual cumulative Generation till date for the year

3    
(MU)

Scheduled cumulative Generation till date for the

4    
year (MU)

Actual cumulative Generation till date for the last

5    
year (MU)

Scheduled cumulative Generation till date for the last

6    
year (MU)

7 Total Cumulative Generation (MU)    

8 Total scheduled cumulative Generation (MU)    

9 Maximum / Minimum Bus Voltage (kV)      

10 Maximum / Minimum Frequency (Hz)      

11 Maximum / Minimum Generation (MW)      

12 Average Generation for the day (MW)    

 13 Performance Indicator of the day    

A Plant Load Factor (%)  

B Unit Availability factor (%)  

C Water Utilization factor (%)  

14 Reservoir level at 24:00 Hrs. (Meters)    

15 Average Tunnel Discharge (m3/s)    

16 Spillway Discharge (m3/s)    

17 Average River in-flow for the day (m3/s)    

Total Average River Inflow for last Year's month

18    
(m3/s)

Standby/Running/
19 STATUS OF UNITs  
Shutdown

A Unit - I  

B Unit - II  

20 Generation Loss (MU):    

I On account of Planned outage  

Ii On account of Forced outage  

On account of Grid
Iii  
Disturbance/System

a) Grid disturbance (High/Under

   
Frequency or system fault)

  b) Upon request of Grid  

21 Brief description of Outages/Grid Disturbances:  

Report Prepared by:  

Table 4.1:Daily Power Plant Performance Report

4.2 Generation and other pertinent information:

a) Comparison with the previous years:

SL No. Particular Year 2016 Year 2015

1 Generation (MU) for the day    

3 Total generation till date for the month (MU)    

 4 Total Actual generation up to last month (MU)    

5 cumulative so far (MU)    

6 Average River Inflow for the day    

Table 4.2:Generation comparison with previous years

i. Designed/Target Generation Vs. Actual Achieved for the year:

Month Monthly Target (MU) Daily Target (MU) Target so far (MU) Actual so far (MU)

Jan        

Feb        

Mar        

Apr        

May        

Jun        

Jul        

Aug        

Sep        

Oct        

Nov        

Dec        

Total

Table 4.3:Target Generation Vs Actual generation achieved for the year

ii. Hourly Average River Inflow & Generation details:

Hours Dam Level Radial Gate Radial Gate 2 Flap Gate 1 Station load Station load
Bus Frequenc
(m) 1 Discharge Discharge Discharge 2016 (MW) 2015 (MW)
Voltage y
(M3/s) (M3/s) (M3/s)

01:00                

24:00                

Averag
   
e            

Max
Min

Table 4.4:Hourly average river inflow Vs Generation details

4.3 Plant Availability Report to PSCC, TPC

MTD YTD
Station (Capacity) DTD
(126 MW) (126 MW)

Peak MW

MU's

Availability (%)

Capacity Charge MYT

Order

Energy Charge MYT Order

Total Cost / Unit

       

Major Events/Remarks

Table 4.5:Power Plant availability report to PSCC, TPC

4.3Data format for DHPS and RMA:

a) During the Month

1 GENERATION: -    

i) Installed capacity = MW

ii) Generation Capacity = MW

iii) Projected Target = MW

iv) Actual generation = MW

2 PEAK GENERATION: -    

i) Unit 1 = MW

ii) Unit 2 = MW
 3 TOTAL ENERGY AVAILABLE: -    

i) DHPC Generation = MU

ii) Import from 22okV DHPC-Tsirang Line = MU

Total =  

4 DISTRIBUTION: -    

i) Net Export to TPTCL = MU

ii) Internal Consumption = MU

5 REVENUE: -    

i) Amount billed to TPTCL = Rs. (in Million)

ii) Amount billed to BPCL (if any) = Nu.

iii) Wheeling Charge = Nu.

6 PEAK LOAD: -    

i) Export to India (TATA) = MW

ii) Sold to BPCL (if any) = MW

Table 4.6:Data during the month

b) Cumulative Progress:
i. Generation and running hours

UNITS ENERGY GENERATION (MU) RUNNING HOURS(Hrs)

Cumulative since Cumulative since

  During the Month During the Month
commissioning commissioning

UNIT I

UNIT II

TOTAL

Table 4.7:Generation and running hours

ii. Export and Revenue from Tata (India) since commissioning

i) Cumulative Gross energy exported to (TATA)

India as per billing till the end of For the Month Energy MU

ii) Cumulative amount billed to (TATA) India till the

end of For the Month Nu. Million
iii) Cumulative amount received from (TATA) India
till the end of For the Month Nu. Million

iv) Difference between (ii) & (iii) due to outstanding

amount for the month of For the Month Nu. Million

Table 4.8:Export and Revenue from Tata (India) since commissioning

4.4 shutdown request form:

Shutdown Approval Request

REF / MSG No. _ Date:
Requesting Agency : Dagachhu Hydro Power Corporation Limited
Type of Shutdown : Planned Ad-hoc Emergency
Shutdown Requested For:LineTransformer Generating Unit Others
Details:

Job Description Detail:

Start Time: Time D/M/Y

End Time: Time D/M/Y
Supervisor: Name: Contact No:
Any Comments:
Copy To:
Signature &
Designation

For System Coordinator Office use only:

REF / MSG No. ________________________________________________
Approved: Not Approved:
Comments:

Conditions of shutdown:
1. Before actually switching off the element prior clearance may be availed from concerned
authority.
2. The shutdown must be normalized within the approved period.
 3. Affected customers should be informed through media well in advance before taking the
shutdown.
Copy To:
Signature:
Designation:

Date:
4.5 Ex-Bus Schedule form:
Format for boundary conditions:

NAME OF GENERATOR: DHPC

Trader TPTCL

Delivery date 19-Oct-16

Exchange code

TIME PERIOD   Bhutan Network Losses

2.00%
FROM TO EX-Bus (MW)
Quantum after loss (MW)

00:00 00:15

00:15 00:30

23:30 23:45

23:45 24:00

TOTAL  

DATED: (Name)

PLACE: Balaygaon, Dagana Operation Unit

4.6 Event Information Report Form:

EVENT INFORMATION REPORT

(To be sent to System Operator by utility as per Grid Code Regulation 2008, Clause No. 6.15)

Reference No.:   Date:  

Dagachhu Hydro Power

From: Time:  
Corporation Limited

Type of Event: Tripping of any transmission line

Date:   Time:  

Name of Plant and/or Equipment Under Breakdown:

Details of Relay
 
Operation: 

Description and Cause of Event:

   

Antecedent Conditions:

Load/Generation (MW):   Voltage (kV):  

Communicatio
Frequency (Hz):    
n Status:

Weather Condition:  

   

Demand and/or Generation Interrupted (MW):  

   

Normalization:

Date:   Time:  

   

All Relevant System Data from Log Book Entry:

   

Sequence of Tripping with Time (If any other line or unit or transformer … etc. failure due
to this event):

   

Remedial Measures and Recommendation for Future Improvement:

   

Any Other Relevant Information:

   

Copy to:
 

Signature:  

Name:  

Designation: Shift In-charge

This report may be faxed but a soft copy should follow to SCO

Table 4.9:Event information report form

4.7 Energy Generation and Consumption Statement:

ENERGY GENERATION AND CONSUMPTION STATEMENT Month:

Month Actual Scheduled Line Aux. Loss Total Energy Sold Royalty *Actual **Actual Total Energy
Energy Ex-Bus Losses (MU) Energy to TPTC as Energy Internal Aux. Energy Consumption
 
Generation Energy (MU) (MU) Sold to per (MU) Consumption Consumption (MU)
(MU) TPTC as JEMR(MU) (MU) (MU)
per billing at DHPC end
(MU) (@12:30)
BST

A B C=B*2% D E F G=12% of E H I K=H+I

January

February

March

April

May

June

July

August

Septembe
r

October

November

December

Total

Table 4.10:Energy generation and consumption statement form

 SECTION A:

OPERATION MANUAL

ANNEXURE 05

Annexure 0 5: Monthly Energy Bill

To
Tata Power Trading Co.Ltd.
Tata Power Company Ltd., C – 43, Sector 62, Noida 201 307
Uttar Pradesh, India

ENERGY BILL FOR THE MONTH OF ___________YEAR_______

 SECTION A:

OPERATION MANUAL

ANNEXURE 06

Bill No.: Bill Date:

Period of Supply: Due Date:

Ref. PPA of 29th September 2014  

Sl.No. Particulars Unit Total

Total Energy made Available at Indo-

Bhutan Border (Delivery Point) after
1 kWh
adjusting 2% Bhutan Network losses
from EX-Bus ( as per details enclosed )

2 Rate Rs./kWh

3 Total Bill Amount Million Rs.

Less: Prompt payment discount @2% of

4 bill amount (if payment is made on or Rs
before due date)

Net Bill Amount (payment to be made

5 Rs.
on or before due date)

Amount in words:

DHPC Bank Account Details:

Current Account No.  00000011128915297

State Bank of India, Hasimara Branch
  Jalpaiguri District, WEST BENGAL, INDIA.  
IFSC Code -   SBIN0001447 (Code of State Bank of India,
Hasimara Branch)

Table 5.1:Monthly Energy Bill

Annexure 0 6: Contingency Plan

CONTINGENCY PLAN & OPERATING PROCEDURES
WITH EAST – WEST INTERCONNECTION

6.1 Introduction
The contingency Plan and Operating Procedures document shall be dynamic document which
shall be modified with change in power system network. The modification shall be carried out
after through discussion in the Protection Coordination Committee (PCC) and approved by the
Bhutan Power System Coordination Committee (BPSCC).
This document shall be also reviewed periodically by PCC members on yearly basis.

6.2 System Improvement Features

6.2.1 Basochhu Pondage
Under normal condition, Basochhu pondage shall be kept filled to meet the load during
emergency. Basochhu Hydropower Plant (BHP) shall inform Power System Operator before
depletion or maintenance of the pondage.

6.2.2 Reactor in Tala Hydropower Plant

Tala Hydropower Plant (THP) has a shunt reactor of 1x63MVAR which shall be connected to the
400kV bus when the system voltage goes above the permissible limit of 1.05 times the rated
voltage and the reactor shall be disconnected when the system voltage goes below the
permissible limit of 0.95 times the rated voltage.

6.2.3 Reactor in Kurichhu Hydropower Plant

Kurichhu Hydropower Plant (KHP) has a shunt reactor of 1x5MVAR which shall be connected to
the 132kV bus when the system voltage goes above the permissible limit of 1.05 times the rated
voltage and the reactor shall be disconnected when the system voltage goes below the
permissible limit of 0.95 times the rated voltage.

6.3 Bus Configuration

With the bus coupler remaining healthy, the bus configuration shall be kept as follows:

6.3.1 220kV Semtokha Substation

a) The 220kV Chhukha – Semtokha line and one of the 50MVA, 220/66kV transformer shall be
connected to Bus A
c) The 220kV Rurichhu – Semtokha line and other 50MVA, 220/66kV transformer shall be
connected to Bus B
d) The Bus Coupler shall be kept closed.

6.3.2 220kV Chhukha Switchyard

Three generating units along with all the 220kV export lines (220kV Chhukha – Birpara line- I & II)
and 220kV Chhukha – Malbase line- III shall be connected to Bus A
a) The other generating unit along with Bhutan loads (220kV Chhukha – Semtokha line and
2x20MVA, 220/66kV transformers) shall be connected to Bus B
b) The Bus Coupler shall be kept closed.

6.3.3 400kV Malbase Substation

a) The 400kV Tala – Malbase Feeder and 400kV Malbase – Siliguri line shall be connected to
400kV Bus A, while 200MVA, 400/220kV ICT shall be connected to 400kV Bus B
b) The tie-breaker shall be kept closed
c) The 220kV Chhukha – Malbase line and 220kV Malbase – Birpara line shall be connected to
220kV Bus A, while the 200MVA, 400/220kV Interconnecting Transformer (ICT) along with the
Bhutan load (220kV Malbase – Singhigoan line- I & II and all 220/66kV transformers) shall be
connected to 220kV Bus B
d) The bus coupler shall be kept closed.

6.3.4 220kV Rurichhu Switchyard

a) One generating unit along with the 220kV Rurichhu – Semtokha line shall be connected to
Bus A, while the other generating unit along with the 220kV Rurichhu – Tsirang line and
30MVA, 220/66kV ICT shall be connected to Bus B.
b) The bus coupler shall be kept closed.

6.3.5 220kV Tsirang Substation

a) The 220kV Dagachhu – Tsirang line and 220kV Rurichhu – Tsirang line shall be connected to
Bus A, while 220kV Tsirang – Jigmeling line and 2x10MVA, 220/66kV transformer shall be
connected to Bus B
b) The bus coupler shall be kept closed.

6.3.6 220kV Jigmeling Substation

a) The 220kV Tsirang – Jigmeling line along with one 63/80MVA, 220/132kV ICT shall be
connected to Bus A, while the other 63/80MVA, 220/132kV ICT shall be connected to Bus B
b) The bus coupler shall be kept closed.

6.4.0 System Under Normal Condition

Under normal condition, the system for the western grid shall be kept as follows:
a) The 66kV Chhukha – Semtokha line and 220kV Chhukha – Semtokha line shall be kept in ring
system. However, the 66kV Semtokha – Olakha shall be kept opened at Olakha end during
lean season when BHP generation is below 30MW.
b) The 66kV Rurichhu – Semtokha line and 220kV Rurichhu – Semtokha line shall be kept in ring
system.
c) The 66kV Chhukha – Phuentsholing line and 220kV Chhukha – Malbase line shall be kept in
ring with 66kV Phuentsholing – Malbase line. The eastern and western grid shall be kept
connected via 220kV Tsirang – Jigmeling line.
d) During the peak seasons, all the international lines shall be kept in service. However, during
the lean seasons some international lines shall be kept OPEN/CLOSE as per system
requirement.

6.5 Contingency and Operating Procedure

6.5.1 Failure of 220kV Rurichhu – Semtokha Line and 220kV Rurichhu – Tsirang Line
If the 220kV Rurichhu – Semtokha line fails along with the failure of 220kV Rurichhu – Tsirang line,
the Power System Operator shall instruct BHP to back down its generation till its total generation
is equal to power carrying capacity of the 66kV Rurichhu – Lobeysa line during peak seasons.

6.5.2 Failure of 220kV Rurichhu – Semtokha Line and 220kV Tsirang – Jigmeling Line
If the 220kV Rurichhu – Semtokha line fails along with the failure of 220kV Tsirang – Jigmeling
line, the Power System Operator shall instruct Dagachhu Hydropower Corporation Ltd. (DHPC)
and BHP to back down its generation till its total generation is equal to power carrying capacity
of the 66kV Rurichhu – Lobeysa line depending upon priority.

6.5.2.1 Synchronization after fault clearance

After the clearance of fault on 220kV Rurichhu – Tsirang line, the synchronization with the
western grid shall be carried out at BHP end. Similarly after the clearance of fault on 220kV
Tsirang – Jigmeling line, the synchronization with the western grid shall be carried out at
Jigmeling end. The synchronization shall be carried out with the instruction from Power System
Operator.

6.5.3 Failure of 220kV Chhukha – Semtokha Line and 220kV Rurichhu – Tsirang Line
If 220kV Chhukha – Semtokha line and 220kV Rurichhu – Tsirang line fails during the lean
generation, Basochhu pondage shall be utilized to meet the Thimphu load including the Lobeysa
load.

6.5.3.1 Operation procedures for above line failure

The following operation procedures shall be followed:
a) The Power System Operator shall inform the Shift In-charge of Semtokha substation, BHP
and CHP regarding the failure of the above lines
b) The Power System Operator shall coordinate with BHP to utilize the pondage for generation
to meet the load of Thimphu during the peak hours. The prioritizing of distribution feeder in
Thimphu shall be carried out by Substation Maintenance Division (SMD), Semtokha in
coordination with Electricity Service Division (ESD), Thimphu.
c) The Power System Operator shall coordinate with the Shift In-charge of Semtokha, BHP and
CHP to extend the BHP power supply to Chhukha and synchronize at Chhukha end once the
220kV Chhukha – Semtokha line is restored.
d) Similarly, in-case of 220kV Rurichhu – Tsirang line, synchronization shall be carried out at
Rurichhu end.
e) After synchronization, BHP shall refill the pondage immediately at midnight following the
utilization, backing down the generation of the BHP lower stage.

6.5.4 Failure of 220kV Chhukha – Semtokha and 66kV Chhukha – Semtokha Line
During the above line failure in the lean seasons, the western load on priority shall be fed from
Basochhu and Eastern Grid. However, for synchronization, the Power System Operator shall
coordinate with the Shift In-charge of Semtokha, BHP and CHP to extend the power to Chhukha
and synchronize at Chhukha end once one of the above lines is restored.

6.5.5 Blackout at 220kV Semtokha Substation

6.5.5.1 Operation Procedure for the above blackout
If complete power blackout occurs at 220kV Semtokha substation, the following procedures shall
be followed:
a) The Power System Operator shall inform the Shift In-charge of CHP and BHP regarding the
nature of the problem.
b) CHP shall immediately extend the grid supply to Semtokha considering the stability of the
Indian Grid and CHP. Then the supply shall be extended to BHP and synchronize with the grid
at their end.
c) In-case of Indian Grid failure with CHP and BHP being pulled out, the Shift In-charge of CHP
control room shall first try to get feedback supply from Indian Grid. If power supply is
available at Birpara end, the power supply shall be extended directly to Semtokha substation
before initiating to normalize CHP’s machines. CHP machines shall be connected to grid once
the supply is extended to Semtokha substation. The supply shall be further extended to BHP
for synchronization with Eastern Grid.
d) If power supply is not available at Birpara end, the Shift In-charge of BHP control room shall
first try to get feedback supply from Eastern Grid. If power supply is available at Tsirang end,
the power supply shall be extended directly to Semtokha substation before initiating to
normalize BHP machines. BHP machine shall be connected to the grid once the supply is
extended to Semtokha substation. The supply shall be further extended to CHP for
synchronization with Western Grid.
e) In-case Indian power supply is not available from both the ends then BHP shall immediately
extend the supply to Semtokha substation. The Shift In-charge of Semtokha substation shall
ensure that the loads are gradually applied in consultation with the Shift In-charge of BHP.
After the complete restoration of power supply to Thimphu, the power supply shall be
extended to CHP depending on the availability of the lines for synchronization at their end.
f) The Indian Grid shall be synchronized at Chhukha and BHP end.

6.5.6 Failure of any one of the 220kV Chhukha – Birpara Line during peak generation
During the peak generation, when one of the 220kV Chhukha – Birpara Feeder trips, the 220kV
bus coupler at Malbase substation shall automatically open by inter-tripping protection scheme
for equal sharing of load between the 220kV Chhukha – Birpara line and 220kV Chhukha –
Malbase line. However, this scheme shall be disabled during lean season as per the instruction of
Power System operator. In general, the following procedures shall be followed:
a) Immediately after the tripping of one of the 220kV Chhukha – Birpara line, the Power System
Operator shall inform the Shift In-charge of Malbase substation regarding the failure of line.
b) If the de-coupling of 220kV bus coupler at Malbase leads to overloading of 66kV Chhukha –
Gedu line, the Shift In-charge of Phuentsholing substation shall open the 66kV Phuentsholing
- Malbase line.
c) After the normalization of the 220kV Chhukha – Birpara line, Power System Operator shall
instruct the Shift In-charge of Malbase substation to close the 220kV bus coupler.
d) Power System Operator shall instruct the Shift In-charge of Phuentsholing substation to close
the 66kV Phuentsholing – Malbase line after closing the 220kV bus coupler at Malbase.

6.5.7 Failure of 220kV Double Circuit Chhukha – Birpara Lines

The maximum power which can be loaded from the 220kV Chhukha – Malbase line (Zebra
conductor) is around 200MW considering the current carrying capacity of 600 Amperes as per
the Current Transformer (CT) setting and power factor of 0.9.

6.5.7.1 Operation procedure for above line failure

During peak generation, if 220kV Double Circuit (D/C) Chhukha – Birpara line trips, the combined
generation from CHP and power flow from BHP to CHP is more than the total line carrying
capacity of 220kV Chhukha – Malbase line and 66kV Chhukha – Phuentsholing line. The following
procedure shall be followed:
a) The Power System Operator shall inform the Shift In-charge of CHP, BHP and DHPC regarding
the failure of the above lines and instruct CHP, BHP and DHPC to reduce their generation
based on priority.
b) Shift In-charge at CHP and Power System Operator shall maintain the total generation such
that total power flow through 220kV CHP – Malbase line does not exceed 200MW and 20MW
through 66kV Chhukha – Phuentsholing line respectively.
c) After normalization of 220kV D/C Chhukha – Birpara lines, the Shift In-charge of CHP shall
inform Power System Operator regarding the normalization of lines. Power System Operator
shall inform the BHP and DHPC.
d) Shift In-charge of CHP, BHP and DHPC may increase their respective generation.

6.5.8 Failure of all 3x50/63MVA, 220/66kV Transformer at Malbase Substation

When the 66kV Chhukha – Phuentsholing line and 66kV Malbase – Phuentsholing line are in ring
system and if all the 3x50/63MVA, 220/66kV transformer at Malbase substation trips, then there
will be surge in power flow through 66kV Chhukha – Phuentsholing line to meet the loads at
Pasakha area, Phuentsholing, Gedu and Gomtu substations leading to overloading of line.

6.5.8.1 Operation procedure to avoid the above problem

The following procedure shall be followed until two of 220/66kV transformers are restored:
a) The Power System Operator shall inform the Shift In-charge of Malbase substation and
Phuentsholing substation.
b) Shift In-charge of Malbase substation shall hand trip the 66kV Malbase – Phuentsholing line
after informing CHP and Power System Operator.
c) After restoration of the 220/66kV transformer at Malbase substation, then Shift In-charge of
Malbase substation shall charge back the 66kV Phuentsholing – Malbase line after intimation
with Shift In-charge of Phuentsholing substation, CHP and Power System Operator.

6.5.9 Failure of 220kV Chhukha Feeder- I, II and III

If the above contingency occurs while Chhukha is generating at its maximum capacity with
Eastern and Western Grid connected, the 220kV Chhukha – Semtokha line, 66kV Chhukha –
Semtokha and 66kV Chhukha – Gedu line will trip due to overloading. Until the restoration of
lines, CHP, BHP and DHPC shall maintain the generation with reference to power carrying
capacity of 132 Jigmeling – Gelephu line (around 60MW) and 66kV Chhukha – Gedu line.

6.5.9.1 Operation procedure for failure of above lines

During the failure of above lines, the following procedures shall be followed:
a) The Power System Operator shall inform the Shift In-charge of CHP, BHP, Semtokha and
Malbase substation regarding the failure of above lines
b) The Power System Operator shall ask the Shift In-charge of Malbase substation to open the
66kV Malbase – Phuentsholing Feeder to avoid the overloading of 66kVChhukha –
Phuentsholing line.
c) Shift In-charge in BHP and Semtokha shall extend the power supply to CHP and the
generating units of CHP shall be synchronized at their end.
d) Power System Operator shall co-ordinate with Shift In-charge of CHP and increase the
generation of CHP, while monitoring the loading of above mentioned lines.
e) Power System Operator shall instruct the Shift In-charge of CHP to increase the generation to
full capacity after normalizing the 220kV Chhukha export feeders.
f) Power System Operator shall instruct the Shift In-charge of Malbase substation to close the
66kV Malbase – Phuentsholing line.

6.5.10 Failure of Both 132kV Motanga – Rangia and 132kV Gelephu – Salakati Line
Till the interconnection of Eastern and Western Grid, during the failure of above lines
simultaneously, Power System Operation shall instruct Shift In-charge of Jigmeling substation to
extend the western power supply to Eastern Grid for faster restoration of KHP generating units.
 SECTION B: MAINTENANCE MANUAL

SECTION B: MAINTENANCE MANUAL

 SECTION B:

MAINTENANCE MANUAL CHAPTER 1: GENERATOR

CHAPTER 1

1.1 Introduction

Thiscontainsessentialinformationneededforsafeandefficientmaintenanceof thegenerator. In order

to keep downtime due to foreseeable wear or to damage that can be identified
at an early stage to a minimum, planned and scheduled inspections are absolutely necessary. At the
same time, the down time required for such inspections must be kept within economically
justifiable limits. That in turn requires:

 doing the inspections at the correct point in time;

 gathering together and getting ready at an early time the replacement parts and the special
equipment that will be needed, and/or ordering them from the manufacturer of the
generator;

 keeping the time required for the inspection short by means of detailed planning and
workmanlike carry through on those plans.
Timely and close cooperation between the operator and the manufacturer of the generator is an
essential prerequisite for success in this respect.
Importantnotes
Alllocalsafetyandenvironmentalregulationsregardingtheplaceofoperationandtheenvironmentmus
tbeobserved.
Targetaudienceandqualificationofpersonnel
Allworkonthegeneratormustbecarriedoutbyspeciallytrainedandauthorized personnel
only.Itishighlyrecommendedtohaveanyworkoncriticalpartscarriedout bythemanufacturerorinco-
operationwiththemanufacturerrespectively.

1.2 Safety Instructions for Maintenance

Prior to starting any maintenance work, the operating and maintenance staff must have read and
understood the safety instructions.
The owner/operator and the supervisor(s) must also be familiar with all applicable safety
instructions and are responsible for the maintenance personnel to observe all safety instructions.
Specificsafetymeasures
Risks when the machine is running:
Whilethemachineisrunning,therearebothmechanicalandelectricalhazards present.
Applyextremecareandavoidtouchingtheslipringsand/oranyrotatingparts.
Topreventaccidentsofanelectricalkinditisabsolutelyessentialtofollowtheappropriateinstructionsin
themaintenancesectionwhenchangingthecarbonbrushes.
Onlyvisualinspectionsandchecksarepermitted
Risks when the machine is at standstill:
Itisessentialthatthemachinecannotbeputintooperation
Besurethattheexcitationcannotbeswitchedonwhilethemachineisatstandstill.

1.3 Preventive Maintenance

Toensurethegeneratoriskeptinasafeandefficientcondition,periodicinspections
mustbeperformed.Theseinspectionsareplannedactivitiesdesignedtodetermineand
evaluatethecurrentstatusofthegeneratorandaredesignatedClassA(first),ClassB
(minor)andClassC(major).
ClassA,ClassB andClassCoverhaulsaredesignedtocheckforchangesinstatusor
conditioninstructuralcomponentswhichwould,incaseoffailure,negativelyaffectthe
operatingsafetyand/orreliabilityoftheplant.
Inordertokeepdowntimeduetoforeseeablewearortodamagethatcanbeidentified
atanearlystagetoaminimum,plannedandscheduledoverhaulsareabsolutely necessary.
Atthesametime,thedowntimerequiredforsuchoverhaulsmustbekeptwithin
economicallyjustifiablelimits thatinturnrequires:

 Doingtheoverhaulsatthecorrectpointintime,
 Gatheringtogetherandgettingreadyatanearlytimethereplacementpartsandthe
specialequipmentthatwillbeneeded,and/ororderingthemfromthemanufacturerofthegene
rator.
 Keepingthetimerequiredfortheoverhaulshortbymeansofdetailedplanningand
workmanship plans.
Timelyandclosecooperationbetweentheoperatorandthemanufacturerofthe
generatorisanessentialprerequisiteforsuccess.
Note:Duetoeconomicconsiderations,theintervalsbetweenoverhaulsshouldbecoordinatedwiththosef
ortheturbine.
Caution:
Thefollowinginspectionsandoverhaulsarerequiredforthesafeoperationofthe generator:
 Generalinspectionsbytheoperator
 Minoroverhauls
 Majoroverhauls
General inspection recommendations
Inspectionworkcarriedoutcarefullyandatthecorrecttimehelpstopreventfaultsor
damageduringoperation.Therefore,inspectionsareanimportantfactortoensure trouble-
freeandsmoothoperationtoavoidcost-intensiverepairs.
Sincetheoperatingconditionsofthemachinescandiffer widely,theintervalsgivenin
theinspectionplanscanbeadaptedtothenormaloperatingconditions.Intheeventof
faultsorextraordinaryoperationconditions(e.g.overload,shortcircuit,asynchronous
operation,excessivespeed)whichresultinanelectricalormechanicaloverloadofthe
machine,thetestsandmaintenanceworkproposedmustbecarriedoutassoonas possible.
Duringoperationofthemachine,allthesystemsandequipmentmustbeconstantly
monitored.Thedisplaysfortemperature,pressure,flowandtheelectricalconditions
mustbecontinuouslychecked.
Partsthatareimportantforoperation–suchastheslidingsurfacesofslip-rings,carbon
brushes,sealingelements–mustbecontinuouslyinspectedvisually.
Exceedingthemaintenanceintervalsreferredtonormaloperationcanadverselyaffect
smoothoperationandresultindamage.Topreventsuchdamage,itscausesshouldbe
rectifiedasquicklyaspossible.
Maintenanceandservicingworkmayonlybecarriedoutbypersonswhohave
appropriateexperienceoflarge-scalegeneratorsandarefamiliarwiththiswork.The
appropriatesafetyinstructionsforallmaintenanceandservicingworkmustbeobserved
andtheprescribedmeasurements should be carriedout.
Itisintheinterestoftheoperatortoreportanychanges and
checksshouldbecarriedouttoastrictscheduleandappropriatechecklists.Checks
shouldbecarriedoutbysuitableinstructedpersonnel,ifpossiblealwaysbythesame
people.Thisisanappropriatewaytoensureearlydetectionofabnormalsymptoms.
Note:
Yearsoffaultlessoperationshouldneverbeareasonforslackeninginspectionprocedureorlessfrequentch
ecks.

1.4 Recommended Inspections

Daily/weeklyinspection
Monthlyinspection
Typesofinspections

Typeofinspection Characteristic

Daily/weeklyinspection Inspectionsandobservationsonthegeneratorduringoperation

Monthlyinspection Visualinspectionsofthegeneratorandcomponentsatstandstill

Table 1.1: Types of Inspection

Daily/weekly inspections
Daily/weeklyinspectionshavetobecarriedoutbytheoperatorwiththegeneratorin operation.
Daily/weeklyinspections

Component Activity

Generator • Watchoutforanyunusualnoises,vibrationsor incidents

• Checkoperationalparameters
• Checkoillevels

Sliprings • Checkslipringsparking

Carbonbrushes • Checkconditionofcarbonbrushes

Brushgear • Checkbrushgearforsmoothandsilentoperation

Airfilters • Checkairfiltersfordirtcontamination

Oilfilters • Checkconditionof the oilfilters

• Checksystemforleakages
Watercoolingsystem • Checkcoolingwaterflow
• Checkvalvesforsignsofleakage

Bearings • Checkbearingtemperatures

Table 1.2: Daily/Weekly Inspection

Monthly inspections
Monthly inspections have to be carried out by the operator with the generator at standstill.
Monthly inspections

Component Activity

Generator • Checkoperationalparameters
• Checkbearingtemperatures
• Checkoilseparatorsanddrainifnecessary

Sliprings • Checkconditionofslipringsurfaces

Carbonbrushes • Checkconditionofcarbonbrushes

Brushgear • Checkbrushwear

Airfilters • Checkairfiltersfordirtcontamination

Oilfilters • Checkconditionof the oilfilters

Bearings • Checkoillevels
Watercoolingsystem • Checksystemforleakages
• Checkcoolingwaterflow
• Checkvalvesforsignsofleakage

Brakingandjackingsystem • Checkbrakingandjackingfordirtdeposits
• Checkbrakingandjackingsystemforleakage

Standstillheating • Checkfunctionofstandstillheating

Table 1.3:Monthly Inspection

1.5 Recommended Overhauls

Overhaulsareplanned,scheduledchecksonpartsoftheplantoronthewholeplant,
andaremadewiththeobjectofavoidingplantoutagescausedbydamagedpartsor
systems.Whenmadeatprescribedintervals, theoverhaulsenabledetectionofwear,
theearlyrecognitionofdamage,andthetimelyreplacementofdefectiveparts.
Theavailabilityofthemachineisnotonlyaffectedbyoperationalfaults,butisalso
significantlyaffectedbythedurationandfrequencyofplannedshutdown.Theplanned
shutdownsmustthereforebeheldwithineconomicallyviablelimitsandtheworkmust
beplannedforoptimumoverhaulresults.Thesegoalsarepossibleunderthefollowing conditions:
 Schedulingoftheoverhaulforthepropertime.
 Accuratepredictionoftheworktobedone.
 Comprehensiveoverhaulplanningandcompetentperformanceofthework,
resultingintheshortestpossibleshutdowntime.
Overhaulplanningrecommendations
About12monthsbeforestartingtheoverhaul,theplantmanagementshouldcontactthe
manufacturer,ifnecessaryalsotheinsurancecompany(e.g.overhauldiscussion,
servicediscussion)and,takingtheobservationsmadeduringoperationandthe
insurancetermsintoaccount,determinetime,typeanddurationoftheoverhaul.Duringthisservicediscu
ssion,thefollowingitemsshouldbeclarified.
Scopeof overhaul
Withtheaidoftheobservationsmadeduringoperation and aswellasoftheoverhaul plans,
theoverhaulscopementionedabovemust possiblybeextended.
Replacement requirement
Theprospectivesparepartsrequirementcanbedeterminedaccordingtothescopeof theoverhaul.
Sparepartsrequirement
Withregardtotherequirementthesparepartsstocksaretobecheckedfor
completenessandgoodcondition.Sparepartsneededadditionallyshouldbeprovided onduetime.
Toolsanddevices
Itistobe ensured that the necessarytoolsanddevices are ready and in stock.
Personnelemployment schedule
Theplantmanagement should drawupapersonnelschedule.
Workschedule
Aworkscheduleistobedrawnupshowingwhichworkistobedoneintheworkshop,andwhichistobedo
neinthoseofthemanufacturer/parts supplier.
Capacityplanning
Theplantmanagementandifnecessary spare partsmanufacturer/suppliershouldhavethenecessary
workshopandmachinecapacityavailable.
Furtherrequests
Induecoursebeforetheoverhaul,the plant/manufacturer/suppliershouldestablishtheactual
generatorconditionsbycheckmeasurements(e.g.pressures,vibrations,foundation
displacement,generatorheat-up,etc.).
Forthediagnosis,theactualgeneratorconditionsarethencomparedtotheoriginal
(desired)conditionsformakingadiagnosis.
Inthiscontext,thepersonnelrequirement,therequiredpersonnelqualification,
compositionoftheoverhaulteamandtheirworkingtime(manufacturers/suppliers,plants
andoutsidepersonnel)shouldbeestablished.
Itisadvisabletodraw-upatimetablefortheentireoverhaulprocedure(barchart,
networkdiagram).Itshouldbenotedthatquickdismantlingaffordsearlyfindings,which
allowsunforeseenworktobeperformedwithintheplannedoutageperiod.
Factorsforoverhaulintervals
Theoverhaultimingisgovernedessentiallybythenumberofoperatinghoursand
starts.BothfactorsarecombinedtoformtheequivalentoperatinghoursTe.

Timingformula

Te=To+ ns×Ts
Overhaul timing factors

Factor Description

Te Equivalentoperatinghours(EOH)

To Numberofoperatinghours

Ns Numberofstarts

Ts Operatinghourstobeenteredforastart.Accordingtocurrent
knowledge10hperstartforsynchronoussalientpolemachines.
Table 1.4: Overhauling timing factors

Values for Te
ThefollowingvaluesaretakenintoaccountforTe:

 Ageing
 Wear
 Dirt contamination
 Shutdown periods
ThenumberofstartsnsintheequivalentoperatinghoursTeshouldbe
enteredforthegeneratoraccountsforeachstart-upand shutdown.
Additionalvalues
 Expansion and friction factors on winding and insulation by temperature and centrifugal force
cycles.
 Special vibration loading when transiting the natural frequencies of various generator parts.
Thesevaluesmustbeaddedforeachstart-upandshutdown.Sincethesevaluesare
dependingonthespecialoperatingconditionsthesystematicsurveillanceandrecordingoftherelevant
operatingparametersisessential.
Typesofoverhauls
Accordingtotheamountofworkinvolved,adistinctionismadebetween
1. Firstoverhaul(A)
2. Minoroverhaul(B)
3. Majoroverhaul(C)
Type of overhauls

Typeofoverh Characteristic Duration(guidev

aul alue)

Firstoverhaul( Systematicchecksandrepairworkduetoinspectedrunningina 1-2weeks

A) ndsettingactions

Minoroverha Systematicchecksandrepairworkwithoutdismantlingofrotor 1-2weeks

ul(B)

Majoroverha Systematicchecksandrepairworkwithdismantlingofrotororr 5-8weeks

ul(C) otorpoles

Table 1.5: Types of overhaul

First overhaul
Thefirstoverhaulisanoverhaulinwhichspecialattentionispaidtochangesafterthe
relativelyshortoperatingtimefrominitialoperationtotheendoftheguaranteeperiod.
Theworkandoverhaulstobeperformedmustbedecidedupontogetherwiththe
manufacturer/supplierinduetime.
Overhaul intervals
ThefirstoverhaulisrecommendedafteranequivalentoperatingtimeTeof8000hto 10000h.Thefollow-
upoverhaulsarescheduledflexibly,andaregovernedbyoperating
experienceandontheperiodicconditiondiagnosestobeperformedonclosedand openmachine.

Table: Overhaulintervals

Type Overhaulintervals[Te](guidevalue) Yearsofoperationsincecommissionin

g

Firstoverhaul(A) after8000hto 10000h maximum2

Minoroverhaul(B) after20000hto30000h maximum8

Majoroverhaul(C) after50000hto60000h maximum12

Stator Overhaulinterval

Component Activity A B C Reference

Statorframe Checkfor
X X x
 Cleanliness
 Cracks

Statorbolts  Checktightnessofallboltsandpins
 Checkstatorjointsfor x x
frettingandclearance

Statorfeet  Checkforcorrosionandmovements X X x

Stator  Checkfordamages
foundation  Checkfoundationanchors x x x

Statorcore Checklaminationfor
X X x
 Corrosion
 Fretting
 Buckling
Pressfingers Checkpressfingersfor
X X x
 Corrosion
 Movements
 Tightness

Pressplates Checkpressplatesfor x

 Tightness

Airducts Checkairductsfor
x
 Cleanliness
 Deformation

Clampingbolts Checkclampingboltsfor
x
 Tightness
 Locking

Insulation Checkinsulationfor
X x
 Cracksand damages
 Corona movements

Statorwindingco Checkfor
vers X x
 Cleanliness
 Cracks

Table 1.7: Overhaulplan-Statorframeandstatorcore

Overhaulplan-Statorwinding

Stator Winding Overhaulinterval

Component Activity A B C Reference

Statorwinding Checkforfirmseatingof
X X x
 Windingbarsintheslots

Checkbarendsatnon-connectionsidefor
X X x
 Cleanlinessand cracks
 Corona anddiscoloration

Checkbarendsat connectionsidefor
X X x
 Cleanlinessand cracks
 Corona and discoloration
 Checkbar-andinterconnections
x X x
 Cleanlinessand cracks
 Corona and discoloration

Checkslotwedgesfor
x X x
 Tightness
 Movements

Checkwindingfor

 Cleanliness
 Moisture

Table 1.8: Overhaulplan-Statorwinding

Overhaulplan– Rotor

Rotor Overhaulinterval

Component Activity A B C Reference

Checkkeysets,spider/rimfor
x X x
 Corrosion
 Movements
Rotorspider
Checkcoverplatesfor

 Corrosion
x X x
 Movements
 Check tightness of cover plates

 Checkcleanliness
x X x
Checkfor

Rotorrim  Corrosion
 Movements

Checkrotorrimboltsfor
x X x
 Tightness
 Locking

Checkbraketrackforcleanliness
Checkfor
x X x
 Discoloration
  Cracks
Braketrack  Deformation
 Movements

Checkbraketrackclampingboltsfor
x X x
 Tightness
 Locking

Checkpolecoilsandinsulationfor
x X x
 Cleanliness
 Cracks
 Movements

Checklockingofterminalsandinsulation X X x

Checkterminalsandinsulationfor
x x x
 Cracks
Rotorpoles
 Discoloration

Checkcoilsupportsfor
x x x
 Cracks
 Discoloration

Checkpolewedgesfor
x x x
 Corrosion
 Movements

Checkdamperwindingfor
x
 Discoloration
 Deformation

Checkinsulationandsupportfor
x x x
 Cleanliness
 Cracks
 Movements
Rotorexcitationl
eads Checkbarsfor
x x x
 Cleanliness
 Movements

Checkexcitationjointsfor
x x x
  Tightness and locking

Table 1.9: Overhaulplan– Rotor

Overhaulplan– Slip rings and brush gear

Slip ring and brush gear Overhaulinterval

Component Activity A B C Reference

Checkconditionofslipringsurfaces
Checkfor
Sliprings
 Cleanliness
x x x
 Oilcontamination
 Corrosion
 Scores and damages
 Polarity wear
 Displacementandlooseness

Checkinsulatingpartsfor
x x x
 Cleanliness
 Outer damages

Check

 Cleanliness
 Spring pressure
Brushholders
 Check clearancebetween slip
x x x
ringsandbrushholders

Carbonbrushes Checkbrushwear x X x

Table 1.10: Overhaulplan– Slip rings and brush gear

Overhaulplan– DE & NDE Bearings

DE Bearing Overhaulinterval

Component Activity A B C Reference

Checkbearingfor
x x x
 Leakages
 Outerdamages

Checkbearingsupportfor
x X x
 Movements
  Tightness

Check bearing insulation for

x X x
 Cleanliness
DEBearing  Cracks

Checkbearingsegmentsfor
X x
 Cracks
 Damages

Checkconditionofbearingsurfaces X x

Check
x X x
 Bearing oil
 Bearing clearance

Checkpumpringsfor
X x
 Wear
 Clearance

Checkfor
x X x
 Cleanliness
 Movements
Bearingbracket
Checkweldedjointsfor
x x x
 Corrosion
 Cracks

Table 1.11: Overhaulplan– DE & NDE Bearings

Overhaulplan– Auxiliaries

Auxiliaries Overhaulinterval

Component Activity A B C Reference

Air/  Checkheat-exchangers for leaks

watercoolingsyst  Cleanheat-exchangers x x x
em  Performwater flowcheck

 Checkoilcoolersandpipingforleakagesan
Oilcoolingsyste dcorrosion x
m  Check flow meter function andtightness x x x

Carbonandbrake  Check function x x x

dustsuctionsyste  Clean system
m

Oilmistsuctionsy  Check oil separator and drain

stem  Clean system x x X

Brakingandjacki  Check system function

ngsystem  Check system for leakages and x x x
dirtdeposits

Brakecylinders  Checkfunctionandtightness of brake

cylinders x x x

Brakepads  Checkbrakepads for wear

 Check distance to brake track x x x

Piping  Checkpiping for leakages

 Checktightness of piping x x x

Oiljackingpump  Checkfunctionandtightness of oilpump x x x

Highpressuresys  Check forLeakagesOil level x x x

tem
 Performpressuretest x x x

Instrumentation Checkprotectivedevices x x

 Signal Transmission
 Tripping action

Table 1.12: Overhaulplan– Auxiliaries

1.7 Sample Checklists

Checklist- Statorframeandstatorcore

Stator
Repairnee

Repairdon
CheckedO

ded
K

Component Activity
Statorframe Check for
 Cleanliness
 Cracks

Statorbolts  Checktightnessofall bolts and

pins
 Check stator joints for frettings
and clearance

Statorfeet  Check for corrosion and

movements

Statorfoundation  Check for damages

 Check foundation anchors

Statorcore Check lamination for

 Corrosion
 Fretting
 Buckling

Pressfingers Check press fingers for

 Corrosion
 Movements
 Tightness

Pressplates Check press plates for

 Tightness

Airducts Check air ducts for

 Cleanliness
 Deformation

Clampingbolts Check clamping bolts for

 Tightness
 Locking

Insulation Check insulation for

 Cracks and damages
 Corona movements

Statorwindingcover Check for

s
 Cleanliness
 Cracks
Table 1.13: Checklist- Statorframeandstatorcore
Checklist- Statorwinding

Stator Winding

Repairnee

Repairdon
CheckedO

ded
Component Activity

e
Checkforfirmseatingof
StatorWinding
 Windingbars intheslots

Checkbarendsatnon-
connectionsidefor

 Cleanliness and cracks

 Corona anddiscoloration

Checkbarendsatconnectionsidefor

 Cleanliness and cracks

 Corona anddiscoloration

Checkbar-andinterconnections

 Cleanliness and cracks

 Corona anddiscoloration

Check slot wedges for

 Tightness
 Movements

Checkwindingfor

 Cleanliness
 Moisture

Table 1.14: Checklist- Statorwinding

Rotor inspection check list

Rotor
Repairnee

Repairdon
CheckedO

ded
K

Component Activity
 Check key sets, spider/rim for

 Corrosion
 Movements
Rotorspider
Check cover plates for

 Corrosion
 Movements
 Check tightness of cover plates

 Check cleanliness
Check for

Rotorrim  Corrosion
 Movements

Check rotor rim bolts for

 Tightness
 Locking

 Check brake track for cleanliness

Check for

 Discoloration
Braketrack  Cracks
 Deformation
 Movements

Check brake track clamping bolts

for

 Tightness
 Locking

Check pole coils and insulation for

 cleanliness
 cracks
Rotorpoles
 movements

Check locking of terminals and

insulation

Check terminals and insulation for

 Cracks
 Discoloration
 Check coil supports for

 Cracks
 Discoloration

Check pole wedges for

 Corrosion
 Movements

Check damper winding for

 Discoloration
 Deformation

Check insulation and support for

 Cleanliness
 Cracks
Rotorexcitationl
 Movements
eads
Check bars for

 Cleanliness
 Movements

Check excitation joints for

 Tightness and locking

Table 1.15: Rotor inspection check list

Slip rings/brush gear inspection check list

Slip rings and Brush gear Assembly

Repairnee

Repairdon
CheckedO

ded
K

Component Activity

Check condition of slip ring

Sliprings surfaces

 Check for
 Cleanliness
 Oil contamination
 Corrosion
 Scores and damages
 Polarity wear
 Displacement and looseness
 Check insulating parts for

 Cleanliness
 Outer damages

Check

 Cleanliness
Brushholders
 Spring pressure
 Check clearance between slip
rings and brush holders

Carbonbrushes Checkbrushwear

Table 1.16: Slip rings/brush gear inspection check list

DE and NDE Bearing inspection check list

DE and NDE Bearing

Repairnee

Repairdon
CheckedO

ded
Component Activity
K

e
DE/NDEBearing Check bearing for

 Leakages
 Outer damages

Check bearing support for

 Movements
 Tightness

Check bearing insulation for

 Cleanliness
 Cracks

Check bearing segments for

 Cracks
 Damages

Check condition of bearing

surfaces

 Check
 Bearing oil
 Bearing clearance
 Check pump rings for

 Wear
 Clearance

Bearingbracket Check for

 Cleanliness
 Movements

Check welded joints for

 Corrosion
 Cracks

Table 1.17: DE and NDE Bearing inspection check list

Auxiliaries inspection check list

Auxiliaries

Repairdon
CheckedO

Repairne
eded
K

e
Component Activity

Air/ Check heat-exchangers for leaks

watercoolingsyst
 Clean heat-exchangers
em
 Perform water flow check

 Check oil coolers and piping for

Oilcoolingsystem leakages and corrosion

 Check flow meter function and

tightness

Carbonandbraked  Check function

ustsuctionsystem  Clean system

Oilmistsuctionsys  Check oil separator and drain

tem  Clean system

 Check system function

Brakingandjackin  Check system for leakages and dirt
gsystem deposits

Brakecylinders  Check function and tightness of

brake cylinders
Brakepads  Check brake pads for wear
 Check distance to brake track

Piping  Check piping for leakages

 Check tightness of piping

Oiljackingpump  Check function and tightness of oil

pump

 Check for
 Leakages
Highpressuresyst  Oil level
em
 Perform pressure test

Check protective devices

Instrumentation
 Signal transmission
 Tripping action

Table 1.18:Auxiliaries inspection check list

 SECTION B:

MAINTENANCE MANUAL

CHAPTER 2
CHAPTER 2: EXCITATION SYSTEM

2.1 SPU 232 processor card

With this card, the SRAM and a battery (type CR 1/3N Varta) exist as separate components. The
service life of the battery totals around 4 years. The battery must be replaced after 4 years at the
latest.
The battery must be replaced within 5 seconds in order to avoid loss of data. If a reserve card is
used which was previously stored for an extended period of time (more than one year), the
battery should be replaced by a new one prior to using the reserve card.

2.2 Cleaning

The equipment must be cleaned whenever inspection work is carried out. The plug-in cards must
be pulled and carefully cleaned approximately every 5 years (depending on the degree of dirt
accumulation and exposure). If the doors are fitted with air filters, these filters must be cleaned
once a year and replaced after around 5 years.
The air filter can be cleaned using compressed air if dry dust only has to be removed. Synthetic-
fiber replacement filter mats, self-extinguishing, class F according to DIN 53438, must be used.
Replacement filter mats: type SK3335.200 Order No. 3173.100 029.211 826

2.3 Checking screws and bolts

The screws and bolts (terminals, bus bar, etc.) must be checked approximately every 5 years
(after 2 – 3 years in the case of new equipment). Recommended torque are as follow:

Thread Torque in NM

M5 3

M6 6

M8 12

M10 24

M12 48

M16 96

Table 2.1:Thread with corresponding torque in NM

2.4Lubrication

Moving mechanical parts, such as de-excitation switches, door hinges, etc., must be oiled or
greased, respectively, whenever inspection work is carried out.

2.5 Maintenance of three-phase switches, de-excitation switch, isolating switches and

power contactors

De-excitation switch: refer to the circuit breaker manual, type:

MEG 1257/I ... 3207/I and MEGT 3207/10 ... 5007/10
Three-phase power switch: refer to the circuit breaker manual, type:
ME 637 N/III ... 3207 N/III and ME 637 N/IV ... 3207 N/IV
The power contactors for starting, braking, initial or test excitation are generally maintenance-
free. However, checks should be carried out on an annual basis in order to detect traces of
contact erosion in the spark chambers. If traces of contact erosion are discovered, the spark
chambers should be dismantled and the contact points located below should be checked with
regard to material erosion. The contacts points or the completed contactors must be replaced, if
necessary.

2.6 Fan

The fan bearings must be replaced after around 50,000 operating hours. For this purpose, the
fans must be dismantled and sent to the manufacturer.
For excitation equipment only:
Since excitation equipment is fitted with two redundant fans per converter, it is possible to
dismantle onefan at a time. This can be done without interrupting operations. If no reserve fan is
(can be) fitted, theremaining opening must be covered by a clean piece of sheet metal or a
similar device in order to avoiddrawing in secondary air and foreign matter.

2.7 Power supply units

We recommend replacing all the electrolytic capacitors in the power supply units or the complete
power supply units after 8 years at the latest.

2.8Inspection

We recommend having the entire electrical functionality checked by an expert every 5 years and
in no case, later than every 10 years.

2.9 How to detect a semiconductor defect

We recommend proceeding as follows in order to find out whether a semiconductor in a

converter circuit has failed as a result of a malfunction:
i. Make sure that the converter concerned is de-energized and protected against re-energizing.
ii. Disconnect one end (anode or cathode) of the semiconductor which is expected to be at
fault from the rest of the circuit (this is typically indicated by a defective fuse). In the case of
converters with arm fuses, by disconnecting or removing the pertinent fuse(s).
iii. Continuity test (in the reverse direction) using a test lamp or Multimeter. If continuity or a
resistance of zero is found for the semiconductor, it has definitely lost its blocking ability and
must be replaced. If no continuity of the semiconductor is found, this does not necessarily
mean that the semiconductor has is full blocking ability.
iv. Checking the blocking ability
Important:
The peak value of the voltage used may not be higher than the maximum permissible blocking
voltage of the semiconductor! Otherwise a failure is definitely caused!
Important:
The semiconductor must be held with nominal force, i.e. it must be left fixed in the module
(between the heatsinks)!
Prior to checking, disconnect parallel circuits (RC circuits; parallel resistors; varistors). In the case
of thyristors, short-circuit the gate/cathode system (both pulse cables); in the case of diodes, use
an auxiliary diode in order to block off the forward direction. Depending on the means available,
the following methods can be adopted:
a. Measuring method, A:
With auxiliary voltage (e.g. receptacle): If nothing else is available, a 60...200W light bulb or a
resistor of a corresponding rating and an ammeter connected in series with the
semiconductor can be used to check the blocking capability up to the peak value of the
available AC voltage. First determine phase and neutral of the receptacle. The phase should
be connected via the resistor whilst the light bulb should be connected to the isolated end of
the semiconductor. If no current flows when the circuit is closed (ammeter reading of less
than approx. 50mA or the light bulb remains dark, respectively), the semiconductor has still
retained its blocking ability (at least up to the peak value of the ACvoltage applied).
b. Measuring method B:
Using a magneto inductor or an insulation tester. If the resistance value measured is higher than
approx. 50kOhm, this suggests that the semiconductor has still retained its blocking ability (at
least up to the inductor voltage).
Important:The peak value of the voltage generated may not be higher than the maximum
permissible blocking voltage of the semiconductor! (Otherwise a failure is definitely caused!)
c. Measurement method C:
Send the semiconductor to the plant supplier in order to have the blocking characteristic
measured.

2.10 Overview of maintenance work

Description Annually After 4 years After 5 years After 8 years

SPU 232 processor card At the latest
according to section 1

Cleaning the air filters X

Cleaning At the latest

Checking screws and bolts After 2 -3 years

in case of new
equipment

Lubricate X

Visual inspection of circuit X

breakers

Isolating switch: visual X Or 10000

inspection, cleaning, switching
lubricating. operations

Maintenance of circuit At the latest

breakers

Power contactors X

Fans Or after 50,000

operating hours

Power Supply units X

Inspection X

Table 2.2:Overview of maintenance

2.11 Change of Hardware components running with a software

Hardware like control units (SPU, ICP), touch display, WAGO bus terminals or fieldbus coupler
have to be loaded with a software when they are replaced.
 SECTION B:

MAINTENANCE MANUAL

CHAPTER 3
CHAPTER 3: TURBINE & AUXILIARIES

3.1Inspection and Maintenance Plan

3.1.1 Activities during operation

No. Maintenance Inspections INTERVALS Note/

Observations

3- monthly

6-monthly

2- Yearly
Monthly

Revision
Weekly

Yearly
Daily

1 Pelton runner

No inspection during operation 3.1.3.1

2 Turbine shaft

No inspection during operation 3.1.3.2

3 Turbine guide bearing 3.1.3.3

Oil level check Daily during

commissioning
and in the first
X month of
operation

4 Nozzles and deflectors 3.1.3.4

Visual check for leakage Daily during

commissioning
x
and in the first
month of
operation.

5 Over speed device

No inspection during operation 3.1.3.5

6 Turbine casing

No inspection during operation 3.1.3.6

 7 Electrical devices

No inspection during operation 3.1.3.7

8 Cooling water system

Check cooling water pump motors X

for current consumption

Cleaning of motor and windings x

Check grease lubricated bearings x

of pumps and motor

Check noise and vibration x

Check different pressure of X

backflushing filters

Check function of backflushing x

filters

Check noise and condition of x

backflushing filters

Check tightness of all connections x

to backflushing filters

Check function and setting of x

differential pressure switch

Check actual adjustment of x

cooling water Flow

Check function and settings of x

flow indicators

9 General checks

Abnormal sound x

Abnormal vibration x

Leakages of oil or water x

Bearing temperatures ok x

Table 3.1:Inspection during Operation

3.1.2 Activities during the Maintenance

Note/
Observation
Interval s
Sl. Maintenance
No. Inspection

6-Monthly
3-Monthly
Monthly

Revision
2-Yearly
Weekly

Yearly
Daily

1 Pelton Runner 3.1.3.1

1st inspection after 600 operating hours

second inspection after 2300 operating hours

Visual check and
Magnetic Particle
examination
3rd inspection after 9200 operating hours

all further inspections after 2 years at the latest  

2 Turbine Shaft 3.1.3.2

After one
Check pretension of year, then
X  
coupling bolts every two
years

After one
Check surface year, then
X  
protection every two
years

After one
Inspection of the year, then
X  
flange transition radius every two
years

3 Turbine Guide Bearing 3.1.3.3

after every
Visual check of bearing 30,000
             
segments operating
hours

Check contact and

accuracy of           x    
thermometers  

Check oil quality           x      

4 Nozzles and Deflectors 3.1.3.4

 After one
Check opening and year, then
        x  
closing times every two
years

Visual check of nozzle,

        X  
needle and seal ring  

Check tightness of
nozzle flanges and         x  
pipings (oil system)  

Check fixation of
protection roof, brake         X  
jet, deflector  

Check feedback
        X  
transmitters  

5 Over speed device 3.1.3.5

Check of safety system         x    

6 Turbine casing 3.1.3.6 

Check of access door         x    

After one
Visual check of inside year, then
        x  
area every two
years

Electrical devices 3.1.3.6

7

  Check and functional

control         x    

Table 3.2:Activities during Maintenance

3.1.3 Maintenance or inspection activities

3.1.3.1 Pelton Runner

Description –Visual check

Visual check of the condition of the runner regarding erosion. The visualcheck shall focus to the
areas and the amount and the quantity of lostmaterial. Lost material can be defined by use of
plastic impression.
Description –Magnetic particle Examination
A magnetic particle examination according quality plan DAG09-TUR-0426shall be carried out.
3.1.3.2 Turbine shaft

Pretension coupling bolts

The pretension of the coupling bolts at the connection runner – turbine shaft and turbine shaft –
generator shaft has to be checked.
Visual inspection
A visual inspection of the surface protection of the turbine shaft in allaccessible areas has to be
done.
Inspection of flange transition radius
A dye penetration and magnetic particle inspection of the flange transition radius has to be done.
Cracks, hairline cracks and crack-like indications are not accepted, they have to be repaired by
grinding.

3.1.3.3 Turbine guide bearing

Visual check
A visual check of the babbit liner of the bearing segments has to be done after every 30.000
operating hours.
Thermometers
The contacts for the Pt100-resistance thermometers and the accuracy of the thermometers of
the turbine guide bearing have to be checked yearly.
Oil quality
The oil quality has to be checked and an oil analysis (ppm, acid contents, viscosity and water
content) has to be performed yearly.
Oil level
The oil level in the guide bearing has to be checked weekly.

3.1.3.4 Nozzles and deflectors

Visual check
A visual check for leakage of the nozzle and the deflector servomotor has to be done weekly.
Also, the drainage piping to the outside of the concrete massives have to be checked.
Servomotors
The opening and closing times of the servomotors have to be checked every two (2) years.
Needle tip and seal Ring

The condition of the whole nozzle as well as the needle tip and needle seal ring have to be
checked regarding erosion yearly. The nozzle tip disassembly is given in Annexure M7.
Tightness
The nozzle flanges and the fitting of the piping (oil system) have to be checked regarding
tightness every two (2) years.
Fixation
The fixation of the protection roof, the protection plate, the brake jet, the deflector and the
deflector servomotor have to be checked yearly.
Feedback Transmitters
The feedback transmitters for the nozzle servomotor and the deflector servomotor have to be
checked for correct and proper function.

3.1.3.5 Over speed device

Safety systems
The unit has to be stopped once a year by a trigger action on the hydraulic valve, to check if all
safety systems are working well.

3.1.3.6 Turbine casing

Access door
The access doors and closing levers for the turbine casing have to be checked for proper function
and water tightness yearly.
Visual check
A visual check of the inside area of the pit liner regarding painting has to be done every two (2)
years. A touch up painting has to be applied if necessary.

3.1.3.7 Electrical devices

Functional control
A check and functional control of all limit switches, pressure switches, temperature transmitters,
solenoid valves etc. for correct and proper function has to be performed every year.

3.1.4 Troubleshooting

The malfunctions and troubleshooting related to Turbine and auxiliaries is given in Annexure M6.
 SECTION B:

MAINTENANCE MANUAL

CHAPTER 4
CHAPTER 4: MAIN INLET VALVE &
AUXILIARIES

4.1 Maintenance

Maintenance and periodic overhauls of all machine parts and systems delivered are of utmost
importance for smooth and uninterrupted operation of the plant. Routine inspections must
therefore be carried out due to the operating time or acc. to fixed time schedules. Routine
checks should be carried out at short intervals, more thorough checks at greater intervals and at
times of low water supply.
Overhauls of the total plant should be planned at approx. 10 - 15 year intervals. These intervals
should be precisely fixed on the basis of operating experiences.
The periodic work listed in these operating instructions are proposals which have been worked
out based on many years’ experiences in the operation of hydraulic steel structures, water
turbines and closing organs, with the aid of feedbacks received from our customers.
Due to changed operating conditions, it may be necessary to adjust the present instructions.
Therefore, any changes, adjustments or irregularities of the operation are to be constantly
recorded. It is the operating personnel’s responsibility to immediately introduce any changes in
maintenance work.
We consider it essential and indispensable that measurements of settings and alignments in
connection with maintenance and overhaul work are recorded systematically.
These measurements must be compared with those measurements made during initial erection,
and/or initial start-up.

4.4.1 Maintenance and inspection plan

4.4.1.1 Activities during operation

Note/
Observation
Interval s
Sl. Maintenance
No. Inspection
6-Monthly
3-Monthly
Monthly

Revision
2-Yearly
Weekly

Yearly
Daily

1 All equipment items

Visual and acoustic

X
checks. Check for
 loosen bolts/parts

2 Main inlet valve and all attached equipment (valves etc..)

Visual and acoustic

checks. Visual    X          
check for leakage

3 Double seals in main waterway

During
operation,
the checking
hole for
tightness is
kept open. If
any leakage
is detected,
Visual tightness the checking
    X          
test of double seals hole
isclosed;
With
nextrevision,
the damaged
O-ringseal
need to
beexchange
d.

4 Moveable seal rings DAG09-SVI-1400

Flushing of the
moveable seal ring
    X      
chambers (2-5
minutes)

5 Anchorage DAG09-SVI-1700

Greasing of the
foundation plates
by use of the
greasing nipples         X      

6 Trunnion seals DAG09-SVI-3100

Visual check for

leakage   X            

Servomotors DAG09-SVI-4200
7
Opening and  Compare
closing time with list of
comparison       x     adjustments
 Visual check for
tightness of the
servomotor x

Water control panel DAG09-SVI-7200

Flushing of the de-

8 sanding device X

Flushing of the
filters X

Dismantling joint on downstream side DAG09-SVI-8200

9
Visual check for
leakage X

Monitoring instruments

Check for damages

and/or proper
function. Record all
10
important
instrument
readings and check
if values are
plausible X

Spindle threads of hand operated valves

11
Grease X

Small parts with sliding surfaces

12
Grease X

Safety devices; Control instruments

13
Visual inspection X

Air vent

14
Visual and acoustic
check X

Hand operated shut-off/isolating valves

15 Manipulation
(Close & open or
open & close) X

Rubber hoses to servomotors

16
Check for damages X
 All oil- and water piping
17
Check for leakage x

Pipe fittings
18
Check for leakage X

Pressure tank

Visual check, check

19
for leakage and
damage, check
pipes X

Hydraulic unit

Visual check, check

20
for leakage and
damage, check
pipes X

Servomotors

21 Opening and
closing time
comparison x

Seals, pipes, valves, fittings

22
Visual inspection,
leakage check X

23 Painting of areas exposed to air

Check for damage

and corrosion
attack. If
necessary, renew X

Screws and other mounting elements

24
Check for tight fit X

Openings and closing times of main inlet valve

25 Check and
compare to
nominal data X

26 Opening and closing times of by-pass

Check and X
compare to
 nominal data

Emergency shut down

Check emergency
shut down
27 operation (only if
the valve is suitable
for this

operation) X

Quick shut down

Check quick shut

28 down operation
(only if the valve is
suitable for this
operation) X

Table 4.1:Activities during Operation

4.4.1.2 Activities in case of Shut down machine

Note/
Interval Observations
Sl. Maintenance
6-Monthly
3-Monthly

No. Inspection
Monthly

Revision
2-Yearly
Weekly

Yearly
Daily

1 Tensioning bolts DAG09-SVI-0000

First check after

three (3) years of
operation. For
bolts in stud
holes the
pretensioning has
tobe checked by
use of a
measuring pin
Check of pre- and dial gauge.
tensioning The check has to
be performed at
least for four (4)
bolts. For other
bolts
externalmicrome
ter should be
used. All
measurements
x shall be recorded.

MT examination X
 of tensioning
shafts for cracks

2 Moveable seals DAG09-SVI-1400

Removal of
slurries in
operating and            x  
maintenance seal
ring chamber

3 Maintenance seal locking device DAG09-SVI-1200

Greasing the
grease nipples on           x    x 
the cover 1202

4 Servomotors DAG09-SVI-4200

Complete venting
of the servomotor To be done after
           
oil chamber after every oil filling to
oil filling prevent damages

5 Accessible bolts and nuts

Firm tightening      x       x   

6 All components exposed to water

Visual inspection
for wear, erosion,
cavitation,
damage by
foreign bodies,
cracks, deposits
of foreign mater,
damage to the
paint coats            X  

Servomotors DAG09-SVI-4200

Opening and  Compare with

7 closing time list of
comparison   x adjustments

Visual check for

tightness of the
servomotor x

Bearings
8
Change x

9 Seals

Change x

Table 4.2:Activities during Shutdown of machines

4.4.2 Troubleshooting

The possible malfunction and troubleshooting related to the main inlet valve and its auxiliaries is
given in Annexure M8.
 SECTION B:

MAINTENANCE MANUAL

CHAPTER 5
CHAPTER 5: GOVERNING SYSTEM

5.1 Hydraulic Governor

Service inspections and maintenance operations carefully done according to the following
instructions are of vital importance for keeping the plant and all its components in a reliable
operating condition.
Service inspections are intended to detect incipient defects and malfunctions early enough to
ensure that by taking immediate remedial action such as repair and replacement of defective
components, etc.
Consequential damage and hence extended periods of standstill of the machine unit will be
avoided.
Maintenance operations contribute towards keeping the plant components in a reliable
operating condition for an extended period of time.
It is recommended to contact Andritz HYDRO in good time whenever major repairs or
replacements of components will be necessary.

5.1.1 Safety instructions

All applicable accident prevention regulations must be observed.

Disassembly, routine repair and maintenance work may only be conducted when the plant is at
standstill and has been locked out to prevent it being switched on again unintentionally.
Before hydraulic parts are disassembled, the hydraulic system must be completely de-
pressurized. The guide vanes must be closed and locked in closed position.
For components in contact with pressure oil or pressure gas (nitrogen), the safety measures
should be selected such that no accidents can happen or damage/environmental pollution occur.

5.1.2Remarks for disassembly / reassembly of hydraulic Governor Equipment

Assembly of hydraulic governor / accumulator station:

After each dismantling of the hydraulic governor / accumulator station parts, tests and checks
during assembly have to be executed and recorded as described in erection procedure.
Environmental issues:
In case of oil change take care that removed oil will be stored/transported in tight, visible marked
bins. Also, used (contaminated oil) cleaning rags should be disposed environment-friendly!
Ensure safe working conditions:
For doing maintenance work on the hydraulic governor, it will be necessary to de-pressurize the
oil system.
For safety reasons the turbine guide vanes must be properly interlocked to prevent it from
moving.
There are the following items for de-pressurizing the hydraulic governor which will have to be
carefully selected by the personnel in charge and strictly applied:

 Actuating the emergency trip (guide vane mechanism).

 Closing the main oil supply valve MEX16AA001 for the governor oil, by means of the fixing
screw on top of cartridge valve cover and disconnecting the power feed cables to the
governor oil pumps from their terminals. This will ensure that no oil pressure will be
admitted to the main control block.
 Release the oil pressure in accumulator and actuator and drain oil to the sump tank until
readings on pressure gauges MEX20CP501 and MEX16CP111 is zero (0) bar.
Corrosion Protection
The corrosion protection can decisively influence the service life of the turbine and thus keep its
value. Special attention is to be paid to the inner painting of equipment for surfaces in contact
with water.
Periodic checks are to be carried out on the outside surfaces of the equipment, whereby layer
thicknesses are to be measured and compared with the values before start-up. This
measurement allows to fix the intermediate checks and the necessary measures to renew and
touch up the corrosion protection.
The corrosion protection was carried out acc. to the valid painting instructions.
Any necessary repairs have to be carried out in the same manner according to these instructions,
whereby utmost attention must be paid to the compatibility of the paint materials.
For doing maintenance work on the hydraulic governor, it will be necessary to stop the turbine.
Due to safety reasons, inlet valve and guide vane mechanism must be properly interlocked to
prevent from moving.

5.1.3Maintenance and inspection plan

Common Instructions:
Oil level: The visual check of the oil level in the sump tank is necessary due to the fact that a
decreasing oil level can cause rising oil temperature.
Therefore, missing oil must be replaced immediately (same type/brand of used oil) and the
reason for the oil loss has to be investigated.
Oil temperature: Excessive oil temperature is a common sign for faulty hydraulic system (i.e.
pump wear, wrong type of hydraulic oil, etc.).
Therefore, a temperature control via thermometer and temperature switches is necessary. The
oil temperature should be between 20°C (minimum) and 50°C (maximum). The reason of
temperature rise above maximum value should be investigated. Please consider that system oil
temperature will rise with a higher ambient air temperature.
Hydraulic oil: Please avoid a change of oil type/brand used for the control system. If a change of
oil type is absolutely necessary, the whole system should be flushed with the new oil type
carefully. Change of hydraulic oil depends on oil aging and contamination. Therefore, it is
necessary to make an oil analysis once a year. If the oil contamination class is higher than 18/16/13
acc. ISO 4406 (class 7 acc. to NAS 1638), clean the oil or change it (flushing necessary).
Pressure and return oil filter: Clean hydraulic oil will ensure a reliable, proper and long lasting
function of all hydraulic parts. Therefore, it is necessary to watch the contamination indicators on
the hydraulic filters regularly. Please note that the check should be done only if the oil
temperature is normal (about 40°C). A low oil temperature will increase the differential pressure
in the filter (because of the higher oil viscosity). If the contamination indicator is activated the
filter should be switched over to the second element (using the handle, this can be done during
unit operation). The contaminated filter element must not be cleaned, but it has to be replaced
by a new one.
Oil filling and air breather: The used oil filling and air breather should be changed every three (3)
years. The oil filling mesh should be checked for cleanliness after each oil-filling. If contaminated,
the breather should be disassembled and cleaned with compressed air.
Silica gel filter: The used silica gel (RD-GEL 25000) has red indicating pellets, these pellets
changing the red colour due to water absorption to transparent/grey. After that the silica gel
should be changed or regenerated soonest.
Proportional valve: Please read the attached operating and maintenance instructions of the
manufacturer (REXROTH) carefully. All repair / maintenance work on proportional valves needs
skilled personnel and a special servo-valve test stand. Therefore, this work can only be done by
the original supplier REXROTH. For the storage of the spare valve a dry, dust free place with low
humidity is required. The appropriate storage has to be checked from time to time. Attention:
The protection plate, mounted on the spare valve should be replaced only right before assembly.
The spare proportional valve is filled with protection oil and is therefore ready for long storage
time.

5.1.3.1 Activities during operation

Plant component Checks / action Remark at weekly intervals

Plant Component Checks/action Remark

At Weekly intervals

Hydraulic Governor Check tightness of all pipe Visual inspection

connections
Accumulator station

Monitoring instruments Record all important instrument

readings (pressure, temperature
and levels) and check if values
 are plausible

Sump Tank Check oil level

Pressure tank

Oil Pumps and motors Check noise and vibration

Oil filters Check contamination indicators

At Monthly intervals

Oil pumps and motors Check motor current

consumption with full flow and
zero flow. Check
function/setting of pressure
regulator

Silica gel filter Check color of silica gel and

change/reactivate filling if
necessary

Table 5.1:Plant component Checks / action

5.1.3.2 Activities in case of shut-down machine

Annually

Oil pump/motors Cleaning of motors and windings.

Check function of pump pressure
regulator.
Release pump relief valves.

Monitoring instruments Functional test for correct Proceed step by step using
tripping (pressure, temperature the settings made during
and level switches) the commissioning

Hydraulic governor Check function of solenoid valves

and confirm the quick response
of shutdown sequence

Sump tank Check and clean air breather Renew the oil charge
according to result of oil
analysis

Control oil Check governor oil quality Clean oil by means of an

(contamination/analysis) external filter if
 contamination class is
higher than 18/16/13 acc.
ISO 4406 (class 7 acc. To
NAS 1638). Renew the oil
charge according to result
of oil analysis

Painting of areas exposed to Check for damage and corrosion See painting specification
air attack.
If necessary, repair/renew.

Screws and other monitoring Check for tight fit Manually check
elements on device
components and pipe work

Main control valve Check function of proportional

valve

Every three years

Oil sump tank Clean sump tank bottom surface

Change air inlet filter (air
breather) on MEX10AT003

Motors Check grease lubricated bearing

Table 5.2:Activities in case of shut-down machine

5.1.4 Troubleshooting

The possible malfunction and troubleshooting related to Hydraulic Governor is given in Annexure
M4.

5.2Digital Governor

For the Digital Governor, perform the following task annually:

 Visually check and clean the digital governor Siemens SICAM TM 1703 ACP, I/O modules,
VibroControl 6000, signal insulators, MCCBs, Convertors, relays, fans, heaters, HMI
panels, etc.
 Check the tightness of all cable terminations.
The alarms and troubleshooting of the digital governor is given in Annexure M3.
 SECTION B:

MAINTENANCE MANUAL

CHAPTER 6

CHAPTER 6: GENERATOR STEP-UP TRANSFORMER

6.1Maintenance Schedule

Preventive Maintenance Procedures Periodicity

Months Scheduled
3 6 12 Outage
Replacement / Regeneration of Silica 
Gel Breather
Dissolved Gas Analysis 
Oil Sampling 
Buchholz Relay Functional Tests 
Tan Delta & Capacitance Measurement 
of Condenser Bushings
OTI / WTI Tests 
Tap changer operation 
Insulation Resistance of Windings 
Oil filtration 
Surface Painting 
Table 6.2:Maintenance schedule for GSU Transformer

6.2Oil sampling

Oil sampling should be tested for the following and results recorded:

6.2.1 Electric Strength:

 If the dielectric strength of oil in transformer is less than 60 kV at 2.5 mm gap, the oil
must be filtered to improve the characteristics.

6.2.2 Moisture Content:

 For transformer of voltage class up to 245kV, if the moisture content is found to have
increased beyond 25 ppm oil should be filtered.

6.2.3 Acidity:
  If the acidity is increased beyond 0.5 m KOH/g, then the oil needs filtration.
 After draining the oil completely from the transformer core, winding, insulation and
interior of tank should be washed by hot oil jet. The oil being used for washing internal
body also must be drained completely.
 Refilling of oil in transformer must be done under vacuum.

6.3 Sampling procedure

Special care in oil sampling is required for Delta connected transformers.

6.3.1 Tools required

 Spanner set
 Thermometer
 Steel sampling bottles with polyethylene cone caps.
 Silicon rubber tubing 10 mm bore - 1 m long.
 Clean synthetic sponge.
 Polyethylene sheet - 1 m square
 Clean cloths
 Self-adhesive labels

6.3.2 Procedure

 The sampling bottles shall be labelled and marked with information like source of sample,
date and time & sample temperature.
 Sample bottle shall not be opened before it is needed for testing.
 Sampling point should be cleaned by using sponge.
 Blanking plate of sampling valve shall be removed by using spanner.
 Clean the silicon rubber tubing thoroughly and fit to sampling pointnipple.
 Rinse the bottle in oil stream and reduce the rate of oil flow to 1litre/minute.
 Put the end of rubber tubing to sampling bottle and fill the bottle frombottom.
 No air bubble shall be introduced into the bottle.
 The bottle is allowed to overflow before it is closed.
 Measure and record the temperature of oil sample as soon as it istaken.
 Put back and tighten the blanking plate.
 Remove all tools, excess oil container and oil sample from the area.
 Arrange for testing oil sample at laboratory.

6.4 Winding Temperature indicator tests

6.4.1 Tools and materials

 Hot oil bath (with heating facility)

 Secondary injection test set
 Multimeter
  Clinical thermometer
 Keys of marshalling box.

6.4.2 Procedures

 The purpose of this check is to confirm that the winding temperatures Indicators are
functioning accurately.
 The transformer shall be isolated and earthed.
 Rotate the indicator pointers slowly to the alarm set value and confirm from the control
room that the alarm signal has been received.
 Rotate the pointer still further and confirm from the control room that trip signal is
received.

6.4.3 Calibration

 Remove the thermal sensing bulbs from the transformer and insert itinto the hot oil bath.
 Check the winding temperature readings up and down the scale atintervals of 5 °C.
 Confirm from control room that remote temperature readings aretallying with the local
readings.
 Replace the sensing element into the transformer pocket.

6.5Buchholz Relay Functional Test

6.5.1 Tools and Materials Required

 Multimeter
 Nitrogen cylinder with regulator and pressure gauge or air supply (4kg/cm²)
 Bucket
 10 mm polythene tube, 10 meters.

6.5.2 Procedures

The purpose of this test is to ensure correct operation of Buchholzrelay.

 Transformer shall be isolated and earthed.

 Connect nitrogen cylinder to the top petcock of Buchholz relay.
 Open the other petcock.
 Allow gas to enter the relay.
 Check and confirm from control room that alarm signal is received.
 Check continuity of alarm contact by using multimeter.
 Close petcock on gas supply side and release all gases trapped inrelay casing.
 Increase the gas pressure to approx. 2 kg/cm² (30 psi)
 Open the test petcock and allow full surge of gas to enter the relay casing.
 Check and confirm from control room that trip signal has been received.
 Check continuity of trip contacts by using multimeter.
 Close Buchholz relay test cocks.
 If relay has not operated, increase gas pressure and repeat the test.
  If the relay is found faculty replace it with a new one.
 Open conservator shut off valve and release all gases trapped.

6.6 Tap-changer Operation

 Regular inspection of tap changing equipment is not required because mechanical

operation of tap changer does not involve significantcontact wear.
 It is sufficient to operate the tap changer through the whole range of tap selector
positions twice a year.
 The purpose of this check is to ensure correct mechanical operation of tap changer.
 Transformer shall be isolated and earthed.
 Note the tap position.
 Operate the tap changer through operating handle through entire rangeof tap positions.
 Return to the original tap position.

6.7 Oil Filtration

Purpose of this maintenance is to improve the unsatisfactory conditionof oil found during
sampling. Transformer shall be isolated and earthed.

6.8.1 Tools and Materials

 Oil conditioning plant (Filter Machine)

 50 mm flexible hoses of sufficient length for oil inlet and outlet.
 Hose adapters to match the flanges of top and bottom filter valves.
 Cleaning cloths

6.7.2 Procedure

 Remove the blanking plate from filter valves and connect the oil inlet hose to top filter
valve and oil outlet hose to the bottom filter valve.
 Open the filter valves and start circulation of hot oil. Oil temperatureshall be 55°C to 70°C.
 Circulate the oil for 4 full passes.
 Re sample and arrange to test.
 Continue until oil condition is acceptable.

6.8 Corrective Maintenance

 All flange gaskets must be renewed wherever joints are dismantled.

 Cleanliness of gasket surfaces and correct compression (40 % ~ 50%approx.) of gasket
must be ensured during reassembling.

6.9 Removing and Refixing of Pumps

6.9.1 Tools and materials

 Jib crane or chain pulley block to handle the weight of pumps.

 Oil drip tray
 Blanking plates
  New gaskets.

6.9.2 Procedure

 Transformer is isolated and earthed.

 Close the isolating valves on either side of pump
 Disconnect the motor supply wires
 Remove the drain plug of the pump and drain oil from the pump.
 Remove the clamping bolts and remove the pump
 Blank off the isolating valve.
 For re-fixing the pump, remove the blanking plates.
 Fix new gaskets.
 Replace and tighten the clamping bolts.
 Open the isolating valves on cooler side.
 Open air release plug and close when oil starts flowing out.
 Open the isolating valve on transformer tank side.

6.10 Trouble Shooting

The trouble shooting of the Generator Step-up Transformer is given in Annexure M11.
 SECTION B:

MAINTENANCE MANUAL

CHAPTER 7

CHAPTER 7: STATION AUXILIARY

TRANSFORMERS

7.1 Station Auxiliary Transformer, 220/11kV, 5MVA

7.1.1 Routine Inspection Schedule

Sr.No. Items to be inspected Frequency

1 Load current Hourly

2 Terminal voltage Hourly

3 Ambient Temperature Hourly

4 Winding Temperature Hourly

5 Oil Temperature Hourly

6 Tap Position Daily

7 Air Cell conservator Daily

8 Oil level in Conservator Daily

9 Oil Level in Bushings Daily

10 Oil Level in OLTC Conservator Daily

11 Oil Level in Breather cup Daily

12 Connections Monthly

13 Dust deposits and physical damages to bushings Monthly

14 Air passage and colour of silica gel in breather Quarterly

15 Cable boxes, gasket joints, gauges etc. Quarterly

 16 Dielectric strength of the transformer oil Half yearly

17 Moisture content of transformer oil Half yearly

18 Dissolved gas analysis of transformer oil Half yearly

19 Resistivity of transformer oil Half yearly

20 Insulation resistance of windings Yearly

21 Tan delta and capacitance of condenser bushings Yearly

22 Operation of relays ad their circuit Yearly

23 Surface Painting 2~3 Years**

Table 7.1: Inspection during operation

Note: **Duration of surface repainting depends on the level of pollution prevailing at site, of
pollution level is high, and a frequent repainting schedule may have to be worked out.

 Lifting of core ad windings are not recommended as a routine inspection.

 Core and coils are to be inspected only if such inspection is warranted by test results of
dissolved gas analysis, any abnormality in performance or for suspected internal damages
due to external short circuit.

7.1.2 Oil sampling

Oil sampling should be tested for the following and results recorded:
1. Electric Strength:
 If the dielectric strength of the oil in the transformer is less than 60kV at 2.5mm gap, the
oil must be filtered to improve the characteristics.
2. Moisture Content
 For transformers of voltage class up to 245kV, if the moisture content is found to have
increased beyond 25 ppm oil should be filtered.
3. Acidity
 If the acidity increases beyond 0.5 mg KOH/g, then the oil needs filtration.
 After draining the oil completely from the transformer, core, winding, insulation and
interior of the tank should be washed by hot oil jet. The oil being used for washing of the
internal body also must be drained completely.
 Refilling of oil in transformer should be done under vacuum.

7.1.3 Maintenance Schedule

Preventive Maintenance Procedures Periodicity

Months Scheduled
3 6 12 Outage
Replacement / Regeneration of Silica 
Gel Breather
Dissolved Gas Analysis 
Oil Sampling 
Buchholz Relay Functional Tests 
Tan Delta & Capacitance Measurement 
of Condenser Bushings
OTI / WTI Tests 
Tap changer operation 
Insulation Resistance of Windings 
Oil filtration 
Surface Painting 
Table 6.2:Maintenance schedule for GSU Transformer

7.1.3.1 Electric Strength:

 If the dielectric strength of oil in transformer is less than 60 kV at 2.5 mm gap, the oil
must be filtered to improve the characteristics.

7.1.3.2 Moisture Content:

 For transformer of voltage class up to 245kV, if the moisture content is found to have
increased beyond 25 ppm oil should be filtered.

7.1.3.3 Acidity:

 If the acidity is increased beyond 0.5 m KOH/g, then the oil needs filtration.
 After draining the oil completely from the transformer core, winding, insulation and
interior of tank should be washed by hot oil jet. The oil being used for washing internal
body also must be drained completely.
 Refilling of oil in transformer must be done under vacuum.

7.1.4 Sampling procedure

Special care in oil sampling is required for Delta connected transformers.

7.1.4.1 Tools required

 Spanner set
 Thermometer
 Steel sampling bottles with polyethylene cone caps.
 Silicon rubber tubing 10 mm bore - 1 m long.
 Clean synthetic sponge.
 Polyethylene sheet - 1 m square
 Clean cloths
 Self-adhesive labels
7.1.4.2 Procedure

 The sampling bottles shall be labelled and marked with information like source of sample,
date and time & sample temperature.
 Sample bottle shall not be opened before it is needed for testing.
 Sampling point should be cleaned by using sponge.
 Blanking plate of sampling valve shall be removed by using spanner.
 Clean the silicon rubber tubing thoroughly and fit to sampling pointnipple.
 Rinse the bottle in oil stream and reduce the rate of oil flow to 1litre/minute.
 Put the end of rubber tubing to sampling bottle and fill the bottle frombottom.
 No air bubble shall be introduced into the bottle.
 The bottle is allowed to overflow before it is closed.
 Measure and record the temperature of oil sample as soon as it istaken.
 Put back and tighten the blanking plate.
 Remove all tools, excess oil container and oil sample from the area.
 Arrange for testing oil sample at laboratory.

7.1.5 Winding Temperature indicator tests

7.1.5.1 Tools and materials

 Hot oil bath (with heating facility)

 Secondary injection test set
 Multimeter
 Clinical thermometer
 Keys of marshalling box.

7.1.5.2 Procedures

 The purpose of this check is to confirm that the winding temperatures Indicators are
functioning accurately.
 The transformer shall be isolated and earthed.
 Rotate the indicator pointers slowly to the alarm set value and confirm from the control
room that the alarm signal has been received.
 Rotate the pointer still further and confirm from the control room that trip signal is
received.

7.1.5.3 Calibration

 Remove the thermal sensing bulbs from the transformer and insert itinto the hot oil bath.
 Check the winding temperature readings up and down the scale atintervals of 5 °C.
 Confirm from control room that remote temperature readings aretallying with the local
readings.
 Replace the sensing element into the transformer pocket.

7.1.6 Buchholz Relay Functional Test

7.1.6.1 Tools and Materials Required

 Multimeter
 Nitrogen cylinder with regulator and pressure gauge or air supply (4kg/cm²)
 Bucket
 10 mm polythene tube, 10 meters.

7.1.6.2 Procedures

The purpose of this test is to ensure correct operation of Buchholzrelay.

 Transformer shall be isolated and earthed.

 Connect nitrogen cylinder to the top petcock of Buchholz relay.
 Open the other petcock.
 Allow gas to enter the relay.
 Check and confirm from control room that alarm signal is received.
 Check continuity of alarm contact by using multimeter.
 Close petcock on gas supply side and release all gases trapped inrelay casing.
 Increase the gas pressure to approx. 2 kg/cm² (30 psi)
 Open the test petcock and allow full surge of gas to enter the relay casing.
 Check and confirm from control room that trip signal has been received.
 Check continuity of trip contacts by using multimeter.
 Close Buchholz relay test cocks.
 If relay has not operated, increase gas pressure and repeat the test.
 If the relay is found faculty replace it with a new one.
 Open conservator shut off valve and release all gases trapped.

7.1.7 Tap-changer Operation

 Regular inspection of tap changing equipment is not required because mechanical

operation of tap changer does not involve significantcontact wear.
 It is sufficient to operate the tap changer through the whole range of tap selector
positions twice a year.
 The purpose of this check is to ensure correct mechanical operation of tap changer.
 Transformer shall be isolated and earthed.
 Note the tap position.
 Operate the tap changer through operating handle through entire rangeof tap positions.
 Return to the original tap position.

7.1.8 Oil Filtration

Purpose of this maintenance is to improve the unsatisfactory conditionof oil found during
sampling. Transformer shall be isolated and earthed.

7.1.8.1 Tools and Materials

 Oil conditioning plant (Filter Machine)

  50 mm flexible hoses of sufficient length for oil inlet and outlet.
 Hose adapters to match the flanges of top and bottom filter valves.
 Cleaning cloths

7.1.8.2 Procedure

 Remove the blanking plate from filter valves and connect the oil inlet hose to top filter
valve and oil outlet hose to the bottom filter valve.
 Open the filter valves and start circulation of hot oil. Oil temperatureshall be 55°C to 70°C.
 Circulate the oil for 4 full passes.
 Re sample and arrange to test.
 Continue until oil condition is acceptable.

7.1.9 Corrective Maintenance

 All flange gaskets must be renewed wherever joints are dismantled.

 Cleanliness of gasket surfaces and correct compression (40 % ~ 50%approx.) of gasket
must be ensured during reassembling.

7.1.10 Removing and Re-fixing of Pumps

7.1.10.1 Tools and materials

 Jib crane or chain pulley block to handle the weight of pumps.

 Oil drip tray
 Blanking plates
 New gaskets.

7.1.10.2 Procedure

 Transformer is isolated and earthed.

 Close the isolating valves on either side of pump
 Disconnect the motor supply wires
 Remove the drain plug of the pump and drain oil from the pump.
 Remove the clamping bolts and remove the pump
 Blank off the isolating valve.
 For re-fixing the pump, remove the blanking plates.
 Fix new gaskets.
 Replace and tighten the clamping bolts.
 Open the isolating valves on cooler side.
 Open air release plug and close when oil starts flowing out.
 Open the isolating valve on transformer tank side.

7.1.11 Trouble Shooting

The trouble shooting of the Station Transformer is given in Annexure M11.

7.2 Auxiliary Transformer, 33/0.4kV (800 KVA)

7.2.1 Introduction

Three three-phase 8,00 kVA, 11/33 kV dry type power transformers are provided as additional
sources of station power supply of the powerhouse The primary is connected as delta and the
secondary (LV side) is connected as star with its neutral solidly earthed.
Off load tap changing links are provided on HV side for variation of voltage from –5% to +5% in 4
equal steps 5 position.

7.2.2 Technical Data

Make Raychen RPG pvt.Ltd. Pune

Type Three phase cast resin dry type

Rating 800 kVA

Voltage HV /LV 33KV/400V

Current HV/LV 13.99/1154.7Amps

No of phases 3

Frequency 50Hz±3%

Connections
HV winding (kV) Delta
LV winging (kV) Star
Vector group -3 phase Dyn5

Tap changing equipment -5% to+5%

Cooling AN type

Frequency 50 Hz±3%

% impedance 7.60

Table 7.2:Technical data of 800kV Transformer

7.2.3 Maintenance

7.2.3.1 Yearly Maintenance

Transformer being dry type, no major maintenance is carried out. However, during annual
shutdown of the generator, the following maintenance shall be carried out.
a. Clean and blow out the dust from inside and outside the transformer.
 SECTION B:

MAINTENANCE MANUAL b. Check for looseness of the fasteners wherever possible

and tighten them, especially the core clamps.
CHAPTER 8
c. Check and record the DC IR values at 2.5 kV for both the
HV and LV windings with respect to earth.
d. Check and tighten all the electrical termination point s to
avoid fire hazard due to lose connections.
e. Measure and record the resistances of the RTDs for winding temperature measurement
using a good multi-meter.

CHAPTER 8: GAS INSULATED SWITCHGEAR

8.1 Maintenance

8.1.1 GIS inspection over view:

Make Proof
Circuit Disconnector/ Performed
Action SF6-Gas Earthing
Breaker Earthing Switch by
Switch (HSES)

Visual - Station
Once a year Once a year Once a year Personnel
Inspection

Minor Every 4 to 6 Every 4 to 6 Every 4 to 6 Station

Every 4 to 6 years
Inspection years years years Personnel

- Manufacturer
Every 12 to
Every 12 to 18 or specially
18 years or
Major years or after trained
after 5000 -
Inspection 5000 switching personnel of
switching
cycles station
cycles
operator

Preventive Depending on1. Depending1. Depending on the1. Depending on Manufacturer

maintenance the result of on the result of the the result of or specially
the above result of the above inspection the above trained
inspection above 2. After 10000 inspection personnel of
inspection operations 2. After 5000 station
2. Every 15 to 3. After completion operations operator
20 years of 100 close/open3. After closing on
3. After cycles by bus short circuit
cumulated transfer current currentAfter
short circuit switching by completion of
 current disconnector 100 close/open
cycles by
currentsinduce
d through
parallel lines.

Table 8.1:Inspection schedule

8.1.2 Check List (After Maintenance) for GIS Bays:

Time: …………………. Date: …………………………

1. Are the Auxiliary supplies to the LCC healthy?
 AC supply: Yes/No
 DC supply A: Yes/No
 DC supply B: Yes/No
2. Are all the indication lamps of LCC working (press lamp test button)? Yes/No
3. Is the control selector switch at ‘REMOTE’? Yes/No
4. Is the operation selector switch at ‘Normal’? Yes/No.
5. Are SF6 gas pressures of all the gas tight compartments of the bays normal? Yes/No.
6. Is the high-speed earth switch open? Yes/No
7. Is the maintenance earth switch open? Yes/No
8. Circuit breaker operation counter readings:

Phase Counter Reading Remark

B
Table 8.2:Surge
counter measurement reading
9. Is there any gas leakage from compartments? Yes/No.
10. Are there any alarm indications in the LCC panel? Yes/No.
11. Are all the earth connections properly made? Yes/No
 SECTION B:

MAINTENANCE MANUAL

CHAPTER 9

CHAPTER 9: POT HEAD YARD

9.1 Maintenance

9.1.1 Yearly Maintenance:

 Check the tightness of various nuts and clamps.

 Check for any cracks on the arms of current path and clean the oxides film formed.
 Clean support insulators, rods and check for damages.
 Check the opening and closing of isolator both manually and electrically (local & remote).
 Check the opening and closing of earth switches both manually and electrically (locally).
 Clean and lubricate main contacts.
 Measure contact resistance & IR values of LAs and isolator post insulators
 Check earthing connection
 Check interlocking circuit
 Conduct thermography to check heating because of loose connection, etc.
 SECTION B:

MAINTENANCE MANUAL

CHAPTER 10

CHAPTER 10:CROSSED LINKED POLYETHYLELE (XLPE) CABLE

10.1 Introduction

Crossed Linked Polyethylene (XLPE) cable of 220 kV, 400 sq.mm, aluminum is connected between
220kv GIS and Point of Transmission Head (POT Head) to evacuate power from Dagachhu
Hydropower Plant through the double circuited transmission towers.

10.2 Technical Details of XLPE

Details Specification

Type 127/220 kV

Make SUDKABEL

Nominal voltage 220KV

Conductor cross section 400 mm2

Insulation thickness (nominal value) 22 mm

Cross section of copper shield wire 224 mm2

Cross section of metallic sheath 50 mm2

Thickness of outer sheath 4mm

Diameter of cable approximately 87mm

Cable weight per meter 7.5kg

Max. permissible operating voltage 245KV

Max. permissible operating current 757A

Frequency 50HZ
Table 10.1:Technical data of Cross Linked Polyethylene Cable

10.3 Maintenance:

Though the cables are maintenance-free, the following basic activities are carried out yearly to
ensure trouble-free operation of the cables throughout the year.

 Cleaning of outer sheath cables and structures externally.

 Physically check the healthiness of indoor and outdoor cable termination ends.
 Checking the tightness of cable fixing clamps and tightened whenever needed.
 Check the earth connections of the structures and the cable sheaths.
 SECTION B:

MAINTENANCE MANUAL

CHAPTER 11

CHAPTER 11: AUXILIARY SUPPLY SYSTEM

11.1 Maintenance of 33kV Switchgear

11.1.1 Levels of maintenance:

Definition Levels

Operation and Maintenance to be carried out by suitably qualified personnel

having received training allowing them to intervene whilst respecting the safety 1
rules.

Complex operations requiring expertise and the implementation of support

implementation equipment in accordance with AREVA’s procedures. These are to
2
be carried out by AREVA or by a specialized technician, trained by AREVA (DAFEP
Training Centre) in the procedures, and who is equipped with specific equipment.

All preventive and corrective maintenance, all renovation and reconstruction

3
work to be carried out by AREVA.

Table 11.1:Levels of maintenance

11.1.2 Preventive maintenance of the moving parts:

Preventive Maintenance Frequency Levels

Sl.No
Recommended operations 3 years 6 years 1 2 3

Removal of dust from the insulating enclosure

1 X X X X
of the poles (clean, dry cloth).

2 Checking the state of the plugging-in clamps. X X

Checking the moving part’s earthing switch

3 X X
device (clamps and contact jaws).

4 Ensure the smooth functioning of the shutters X X X

 (Plugging-in/withdrawing).

Checking the state of the plugging-in

5 X X
electrodes.

Cleaning of the insulating elements, with a

6 X X
clean dry cloth.

7 Cleaning and lubricating the mechanical parts. X X

8 Examination of the electrical power contacts. X X

Checking for the absence of overheating or of X

9 discharges in the plugging-in electrodes. X

Table 11.2:Maintenance schedule of moving parts

11.1.3 Preventive maintenance of the functional units:

Preventive Maintenance Frequency Levels

Sl.No.
Operations recommended at the functional
3 years 6 years 1 2 3
unit level

Verification of the presence and condition of

1 X X X X
accessories (levels, etc.)

Visual inspection of exterior appearance

2 X X X X
(cleanliness, absence of oxidation, etc.).

Cleaning of external elements, with a clean dry X

3 cloth. X X X

Checking the tightness to torque (covers, wiring

4 X X X
ducts, connections, etc.).

Checking the mechanical controls by carrying

5 X X X X
out a few operations.

Checking the positioning of the status

6 indicators X X X X
(Open and closed).

Control of the status and the functioning of the

7 X X X X
mechanical locking by key locks.
 Dusting and cleaning the internal mechanical X
8 elements (without solvent). X X X

Inspection of the tightening of the threaded X X X

9 fasteners and presence of internal stops.

Dusting and cleaning the internal mechanical X X

10 elements (with solvent).

Lubrication and greasing of mechanical

X X
11 elements
(With recommended products).

Monitoring the general appearance of the X X

12 mechanical components and connections.

13 Testing the “function” of mechanical interlocks X X

Table 11.3:Maintenance of the functional units

11.1.4 Preventive maintenance of Bus bar compartment

Preventive Maintenance Frequency Levels

Sl.
No. Operations that are specific to the bus-bar
3 years 6 years 1 2 3
compartment

Checking the tightness of the bus-bar

1 X X
connections.

Checking the leak tightness in the

2 X X
compartment.

Cleaning the internal elements (insulation, X

3 connections, supports, etc.). X X

Visual inspection of the appearance of the X X

4 internal components.

Table 11.4:Maintenance of Bus Bar compartment

11.1.5 Preventive maintenance of the High Voltage Cables compartment

Sl.No. Preventive Maintenance Frequency Levels

 Operations that is specific to the “High
3 years 6 years 1 2 3
Voltage cables compartment.

Checking the state of the earthing switch

1 X X
contacts.

Checking the leak tightness in the

2 X X
compartment

Examination of the state of the cable X

3 reassembles. X

Cleaning the internal elements (insulators, X X

4 connections, supports, etc.).

5 Cleaning and lubricating the mechanical parts. X X

Visual inspection of the appearance of the X X

7 internal components.

Table 11.5: Maintenance of the High Voltage Cables compartment

11.1.6 Preventive maintenance of the Low Voltage Box

Preventive Maintenance Frequency Levels

Sl. No.
Operations specific to the Low Voltage box 3 years 6 years 1 2 3

1 Checking the state of the internal components. X X X

Checking the tightness to torque of the

2 X X X
terminals and electrical connections in general.

Examination of the general state of the wiring

3 and the relays. X X X

Table 11.6:Maintenance of the Low Voltage Box

11.1.7Maintenance on 33 kV Vacuum circuit breakers

To ensure safe operation and to prolong the lifespan of circuit breaker in efficient condition,
preventive maintenance must be performed.

Maintenance Frequency Remarks

Sl. No. Recommended operation 6 months 1 years

 Inspection and cleaning of circuit breaker 
1
insulation.

Removal of dust from the insulating enclosure of

2 the poles.(clean, dry cloth)


Physically check all the circuit breaker wiring for

3 evidence of scratch, cuts, burning or mechanical

damage.

Check the control cables of circuit breaker and

ensure proper local/remote operation as per the
4 
relevant schematic drawings.

Conduct timing test of all the vacuum Circuit

Breaker for open/close and close/open operation.
5 

Check for proper operation of mechanical and

electrical switches such as trips, Local/Remote.
6 

7 Verify all the interlocks and alarm as per scheme. 

Check all the light points and heating elements 

provided in control cubicle and control blocks of
the circuit breakers, if all are working. The
8 heating elements must be switched on
permanently, even during summer, in order to
prevent the ingress of moisture and
condensation.

Check the tightness of the circuit breaker 

9 terminals nuts & bolts and electrical connections
in general.

Table 11.7: Maintenance on 33 kV Vacuum circuit breakers

11.1.8 Maintenance on Metering and protection Instruments:

11.1.8.1 Current transformer:

Maintenance Frequency remarks

Sl. No. Recommended operation 6 months 1 years

Thoroughly inspect for sparking or heating

of individual current transformer,
 1 connections and terminals for looseness as 
well.

Clean the external of current transformer 

2
with a clean dry cloth.

Table 11.8:Inspection of Current Transformer

11.1.8.2 Potential transformers:

Maintenance Frequency remarks

Sl. No. Recommended operation 6 months 1 years

Visually inspect the potential transformer

for any abnormalities
1

Clean the external of potential transformer 

2 with a clean dry cloth.

Table 11.9:Inspection of Potential Transformer

11.2 Maintenance of 400V Supply System

11.2.1 Yearly/Annual maintenance

1. Clean and blow out the dust from the control panel.
2. Check the electrical terminations for any looseness and tightened if required.
3. Check the interlocks.
4. Check all the indications for their correctness.
5. Measure and record the IR value/resistance of closing and trip coil.
6. Recondition/ replace silica gel.
7. Cleaning of breaker cubicles and MCCs.
8. Check the availability of DC supply for trip circuit.
9. Check HV and LV bushing connection and ensure no loose contact.
10. Measure and record the IR for all the auxiliaries Transformer.
 SECTION B:

MAINTENANCE MANUAL

CHAPTER 12

CHAPTER 12: DIVERSION WEIR AND DESILTER

12.1 Intake Gate

The equipment is largely maintenance-free. Special care should be taken that everything is kept
as clean as possible particularly while making any adjustments or replacements and during first
filling with hydraulic oil or subsequent oil change.
To prevent corrosion, it is recommended to inspect the equipment once a year and to repair any
damaged coating.
Required information regarding dismantling respectively fixation (fastening torque) are given in
the relevant data sheet.
Apply O-ring grease on all O-rings before fitting them in place, (extended useful service life) use
only appropriate O-Ring grease!
To seal Joint flange-faces use Loctite 573, as sealing medium for oil and water. Check number of
spare parts and their correct function before start of dismantling.

12.1.1 Periodic Inspection and Maintenance

Interval Required work for inspection and maintenance

Monthly Visual control of the entire equipment for loose bolts or parts.

Visual control of the entire piping system for leakage / tightness

Record all important instrument readings and check if values are plausible

Visual control of signal lamps (Done by the Lamp test switches).

Visual control of the color of the Dehumidifying filter – Reactivating if

necessary.

Visual control of the difference pressure at oil return line filter

Visual control of valves for tightness and damages.

Visual control of servomotors especially at the piston rod passage for traces
of oil.
 Visual control of filling quantity of hydraulic power unit

Half a Year Visual control of the entire equipment

Detection of leakages

Function test of the entire equipment has to be carried out.

Inspection of oil if it is contaminated by water.

Test of oil sample in Laboratory

Function test of all heaters

Visual control of hoses for leakages and damages

Every Year Visual inspection of the hydraulic cylinder

Check tightening of terminals

Calibrate level sensors

Check position transmitters

Every two years Check condition of oil

Test of oil sample in Laboratory

Inspection of corrosion protection

Every five Years Change all hoses in cause of age-brittle

Table 12.1:Inspection schedule of Intake Gate

12.2 Diversion Weir Gates

The equipment is largely maintenance-free. Special care should be taken that everything is kept
as clean as possible particularly while making any adjustments or replacements and during first
filling with hydraulic oil or subsequent oil change.
To prevent corrosion, it is recommended to inspect the equipment once a year and to repair any
damaged coating.
Required information regarding dismantling respectively fixation (fastening torque) are given in
the relevant data sheet.
Apply O-ring grease on all O-rings before fitting them in place, (extended useful service life) use
only appropriate O-Ring grease!
To seal Joint flange-faces use Loctite 573, as sealing medium for oil and water.
Check number of spare parts and their correct function before start of dismantling.

12.2.1 Periodic Inspection and Maintenance

Interval Required work for inspection and maintenance

Monthly Visual control of the entire equipment for loose bolts or parts.

Visual control of the entire piping system for leakage / tightness

Record all important instrument readings and check if values are plausible

Visual control of signal lamps (Done by the Lamp test switches).

Visual control of the color of the Dehumidifying filter – Reactivating if

necessary.

Visual control of the difference pressure at oil return line filter

Visual control of valves for tightness and damages.

Visual control of servomotors especially at the piston rod passage for traces
of oil.

Visual control of filling quantity of hydraulic power unit

Half a Year Visual control of the entire equipment

Detection of leakages

Function test of the entire equipment has to be carried out.

Inspection of oil if it is contaminated by water.

Test of oil sample in Laboratory

Function test of all heaters

Visual control of hoses for leakages and damages

Every Year Visual inspection of the hydraulic cylinder

Check tightening of terminals

Calibrate level sensors

Check position transmitters

Every two years Check condition of oil

Test of oil sample in Laboratory

Inspection of corrosion protection

Every five Years Change all hoses in cause of age-brittle

Table 12.2:Inspection schedule of Weir gates

12.3 Trash Rack Cleaning Machine

12.3.1 Periodic Inspection and Maintenance

Interval Required work for inspection and maintenance

Monthly Visual control of the entire equipment for loose bolts or parts.

Visual control of the entire piping system for leakage / tightness

Record all important instrument readings and check if values are plausible

Visual control of signal lamps (Done by the Lamp test switches).

Visual control of the color of the Dehumidifying filter – Reactivating if

necessary.

Visual control of the difference pressure at oil return line filter

Visual control of valves for tightness and damages.

Visual control of servomotors especially at the piston rod passage for traces
of oil.

Visual control of filling quantity of hydraulic power unit

Half a Year Visual control of the entire equipment

Detection of leakages

Function test of the entire equipment has to be carried out.

Inspection of oil if it is contaminated by water.

Test of oil sample in Laboratory

Function test of all heaters

Visual control of hoses for leakages and damages

Every Year Visual inspection of the hydraulic cylinder

Check tightening of terminals

Calibrate level sensors

Check position transmitters

Every two years Check condition of oil

Test of oil sample in Laboratory

Inspection of corrosion protection

Every five Years Change all hoses in cause of age-brittle

Table 12.3:Inspection schedule of Trash Rack Cleaning Machine

12.4 Desilter

12.4.1 Mechanic and steel structure

The steel construction is to be controlled yearly for the appearance of cracks. An immediate
reclamation is to be arranged with the declaration of such defects, in connection with the
manufacturer.
The corrosion prevention to be checked for spalling and subsurface corrosion. Defects should be
corrected as soon as possible.

12.4.2 Screws and fastening elements

The fastening screw are to be controlled regularly for loosening. With the declaration of defects
of this type, consultation with the manufacturer is absolutely required for confirmation of action.

12.4.3 Control after Flooding

After flooding, the system should be cleared of large wood or rather gear establishment. This is
valid for the area directly before and after the inlet rake.

12.4.4 Hydraulic System

The components of the hydraulic system are generally maintenance-free. The maintenance work
concentrates on the filter element and oil changes. Both in the sense of the cleanliness of the
system. Premature outages and repairs can be prevented with the monitoring and periodic
maintenance of the system.

12.4.5 Maintenance planning and inspection

V=Visual P=Check W=Change D=Check and Set

E=Set N=Grease R=Cleaning

By operating

As needed
1/2 Yearly
Monthly

Object / Components
Yearly
test

Steel Construction V

Rust free Components V

Corrosion Prevention V

Screws/Fastening Elements P

Control Cabinet and Electrical Connections V

Main and Malfunction Power Switch P

Cable and Isolated Parts V

Hydraulic Liquid P
Hydraulic Oil Level P

Sealing-Hydraulic System V

Hydraulic Oil Filter W W

Silica Gel-Air Filter W

Operating Pressure P

Stroke Rope V N

Rope Drum Bearing N

Linkage Drive Gear Oil W

Table 12.4:Maintenance inspection of Desilter Gates

12.5 Troubleshooting

The errors and troubleshooting the problems related to Diversion Weir Intake Gates and Weir
Gates, Desilter Gates, Trash Rack Cleaning Machine and Screen Cleaning Machines are given
Annexure M1.

12.6 Replacement of seal

The replacement of seals for the Diversion Weir Gates, Desilter Gates and Stop Log gates are
given in Annexure M4.
 SECTION B:

MAINTENANCE MANUAL

CHAPTER 13

CHAPTER 13: FIRE DETECTION AND

PROTECTION SYSTEM

13.1 Maintenance hydrants and hose reel

Monthly inspection:
1. Check all the valves are in correct operating position as follows.
2. Check that all hydrant valves are accessible and that all required operating handles are lifted
and secure.
3. By visual inspection, check for leaks on all valve and lookout for leaks on the pipe flanges and
from valve spindles.
4. Check all the required hoses are supplied with correct fittings and are properly use. Generally,
check that all equipment and storage cabinets are in good repair.
5. Check water is available to fire hydrant and hose reel.

13.2 Yearly inspections:

1. Examine all piping generally for signs of corrosion or leak. Repair pipe finish or replace piping
as necessary.

13.3 Maintenance of deluge valve

1. Check the valve for proper operations.

2. Replace the damaged parts.
3. Check for isolation valves provided on deluge valves. Ensure they are open.
4. Check for the orientation of the nozzle in line with the layout drawings.
5. Check for cleanliness of nozzles.
6. Do not paint the nozzles/quartzite bulb detector.
7. Ruptured bulb of QBD to be replaced immediately after operation.

13.4 Periodical Testing and Maintenance of HVW Spray system

1. Water spray system requires competent and effective care and maintenance to assure that
they will perform their purpose effectively at the time of fire. System shall be serviced and
tested periodically by personnel trained in this work. Maintenance contract with a qualified
agency for service test and operation at regular intervals is recommended.
2. Make sure operating and maintenance instruction and layout shall be available at the fire
station. Plant personnel be trained and assigned the task of operating and maintenance.
3. The equipment shall be checked weekly or other frequently regular schedule for various
defects.
4. At least once a week the readings of pressure gauges of various deluge valves are recorded.
5. The piping shall be examined thoroughly at an interval not more than one year.
6. The functioning of all the deluge valve and automatic detection equipment shall be examined
and serviced by qualified personnel annually.
7. Discharge test of sprayers shall be made at least quarterly. After each operation projector
nozzles with individual cleaner shall be removed and cleaned thoroughly.
8. Manual tripping devices shall be operated at least twice annually.
9. When normally open valves are closed following the system operation or test, suitable
procedure shall be followed to ensure that they are reopened and the system is promptly
restored to full normal operating condition.
10. All projectors/nozzles shall be inspected for proper positioning or test external loading
corrosion and cleaned if necessary based on experience but at least in three months. The
entire system shall be flushed at least once a year. It is important to ensure that the sprinkler
bulbs detectors are kept free from dust or paint. All items pertaining to the spray system shall
be painted at least once in two years, if required.
 SECTION B:

MAINTENANCE MANUAL

CHAPTER 14

CHAPTER 14: DIESEL GENERATORS

14.1 400kVA Diesel Generator

14.1.1 Preventive Maintenance

Preventive maintenance is the easiest and least expensive type of maintenance. It permits the
Maintenance Division to do work at convenient time.
a. A good Maintenance Schedule depends on Engine application: Actual operating environment
of the engine governs the maintenance schedule. The suggested check-sheet on the
following page indicates more checks have to be performed more often under heavy dust or
other special conditions.
b. Using the suggested schedule check sheet: The maintenance schedule check-sheet is designed
as a guide until adequate experience is obtained to establish a schedule to meet a specific
operation. A detailed list of component check is provided through several check periods;also
a suggested schedule basis is given for hours of operation, or calendar of time. A
maintenance schedule should be established using the check-sheet as a guide; the result will
be a maintenance program to fit a specific operation. The check-sheet shown can be
reproduced by any printer. The person making each check can then indicate directly on the
sheet that the operation has been completed. When a complete column of checks is
indicated, the engine will be ready for additional service until the next check is due.
c. Storage for Engines out of Service: If an engine remains out of service and its use is not
immediately forthcoming, special precautions should be taken to prevent rust as per
procedure given in section 1.
d. Scheduled Maintenance: For maintenance schedule of all other engines are given below:

14.1.2 Stand-By Generator set Maintenance

6 Monthly

Annually
Monthly
Weekly
Daily

Sl. No.  Components/objects

1 check for oil leakages X x x x X

2 check operation of oil heaters X x x x X

3 check hydraulic governor oil level x x x x

4 change full filters x x

5 change by pass filter x x

6 change engine oil x x

7 change hydraulic governor oil x x

8 check cooling water leakages X x x x x

9 check for radiator air restriction x x x

10 check operation of coolant heater X x x x x

11 check hose and connections x x x

12 check coolant level x x x x

Check anti-freezing & concentration of

x x x
13 coolant

14 check belt condition and tension x x x

15 check fan hub drive pulley & water pumps x

16 check heat exchange anode plugs x x

17 check cooling motor operated louvers x x x

18 change cooling water filters x x

19 clean water separator X x

20 clean cooling system x

21 check air cleaner restriction x x x x

22 check air piping and connection x x

23 clean crankcase breathers x x

24 change air cleaner element x x

25 check fuel leaks X x x x

26 check fuel lever x x x

27 check governor linkage x x

28 check fuel lines and connection x x

29 check fuel transfer pump x x x

30 drain sediment from tanks x x

31 change fuel filters x x

32 change float tank breather x

33 check exhaust leaks x x x

34 check for exhaust restriction x x x

35 drain condense trap x x x

36 torque exhaust manifold x

37 torque turbocharger cap screws x

38 check battery charging system x x x x

39 check battery specific gravity x x x

40 check safety controls and alarms x x

41 check for unusual vibration x x x x

42 check mounting hardwires x

43 clean engine x

44 check air inlet & outlet for restriction x x x

45 check windings & electrical connection x

46 check operation of generator heater staps x

47 grease bearing x

measure & record generator winding

x
48 resistance

49 clean generator x x

50 start switch in automatic X x x x x

51 check instrumentation x
 52 check power distribution wiring x x

53 check power circuit breakers x x

54 check transfer switch X x

55 perform operational load test x X x x

56 perform generator load bank test x

57 check service tool availability X x x

Table 14.1:Standby Generator Set Inspection plan

14.2 160kVA Maintenance Schedule

Every 475-500 Hrs. or 12 Months

Every 225-250 Hrs. or 6 Months,

Months, whichever is earlier

Every 9500-1000 Hrs. or 24
whichever is early

whichever is early
Daily
Components/objects

Check lubricating oil level x x x x

Change Lubrication Oil x x x

Change Lubricating Oil Filter x x x

Clean Breather x x

Check Blow eye x

Check coolant level in radiator and recovery Bottle x X x x

If required, fill Premix Coolant, at the Rate of 9 Lit/min. x X x x

Check Belt Condition x X x x

Check coolant level and top up, if required X x x

Check fan hub and fan drive arrangement X x x

Check seal of cap, radiator X x x

Check coolant condition x x

Check recovery bottle and seals x x

Check connection and sealings of radiator x x

Clean radiator, extremely x x

Check Belt tension and replace belt, if required x

Replace coolant and use Premix Coolant only x

Replace Cap. Radiator x

Check Fuel Strainer x X x x

Clean Breather on fuel tank x X x x

Drain sediments from fuel water separator x X x x

Change fuel filters and fuel water separator X x x

Drain sediments from fuel tank X x x

Check all joints in fuel lines and tighten x x

Check feed pump and clean baby filter x x

Clean Fuel Tank x

Replace Fuel hoses if required x

Vacuum indicator for air restriction (red Band) x X x x

Check Sealings and condition of air filter x X x x

Clean air filters in reverse direction, using dry air with

X x x
max 0.5kg/Cm2 pressure

Check Turbocharger End Clearances x

Check for leaks and rectify if required x

Run engine and record, all parameters x

Check Battery condition X

Clean battery leads X

Secure all connectors in Engine Electrical System. X

Check AVMs and replace if required x

Tighten all clamps X

Check valve lashes and adjust, if required X

Table 15.2: Inspection Schedule of 160kVA DG set

 SECTION B:

MAINTENANCE MANUAL

CHAPTER 15

CHAPTER 15: CONTROL AND PROTECTION

SYSTEMS

15.1 Control System

The overall control system of Dagachhu Hydropower Plant is ALSPA series 6. However, we have
Siemens S7 control system for Diversion Weir and Desilter.

15.1.1 Optimum Environmental Conditions

Correct environmental conditions are vital to the reliable operation of all electrical equipment.
Carry out the following operations:
 Measure the temperature at the following points:
 Ambient temperature within the cabinet
 Temperature near the aircraft evacuation exits located at the back of the rack
 Ambient temperature within the network cabinet.
The temperatures are
cabinet, with the doors closed and the ventilators running.
 Measure the degree of hygrometry in all premises where hardware is installed.
 Check that there is no sign of corrosion or condensation on the cabinet and rack walls.

15.1.2 Dust cleaning

 Once you switch off and take all necessary precautions relative to shutting off power, remove
the dust with a low power suction cleaner on:
 The inside and the outside of the cabinets
 The racks
 The peripherals.
 Clean the protection ventilator grills.
 If there is too many dust on the modules, complete the dust removal with the cleaning of the
modules.
Only clean the
complicate the restart of the equipment.

15.1.3 Cleaning of the modules

Before you extract a module, locate its position on the rack and check if its cable is well identified.
Never use aerosol to clean the modules.
Cleaner aerosols leave a thin layer of grease which can alter the functioning of the modules.
Clean rack by rack, starting from the top level. For each rack:
 Disconnect the first module and put it on a clean and dust-free anti-static support
 Repeat the operation for every module of the rack
 Remove the dust at the bottom of the rack, on the connectors and on card- guides with a low
suction cleaner.
 Remove the dust on the modules with a brush and an appropriate product.
 Once you check and clean the modules, reconnect and lock each module in its original
location.
 Plug in and lock every connection.

15.1.4 Electrical checking

 Move away any electrical equipment which could create electromagnetic disruptions;
 Check that the internal light in the cabinet is working correctly;
 Check that the door contact in the cabinet is working correctly;
 Check that the door grounding braid is properly attached;
 Check that the chassis earth connection is properly attached;
 Check that the cableway insulation is not damaged in any way.

15.1.5 Ventilation cleaning

 Clean the ventilation fans and louvers.

 Ensure that every rack and door ventilators are working properly.

15.1.6 Functional test

Accomplish the following actions once you replace the sources and restart the hard ware:
 Check that the hardware is operational
 Restart the various application programs.

15.1.7 Power sources checking

Inspection of the power sources involves checking all of the different power sources required for
the hardware to function correctly;
 Measure the voltage on each operating cabinet
 Corrective action must be taken wherever tolerances are exceeded
 Measure the polarities according to the description of each equipment and compare the
results with its technical characteristics.

15.1.8 Stations maintenance

Follow this procedure in order to complete the maintenance of the stations:

 Stop the operating system
 Switch off the CPU
 Disconnect all input cables
 Open the unit which contains the hard disk
 Clean out the interior with a low power suction cleaner and a brush if necessary
 Clean the screens of the stations with suitable product
 Clean the mouse with suitable product
 Clean the keyboard with a cloth impregnated with isopropyl alcohol.
Do not spray the keyboard directly with any kind of product.
In a normal operating environment, the CPU requires vacuum cleaning only once a year.

15.1.9 Printer maintenance

Only use the consumables preconized for the printer maintenance.

15.1.9.1 General cleaning

 Switch the printer off

 Open the drawers and the hoods one by one
 Use a low power suction cleaner inside the printer to remove any paper residues
 Use a soft brush carefully to remove any dust or fluff
 Clean the hoods with a soft cloth impregnated with dilute detergent or with an appropriate
aerosol cleaner
 Leave the hoods to dry in order to prevent the cleaning product from penetrating the
interior of the printer.
Do not use alcoho
printing mechanism or with the electronic components. Do not use a hard brush or
abrasive materials. Do not spray lubricant inside the printer.

15.1.9.2 Cleaning of the print-head

 Follow the procedure specified for each printer.

15.1.9.3 Print test

The print test allows checking the print quality. Follow this procedure to execute the print test:
 Load paper
 Switch the printer off (the self-test carries on)
 Launch a print test
 Control the print quality
 In case of poor quality print replace the print cartridge according to the indications. The
printer is now operational and ready to print.
Some printers require a periodical print in order to clean the nozzles.

15.1.10 Maintenance of the spare part

Check the storage conditions of the spare parts:

 Store the spare REPROM on antistatic bars;
 Store the modules under antistatic protections;
 Check the physical condition of spare and wear modules (no dust, knocks, deformation or
oxidation);
 Run each module through an operational cycle with the test programs.

15.1.11 Maintenance of the Ethernet network

Network transmission housings (Hub, switch, converters) have to be periodically checked. In

some cases, especially in redundant structures, the state of the hardware has to be periodically
checked.
 Read the state indicators.

15.2 Automatic Synchronizer (SYNCHROTACT 5)

Both the generating units are provided with SYNCHROTACT 5 used to automatically synchronize
and connect generators to the power system or to connect power systems which are already
synchronized. The field of application extends from straight forward synchrocheck tasks to fully
automatic double-channel paralleling.
The purpose of the device in synchrocheck applications (MAN operating mode) is to prevent
incorrect switching by manual or automatic paralleling equipment. The device's output contact is
closed within the prescribed limits permitting closing of the circuit-breaker and allows the
paralleling command to pass. When being used for automatic synchronization and paralleling
(AUTO operating mode), the device performs all the functions needed to safely connect plant
and systems, e.g. detection of asynchronous, synchronous and dead bus states on both sides of a
circuit-breaker, matching of voltage and frequency at the correct rate for the item of plant or
system to be synchronized, precision paralleling while taking proper account of paralleling time
etc. All the parameter settings involved in a paralleling operation are contained in a single
parameter set. The settings determine the conditions for paralleling and the response of the
voltage and frequency matching functions. The settings are entered by means of the buttons on
the front of the device and are displayed on a two-line LCD. The light emitting diodes (LED's) on
the front plate signal all important operating states.
SYNCHROTACT has been designed for simple fast installation in switch panels. All the external
connections are made at the rear via non-screw coded connectors. All parameter settings can
also be viewed on a PC connected to the RS232 serial interface using the "Terminal" function
provided with MS Windows. The device includes comprehensive self-monitoring functions which
ensure high operational reliability and availability. Its high-quality digital components and
processing exclude inaccuracies due to the influences of temperature and ageing. The highest
possible security against incorrect paralleling is achieved by a system with two independent
devices operating in a double-channel configuration. The measurement, the computation of the
optimum instant for paralleling and the auxiliary supplies of the two devices are completely
independent and paralleling is only permitted if both the channels come to the same conclusion.
15.2.1 Maintenance Instructions

The device does not require any maintenance. Before leaving the works every unit is subjected to
thorough final testing. Experience has shown that in the majority of cases problems during
commissioning are to be found in the external wiring as a consequence of mistakes while
performing commissioning procedures. Should a disturbance occur during operation, it is
important to ascertain whether the problem is in the device itself or in the external circuit.
For the replacement of defective SYNCHROTACT unit, refer Annexure M9.

15.2.2 Troubleshooting

For Troubleshooting of SYNCHROTACT 5 refer Annexure M10.

15.3 Protection System

All most all the protective relays installed at the Power House are of Numerical type. These are
microprocessor-based relays in contrast to other relays that are electro-mechanically controlled.
These relays provide great precision and convenience in application. By combining several
functions in one case, numerical relays also save capital cost and maintenance cost over
electromechanical relays.

15.3.1 Startup of System start-up check list for Protection

Caution: Before energizing, check that all cubicle doors are locked and that all equipment is insured
and free of maintenance Permits to Work.
a. Preconditions for Protection Cubicles
1. Permit to Work on protection systems
cleared and signed off by all relevant parties
2. 110VDC Power supply MCBs 01CHE01-F1 for F100 closed
01CHE01-F2 for F200 closed
01CHE01-F3 for binary input closed
3. Rotor earth fault device MR627 in operation 01CHE01-S3 for G01 Pos. On
4. AC supply is on
b. Checking the CT connections
The CT’s must be connected in strict accordance with diagram supplied with the equipment.
The following checks must be carried out to check the CT’s and CT circuits:

 polarity check
 primary injection test
 plot the excitation curve
 CT circuit grounding.
The polarity check (as close as possible to the protection equipment) not only checks the current
input circuit as a whole, it also checks the phase-angle of the CT.
Primary injection checks for a ratio error and the wiring to the protection equipment. Each phase-
to-neutral and phase-to-phase circuit should be injected. In each case, the phase currents and the
neutral current should be measured.
The relative polarities of the CT’s and their ratios can also be checked using load current.
Plotting the excitation curve verifies that the protection is connected to a protection core and
not a metering core.
c. Checking the VT connections
The VT’s must be connected in strict accordance with diagram supplied with the equipment.
The following checks must be carried out to check the VT circuits:

 polarity check
 wiring check
 VT circuit grounding.
The rated voltage of an E/F protection scheme is defined as the voltage which occurs between
the terminals “e” and “n” for a solid phase-to-ground fault. An E/F of this kind, e.g. on T phase
(see Figure 15.1), causes the voltages of R and S phases to increase from phase-to-neutral to
phase-to-phase potential and these add vectorially to produce a voltage between terminals “e”
and “n", which is three times the phase-to-neutral voltage.

Figure 15.1:Voltages in an ungrounded three-phase power system

d. Checking the auxiliary supply connections
Check that the supply is connected with the correct polarity. The DC supply voltage must lie
within the permissible operating range of the power supply unit installed under all operating
conditions (see Technical Data for the respective power supply unit).
e. Checking the duty of the tripping and signal contacts
Check that the loads connected to all the contacts are within the specified ratings given in the
“Contact ratings” section of the data sheet.
f. Checking the opto-coupler inputs
Check the polarity and supply voltage of all opto-coupler inputs in relation to the ordering code
(also given on the rating plate at the rear of the equipment).

15.3.2 Visual Function Check

a. Check of all protection relays working

All displays and indication of operation signals has to be on (lighting).
b. Connecting the setting and control PC
Connect the serial interface of the PC to the interface connector on the front of the equipment.
Details of the communication parameters and the connector pins are given in the following
Sections.
Minimum PC requirements
The minimum requirements to be fulfilled by the MMC PC are:

 Windows XP or 7 operating system

  1000 MByte RAM
 1 CD/DVD-ROM drive and a hard disc with at least 30 GByte of free space
 1 serial interface (RS-232C)
Serial interface parameters
The MMC initializes the serial interface and automatically sets the corresponding parameters.
PC connecting cable
The connecting cable between the serial interface connectors on the front plate of the
protection equipment and on the PC, is standard serial cable (9-pin SUB-D plug male/female) with
1:1 connection.

15.3.3 Shutting Down Protection System

After shutting down has been completed, one or more components are isolatedand earthed and
available for maintenance and major inspection.
Details of several unit shut downs to follow from control system descriptions

15.3.4 Faults

Details of faults/alarms to follow from control system descriptions.

15.3.5 Maintenance

Because of the self-testing and monitoring features included, the equipment requires neither
special maintenance nor periodic testing.
Where testing is considered necessary, the following procedure is recommended:

 Measure the currents and voltages in the secondary of the main CT’s and VT’s and
compare the results with the values displayed by the MMC.
 Test the external circuits using the test functions provided by the MMC.
The life of the wet electrolytic condensers is about 20 years. This assumes a mean ambient
temperature outside the casing of 40 °C.
a) Initial Problem Identification
Use table 15.1 below to find the description that best matches the problem experienced, then
consult the section referenced to perform a more detailed analysis of the problem.

Symptom Refer to

Relay fails to power up Table 15.2

Relay power ups but indicates error and halts Table 15.3
during power-up sequence

Relay powers up but out of service LED is Table 15.4

illuminated
Error during normal operation -

Mal-operation of the relay during testing -

Table 15.1:Problem identification

b. Power-up errors
If the relay does not appear to power up, use the procedure in Table 15.2 to determine whether
the fault is in the external wiring, auxiliary fuse, power supply module of the relay or the relay
front.

Test Check Action

1 Measure auxiliary voltage on terminals If the auxiliary voltage is present and correct,
1 and 2. Verify the voltage level and go to test 2. Otherwise check the wiring and
polarity against rating the label on fuses in the auxiliary supply
front. Terminal 1 is -dc and 2 is +dc

2 Do LEDs/ and LCD backlight illuminate
on power-up, also check the N/O
watchdog contact for closing
If they illuminate or the contact closes and no
error code is displayed, then error is probably
in the main processor board (front panel). If
they do not illuminate and the contact does
not close, then proceed to test 3.

3 Check Field voltage output (normally If field voltage is not present, then the fault is
48V DC) probably in the relay power supply module.

Table 15.2:Failure of relay to power up

c. Error message/code on power-up
During the power-up sequence of the relay self-testing is performed as indicated by the
messages displayed on the LCD. If an error is detected by the relay during these self-tests, then
an error message will be displayed and the power-up sequence will be halted. If the error occurs
when the relay application software is executing, then a maintenance record will be created and
the relay will reboot.

Test Check Action

1 Is an error message or code If the relay locks up and displayed an error

permanently displayed during power code permanently, go to test 2. If the relay
up? prompts for user input, go to test 4. If the
relay re-boots automatically, go to test 5.

2 Record displayed error, then remove Record whether the same error code is
and re-apply relay auxiliary supply. displayed when the relay is rebooted. If no
error code is displayed, then contact the local
service center stating the error code and relay

3 Error code identification
The following text messages (in
English) are displayed if a fundamental
problem is detected preventing the
system from booting:
Bus Fail - address lines
SRAM Fail - data lines
FLASH Fail format error
FLASH Fail checksum
Code Verify Fail
The following hex error codes relate to
errors detected in specify relay
modules:
0c140005/0c0d0000
0c140006/0c0e0000
The last 4 digits provide details on the
actual error.
4 The relay displays a message for
corrupt settings and prompts for
restoration of defaults to the affected
settings.
5 The relay resets when the power up is
complete. A record is error code is
displayed
information. If the same code is displayed
proceed to test 3.
These messages indicate that a problem has
been detected on the relays main processor
board in the front panel.
Input Module (inc. Opto-isolated inputs)
Output Relay Cards
Other error codes relate to problems within
the main processor board hardware or
software. It will be necessary to contact
Alstom Grid with details of the problem for a
full analysis.
The power up tests have detected corrupted
relay settings. Restore the default settings to
allow the power-up to complete, then re-
apply the application specific settings.
Error 0x0E080000, programmable scheme
logic error due to excessive execution time.
Restore default settings by performing a
power up with <= and => keys depressed,
confirm restoration of defaults at prompt
using 󠇯enter key. If relay powers up
successfully, check programmable logic for
feedback paths.
Other error codes will relate to software
errors on the main processor board, contact
 Alstom Grid.

Table 15.3:Error message/code on power-up

d. Out of service LED illuminated on Power Up

Test Check Action

1 Using the relay menu confirm If the setting is enabled, then disable the test mode and
whether the commission test make sure the out of service LED is OFF.
/ test mode setting is
enables. If it is not enabled,
go to test 2.

2 Select View Records, then
view the last maintenance
record from the menu.
Check for H/W Verify Fail this indicates a discrepancy
between the relay model number and hardware;
examine the “Maint. Data”, this indicates the causes of
the failure using bit fields.
Bit Meaning

0 The application type field in the model number does

not match the software ID

1 The application field in the model number does not

match the software ID

2 The variant 1 field in the model number does not

match the software ID

3 The variant 2 field in the model number does not

match the software ID

4 The protocol field in the model number does not

match the software ID

5 The language field in the model number does not

match the software ID

6 The VT type field in the model number is incorrect

(110V VTs fitted)

7 The VT type field in the model number is incorrect

(440V VTs fitted)

8 The VT type field in the model number is incorrect

(no VTs fitted)
Table 15.4:Out of service LED illuminated

15.3.6 Maintenance period

It is recommended that products supplied by ALSTOM GRID receive periodic monitoring after
installation. As with all products some deterioration with time is inevitable. In view of the critical
nature of protective relays and their infrequent operation, it is desirable to confirm that they are
operating correctly at regular intervals.
Alstom Grid protective relays are designed for life in excess of 20 years.
The P34x generator relays are self-supervising and so require less maintenance than earlier
designs of relay. Most problems will result in an alarm so that remedial action can be taken.
However, some periodic tests should be done to ensure that the relay is functioning correctly and
the external wiring is intact.
If the customer’s organization has a Preventative Maintenance Policy, the recommended product
checks should be included in the regular program. Maintenance periods depend on many factors,
such as:

 The operating environment

 The accessibility of the site
 The amount of available manpower
 The importance of the installation in the power system
 The consequences of failure

15.3.7 Maintenance checks

Although some functionality checks can be performed from a remote location using the
communications ability of the relays, these are predominantly restricted to checking that the
relay is measuring the applied currents and voltages accurately, and checking the circuit breaker
maintenance counters. Therefore, it is recommended that maintenance checks are performed
locally (that is at the substation itself).
Before carrying out any work on the equipment, the user should be familiar with the contents of
the Safety and technical data sections and the ratings on the equipment’s rating label.
a. Alarms
Check the alarm status LED to identify if any alarm conditions exist. If the LED is ON, press the
read key [ ] repeatedly to step through the alarms. Clear the alarms to switch the LED OFF.
b. Opto-isolators
Check the relay responds when the opto-isolated inputs are energized.
c. Output relay
Check the output relays operate.
d. Measurement accuracy
If the power system is energized, compare the values measured by the relay with known system
values to check they are in the approximate expected range. If they are, the relay is performing
the analog/digital conversion and calculations are being performed correctly. Alternatively, check
the values measured by the relay against known values injected into the relay using the test
block, if fitted, or injected directly into the relay terminals. These tests prove the calibration
accuracy is being maintained.

15.3.8 Method of repair

If the relay develops a fault while in service, depending on the type of the fault, the watchdog
contacts change state and an alarm condition is flagged. Due to the extensive use of surface-
mount components faulty PCBs cannot be repaired and should be replaced. Therefore, either the
complete relay or just the faulty PCB, identified by the in-built diagnostic software, can be
replaced. The preferred method is to replace the complete relay. This ensures the internal
circuitry is protected against electrostatic discharge and physical damage at all times and avoids
incompatibility between replacement PCBs. However, it may be difficult to remove an installed
relay due to limited access in the back of the cubicle and rigidity of the scheme wiring. Replacing
PCBs can reduce transport costs but requires clean, dry conditions on site and higher skills from
the person performing the repair. However, if the repair is not performed by an approved service
center, the warranty will be invalidated.
a. Replacing the complete relay
The case and the rear terminal blocks are designed to ease removal of the complete relay,
without disconnecting the scheme wiring. Before working at the rear of the relay, isolate all
voltage and current supplies to the relay. MT Note: The MiCOM ALSTOM range of relays have
integral current transformer shorting switches which will close when the heavy-duty terminal
block is removed.
1. Disconnect the relay earth connection from the rear of the relay.

Figure 15.2:Location of securing screws for terminal blocks

There are three types of terminal block used on the relay, RTD/CLIO input, heavy duty and
medium duty, which are fastened to the rear panel using screws (crosshead on the heavy and
medium duty blocks, slotted on RTD/CLIO input blocks), as in Figure 15.2.
Note:The use of a magnetic bladed screwdriver is recommended to minimize the risk of the screws
being left in the terminal block or lost.
2. Without exerting excessive force or damaging the scheme wiring, pull the terminal blocks
away from their internal connectors.
3. Remove the screws used to fasten the relay to the panel, rack, etc. These are the screws with
the larger diameter heads that are accessible with the access covers are fitted and open.
If the top and bottom access covers have been removed, do not remove the screws with the
smaller diameter heads which are accessible. These screws hold the front panel on the relay.
4. Withdraw the relay from the panel, rack, etc. carefully because it will be heavy due to the
internal transformers.
5. To reinstall the repaired or replacement relay follow steps 1 to 5 in reverse. Relocate each
terminal block in the correct position. Replace the case earth, IRIG-B and fiber optic
connections. To help identify each terminal block, they are labeled alphabetically with ‘A’ on
the left-hand side when viewed from the rear.
Once reinstallation is complete the relay should be recommissioned.
b. Changing the battery
Each relay has a battery to maintain status data and the correct time when the auxiliary supply
voltage fails. The data maintained includes event, fault and disturbance records and the thermal
state at the time of failure. This battery will periodically need changing, although an alarm will be
given as part of the relay’s continuous self-monitoring in the event of a low battery condition. If
the battery-backed facilities are not required to be maintained during an interruption of the
auxiliary supply, the steps below can be followed to remove the battery, but do not replace with
a new battery.
c. Instructions for replacing the battery
1. Open the bottom access cover on the front of the relay.
2. Gently extract the battery from its socket. If necessary, use a small insulated screwdriver to
prize the battery free.
3. Ensure that the metal terminals in the battery socket are free from corrosion, grease and
dust.
The replacement battery should be removed from its packaging and placed into the battery
holder, taking care to ensure that the polarity markings on the battery agree with those adjacent
to the socket.
Note:Only use a type ½AA Lithium battery with a nominal voltage of 3.6 V and safety approvals such
as UL (Underwriters Laboratory), CSA (Canadian Standards Association) or VDE (Vereinigung
Deutscher Elektrizitätswerke).
4. Ensure that the battery is securely held in its socket and that the battery terminalsare making
good contact with the metal terminals of the socket.
5. Close the bottom access cover

15.3.9 Post modification tests

To ensure that the replacement battery will maintain the time and status data if the auxiliary
supply fails, check cell [0806: DATE and TIME, Battery Status] reads Healthy.
If you need further confirmation that the replacement battery is installed correctly, perform the
commissioning test.
a. Battery disposal
Dispose the removed battery according to the disposal procedure for Lithium batteries in the
country in which the relay is installed.

15.3.10 Cleaning

Before cleaning the relay ensure that all ac and dc supplies, current transformer and voltage
transformer connections are isolated to prevent any chance of an electric shock while cleaning.
Before cleaning the relay ensure that all ac and dc supplies, current transformer and voltage
transformer connections are isolated to prevent any chance of an electric shock whilst cleaning.
Only clean the equipment with a lint-free cloth dampened with clean water. Do not
usedetergents, solvents or abrasive cleaners as they may damage the relay’s surface and leave a
conductive residue.
 SECTION B:

MAINTENANCE MANUAL CHAPTER 16: IP CAMERA SYSTEM

CHAPTER 16

16.1 Maintenance

Our IP Camera system plays a key role in monitoring the various unmanned sites of the power
plant. Functioning of all the cameras round the clock is required to assist the numerous sites of
the power plant. Maintenance work must be carried out to ensure all the cameras are in good
condition all the time. While performing the maintenance work, all the safety measure should
have followed at the work place for the safety of equipment and the person working at site.

Frequency of
maintenance work.
Sl. Preventive maintenance work Remarks
No.
6 months 1 year

Inspect cables and connectors between pole

and mounting base for abrasions, crake and
1 
deterioration.

Inspect camera pole for any crake, mechanical

damage and corrosion.
2 

3 Clean camera enclosure glass plate and its lens.

4 Clean the cameras (External) along with

tightening of its nuts & bolts. 

5 Remove dirt, moistures and any other foreign

substances form inside and outside of camera.


6 Confirm the operation of camera enclosure fan

and heater.


7 Verify the operation of camera pan, tilt and

zoom form control room operator. Ensure any

objects do not interfere with camera moments.

8 Blowing/dusting of CCTV server PC, Network

video recorder, NVR penal and its switches.


Table 16.1:Inspection plan for IP Camera

 SECTION B:

MAINTENANCE MANUAL CHAPTER 17: HEATING, AIR CONDITIONING

CHAPTER 17 & VENTILATION SYSTEM (HVAC)

17.1 Maintenance schedule

Frequency of
maintenance work.
Sl. No. Preventive maintenance work Remarks

½ year 1 year

Cleaning of outer cover of all the ventilating

system along with tightening of its base &
1 
frame nuts & bolts.

2 Checking tightness of motor power cable nuts


& bolts.

3 Cleaning & inspection of control circuit and its


control panel.

4 Measure the IR value of motors for future

reference and record.


Table 17.1:Inspection schedule for HVAC

 SECTION B:

MAINTENANCE MANUAL CHAPTER 18: DC SUPPLY SYSTEM

CHAPTER 18

18.1 Technical details of the 110V DC, 440AH FLOAT CUM BOOST Battery Charger

We have two battery banks inside the Powerhouse Cavern and another at the Control Building.
All the ratings are same and the technical details are given below:

Nominal AC Input

Main AC Supply : 3Ф, 415VAC @50Hz, 4 Wire System

Battery Details

No. of Cells : 55

AH Capacity : 440 AH

Each Cell : 2V Nominal

Make : Exide Industries Limited

Boost Charging Current : 66 A DC

Trickle Charging Current : 2000mA-6000mA

Battery Charger Details

Type : Float Cum Boost Charger

DC Output : 132.0 VDC, 185 A Maximum

Float Mode : 123.7 VDC Maximum

Boost Mode : 132.0 VDC Maximum

Cubicle : Front & Rear Access, Made from 2.03 mm CRCA

Dimension : 2000 X 1200 X 700 mm (H x L x W)

Paint : Powder Coating, Siemens Grey RAL: 7032

Construction : Floor Mounting

Cable Entry : Bottom only

DC Control Voltage : 24.0 V derived from DC to DC converter for Protection

 Cards (E7, Fuse failure Cards E4, E5, E6, E9, E10, Earth
Leakage card E8) & Digital meters and DC Transducers
power supply

AC Control Voltage : 415V AC Input for power Contactor, Auxiliary Contactor.

: 16V AC derived from 415/16V Transformer M7 for AC U/V

sensing for protection card.

: 230.0V AC for internal lighting, heater and 3 pin socket.

18.2 General Features

Following are the general features of the Battery Charger. These are provided in the battery
charger to make it sturdy and reliable DC source with necessary protections for ease of operation
and maintenance.
1. The charger is protected on the AC & DC side by SFU.
2. RC Surge suppressors protect diode and SCRs against line surges.
3. In the event of AC power failure, the DC emergency contactor gets energized and
connects the totally battery bank across the load and maintains load supply.
4. The 80 % battery tap is permanently connected to the load to maintain DC continuity to
the load even during the period when DC contactor energizes.
5. DC current limit is provided to protect charger against DC Overload.
6. Heavy filters are provided after rectification to provide almost ripple free DC.
7. SCR controlled Boost chargers constant current charging of batteries should be carried
out.

18.3 Charging Working Philosophy

The rectified output is obtained from Three-phase controlled rectifier bridge consisting of six
SCRs with individual RC networks across each device. Separate surge suppressor is provided
before the bridge to protect the rectifier against voltage surges.
Phase angle controlled rectification is the working principle of the Charger. SCR is a three-
terminal device, namely Anode, Cathode and Gate. Phase angle control pulses are applied
between Cathode and Gate. Depending on the position of pulse the SCR conducts and thereby
the magnitude of DC
voltage is controlled. A minimum current equal to latching current should flow through SCR to
retain it in conduction so the latching resistor is provided. The SCR will not conduct till the gate
pulse is applied.
As its name signifies charger is designed to operate in either Float or Boost mode depending on
the requirement of the system. During Float mode operation of charger besides delivering to the
DC load of the DCDB, it is used to trickle charge the battery bank. Trickle charging of battery is
important to keep battery in live & healthy condition. Whereas Boost mode is to be used when
batteries are deeply discharged, and trickle charging is not sufficient to bring battery bank to the
fully charged condition.
Boost mode of the charger is constant current i.e. rated regulated current is maintained across
battery terminals and depending upon the state of the battery voltage will build up gradually
once the batteries set voltage reaches 132.0 V DC. Batteries have reached fully charged state,
boost charging of batteries are terminated and charger switches to Float mode or operation
which is constant voltage mode, and is set at 123.7 V DC which calculates to 2.25 V/Cell equivalent
to trickle charging voltage of the battery. To prevent excess overload, regulator module is
provided with current limit feature. This feature becomes essential part of the system as it
provides voltage drooping effect if current drawn is beyond the factory set limit to safeguard
charger components. Moreover, to prevent any overloading, overload relays are provided on the
AC side and thus prevents from damaging main transformers.
System provides other features like automatic changeover from Boost mode to float mode once
battery is fully charged. It is important as overcharging of batteries might damage them and
reduce its life.

18.4 Preventive Maintenance

The following checks should be carried out every month and recorded for future references. Any
defect found should be noted and attended.
1. Measure the Voltage of all the 55 cells of all the chargers. If the cells are not healthy,
replace the defective cell.
2. Check the charging voltage and current of station battery.

18.5 Annual Maintenance

1. Visual Inspection of all equipment for dirt deposits and burns.

2. Check all cable terminals for any loose connection.
3. Check that all the components mounted in the charger cubicle, on mounting plates fixed
using proper screw/ nuts and bolts.
4. Check the indications and indicating lamps.
5. Measure and record important readings if plausible.
6. Check whether all the cards and components inside the cubicle are in good condition or
not.
7. Check the physical condition of all the cells and clean.

18.6 Troubleshooting

The troubleshooting of the problems with the DC System is shown in Annexure M2

 ANNEXURE
SECTION B: MAINTENANCE MANUAL

(MAINTENANCE MANUAL)
 SECTION B:

MAINTENANCE MANUAL Annexure M 1: Troubleshooting of Diversion Weir

ANNEXURE M 1 and Desilter Equipment

1.1 Intake gate

1.1.1 Malfunctions related toIntake Gate

The type of malfunctions and remedial measures for Weir Intake gate is given below:

Type of malfunction Remedial action

Loose bolts are detected Tight the bolt/nut. Observe the fastening torque in
accordance with the relevant drawing/data sheet

Monitoring instruments are faulty Check power supply (if any), check measuring circuit,
(electrically) replace instrument

Monitoring instruments are faulty Check actuation mechanism, check hydraulic pressure (if
(mechanically) any), replace instrument

Hydraulic filters are contaminated Replace the filter element. Observe isolation instructions!

Silica gel air filters are saturated Reactivate silica gel by heating (130°C).

Valves are leaking Check if valves are fully closed. Replace sealing if required.

Gate servomotors are leaking For replacing the seals please contact ANDRITZ Hydro

Filling volume of hydraulic power Check for leakages, refill oil

unit is too low

Filling volume of hydraulic power Check for water in the reservoir, drain oil
unit is too high

Hydraulic piping is leaking Try too tight the leaking fitting WITH PRESSURELESS
SYSTEM without any increased effort. If the fitting is still
leaking replace the sealing ring (if any) or replace the
cutting ring (if any)

Hydraulic oil is contaminated by Entire oil system has to be drained and cleaned (all parts).
water Oil filling has to be treated or replaced

Hydraulic oil is worn Replace the entire oil filling

Table 1.1:Malfunction and remedial measures related to Intake gate

1.1.2 Alarms related to Intake Gate

All alarms are indicated at the touch screen panel –A02 on the local control cubicle with clear text
provided with time stamp. All alarms are latched and is given below:

Alarms Remedial actions

Common Alarms

Common - Phase Sequence or AC Failure  Check power supply at all 3 phases

 Check supply voltage of power supply
 Check motor circuit breaker –Q06

Common - 400V Main Systems AC earth  Check the main supply

leakage

Common - 230V Auxiliary Systems AC Failure –  Check the motor space heaters –E01 and –
F02 E02 for short circuits

Common - 230V Auxiliary Systems AC Failure –  Check the equipment for short circuits
F04/-F05/-F06

Common - 24VDC Control voltage failure –F11/-  Check the appertaining equipment for
F12/-F13 short circuits
 Check the appertaining 24VDC equipment
for overload

Common - 24VDC Valve supply voltage failure  Check the appertaining equipment for
–F14 short circuits
 Check the appertaining 24VDC equipment
for overload

Common - Headwater Level Sensor Failure  Check the level sensor

 Check the cabling of level sensor
 Replace the level sensor

Alarms related to Intake Gate

Intake - Motor no.1 overload  Check the equipment for short circuits
 Check the electric motor

Intake - Motor no.2 overload  Check the equipment for short circuits
 Check the electric motor

Intake - Motor no.1 not in AUTO mode  Check position of selector switch –S11

Intake - Motor no.2 not in AUTO mode  Check position of selector switch –S12
Intake - Gate not in REMOTE mode  Check position of selector switch –S13

Intake - Oil level low  Check the hydraulic system for leakages
 Refill oil

Intake - Oil level too low  Check the hydraulic system for leakages
 Refill oil

Intake – Return line filter clogged  Replace the filter element

Intake - Pump pressure low – motor pump  Check if the hydraulic system for rupture
no.1 of a pipe
 Check if the hydraulic system for rupture
of a hydraulic hose
 Check function of pressure relief valve
AA301 (incl. pilot operation valve AA101-
Y01)

Intake - Pump pressure low – motor pump  Check if the hydraulic system for rupture
no.2 of a pipe
 Check if the hydraulic system for rupture
of a hydraulic hose
 Check function of pressure relief valve
AA301 (incl. pilot operation valve AA101-
Y01)

Intake - Operation pressure low – pipe rupture  Check if the hydraulic system for rupture
of a pipe
 Check if the hydraulic system for rupture
of a hydraulic hose

Intake - Opening pressure high  Check if the gate is stuck physically

 Check if one or more shut off valve is
closed by error

Intake - Closing pressure high  Check if the gate is stuck physically

 Check if one or more shut off valve is
closed by error

Intake – Unbalanced operation  Check if the gate is physically unbalanced

Intake - Pressure Transducer CP001-B01 Failure  Check the pressure sensor

 Check the cabling of pressure sensor
 Replace the pressure sensor

Intake - Pressure Transducer CP011-B01 Failure  Check the pressure sensor

  Check the cabling of pressure sensor
 Replace the pressure sensor

Intake - Pressure Transducer CP012-B01 Failure  Check the pressure sensor

 Check the cabling of pressure sensor
 Replace the pressure sensor

Intake - Position Transducer CG010-B01 Failure  Check the pressure sensor

 Check the cabling of pressure sensor
 Replace the pressure sensor

Intake - Position Transducer CG020-B01 Failure  Check the pressure sensor

 Check the cabling of pressure sensor
 Replace the pressure sensor

Intake - Level Sensor after Trash rack 1 Failure  Check the pressure sensor
 Check the cabling of pressure sensor
 Replace the pressure sensor

Intake - Level Sensor after Trashrack 2 Failure  Check the pressure sensor
 Check the cabling of pressure sensor
 Replace the pressure sensor

Intake - Trashrack 1 head loss Alarm  Clean trash rack

 Check if TRCM is in AUTO mode

Intake - Trashrack 2 head loss Alarm  Clean trash rack

 Check if TRCM is in AUTO mode

Intake – Crack open limit switch failure  Check the limit switch CG002-S01

Alarms related to Trash Rack Cleaning Machine

TRCM – Warning  Check TRCM Manual

TRCM- Alarm  Check TRCM Manual

Table 1.2: Alarms related to Intake gate

1.2 Weir Gates

All alarms are indicated at the touch screen panel –A02 on the local control cubicle with clear text
provided with time stamp.

Alarms and Warnings Remedial actions

Weir - Motor no.1 overload
Weir - Motor no.2 overload
Weir - Motor no.1 not in AUTO mode
Weir - Motor no.2 not in AUTO mode
Weir - 230V Auxiliary Systems AC Failure –F03
Weir - 230V RIO Auxiliary Systems AC Failure – 
F07
Weir - 24VDC RIO supply voltage failure –F15
Weir RIO - 24VDC Control voltage failure – 
F111/-F112/-F113
Weir RIO - 230V Auxiliary Systems AC Failure – 
F101
Weir - Oil Level Low
Weir - Oil Level Too Low
Weir – Return line filter no.1 clogged
Weir – Return line filter no.2 clogged
Weir - Pump pressure low – motor pump no.1
 Check the equipment for short circuits
 Check the electric motor
 Check the equipment for short circuits
 Check the electric motor
 Check position of selector switch –S21
 Check position of selector switch –S22
 Check the motor space heaters –E01 and –
E02 for short circuits
Check the equipment for short circuits
 Check the appertaining equipment for
short circuits
 Check the appertaining 24VDC equipment
for overload
Check the appertaining equipment for
short circuits
 Check the appertaining 24VDC equipment
for overload
Check the equipment for short circuits
 Check the hydraulic system for leakages
 Refill oil
 Check the hydraulic system for leakages
 Refill oil
 Replace the filter element
 Replace the filter element
 Check if the hydraulic system for rupture
of a pipe
 Check if the hydraulic system for rupture
of a hydraulic hose
 Check function of pressure relief valve
AA301 (incl. pilot operation valve AA101-
Y01)
Weir - Pump pressure low – motor pump no.2  Check if the hydraulic system for rupture
of a pipe
 Check if the hydraulic system for rupture
of a hydraulic hose
 Check function of pressure relief valve
AA301 (incl. pilot operation valve AA101-
Y01)

Weir - Pressure Transducer CP001-B01 Failure  Check the pressure sensor

 Check the cabling of pressure sensor
 Replace the pressure sensor

Radial Gate 1 - 24VDC Valve supply voltage  Check the appertaining equipment for
failure –F114 short circuits
 Check the appertaining 24VDC equipment
for overload

Radial Gate 1 - Operation pressure low – pipe  Check if the hydraulic system for rupture
rupture of a pipe
 Check if the hydraulic system for rupture
of a hydraulic hose

Radial Gate 1 - Opening pressure high  Check if the gate is stuck physically
 Check if one or more shut off valve is
closed by error

Radial Gate 1 - Closing pressure low  Check if the gate is stuck physically
 Check if one or more shut off valve is
closed by error

Radial Gate 1 - Pressure Transducer CP012-B01  Check the pressure sensor

Failure  Check the cabling of pressure sensor
 Replace the pressure sensor

Radial Gate 1 - Position Transducer CG001-B01  Check the position transducer

Failure  Check the cabling of position transducer
 Replace the position transducer

Flap Gate 1 - 24VDC Valve supply voltage  Check the appertaining equipment for
failure –F114 short circuits
 Check the appertaining 24VDC equipment
for overload

Flap Gate 1 - Operation pressure low – pipe  Check if the hydraulic system for rupture
rupture of a pipe
  Check if the hydraulic system for rupture
of a hydraulic hose

Flap Gate 1 - Closing pressure high  Check if the gate is stuck physically
 Check if one or more shut off valve is
closed by error

Flap Gate 1 - Opening pressure low  Check if the gate is stuck physically
 Check if one or more shut off valve is
closed by error

Flap Gate 1 - Pressure Transducer CP011-B01  Check the pressure sensor

Failure  Check the cabling of pressure sensor
 Replace the pressure sensor

Flap Gate 1 - Position Transducer CG001-B01  Check the position transducer

Failure  Check the cabling of position transducer
 Replace the position transducer

Radial Gate 2 - 24VDC Valve supply voltage  Check the appertaining equipment for
failure –F115 short circuits
 Check the appertaining 24VDC equipment
for overload

Radial Gate 2 - Operation pressure low – pipe  Check if the hydraulic system for rupture
rupture of a pipe
 Check if the hydraulic system for rupture
of a hydraulic hose

Radial Gate 2 - Opening pressure high  Check if the gate is stuck physically
 Check if one or more shut off valve is
closed by error

Radial Gate 2 - Closing pressure low  Check if the gate is stuck physically
 Check if one or more shut off valve is
closed by error

Radial Gate 2 - Pressure Transducer CP012-B01  Check the pressure sensor

Failure  Check the cabling of pressure sensor
 Replace the pressure sensor

Radial Gate 2 - Position Transducer CG001-B01  Check the position transducer

Failure  Check the cabling of position transducer
 Replace the position transducer
Flap Gate 2 - 24VDC Valve supply voltage  Check the appertaining equipment for
failure –F115 short circuits
 Check the appertaining 24VDC equipment
for overload

Flap Gate 2 - Operation pressure low – pipe  Check if the hydraulic system for rupture
rupture of a pipe
 Check if the hydraulic system for rupture
of a hydraulic hose

Flap Gate 2 - Closing pressure high  Check if the gate is stuck physically
 Check if one or more shut off valve is
closed by error

Flap Gate 2 - Opening pressure low  Check if the gate is stuck physically
 Check if one or more shut off valve is
closed by error

Flap Gate 2 - Pressure Transducer CP011-B01  Check the pressure sensor

Failure  Check the cabling of pressure sensor
 Replace the pressure sensor

Flap Gate 2 - Position Transducer CG001-B01  Check the position transducer

Failure  Check the cabling of position transducer
 Replace the position transducer

Table 1.3:Alarms related to Weir Gates

1.3 Trash Rack Cleaning Machine

Possible Malfunction related to Trash Rack Cleaning Machine are given below:

Malfunction Type Cause of Malfunction Troubleshooting

emergency stop operator Additional information for Unlatch by turning. See

mistake emergency off [0010]
building [0] emergency off: emergency
offleft side of the building
active

fault profinet connection [3] The Profinet connection is Check the radio
module and the rest of the
broken up
Profinet lines

voltage control 400VAC [8] El. provisions mistake, phase Find mistake, acknowledge
after troubleshooting
cancelled, security
circuit breaker control
voltage [9]
emergency stop [10]
emergency pull cord [13]
emergency stop control unit
[15]
circuit breaker hydraulic
pump [33]
hydraulic pressure min [34]
circuit breaker fan [35]
circuit breaker oil heating [37]
warning hydraulic filter
clogged [169]
hydraulic oil level fault [41]
hydraulic oil temp. max [43]
positioning fault drive [58]
linear encoder driving fault
Control fuse fail
Emergency off relay deleted.
Isthe case when:One of the
emergency off switches is
activated, Tensionon
Additional information f.
emergency off: rip cord in
drive direction right released
Additional information f.
emergency off: emergency off
control pendant active
Motor overloaded or defect
Pump defect, leakage, hose
Break
Motor overloaded or defect
Heater defect
Drop pressure too big over
Filter
Hydraulic switches off due to
oil deficiency
Oil temperature > approx.
70°C, Cooler could be defect
or contaminated
The positioning is failed
Travel path sensors report
Find mistake, acknowledge
after troubleshooting
Unlock possible activation of
the emergency off switch, set
back with the blue button in
the cabinet or on the switch
gear cabinet
Rip cord line unlocked using
buttons on the casing. See
mistake emergency off [0010]
Unlocked with turning. See
mistake emergency off [0010]
Check to see if the control
pendant is pulled in.
Check pump, turn back on
Check pump (pressurization),
check line
Check exhauster, turn back
on
Check heater
Change filter cartridge
Check system for leakage,
refill oil
Check cooler, clean, let cool
Check the chassis, rails and
linear measuring system
Control if the read head calls
[59]
time fault driving [60]
frequency converter driving
[61]
time fault leak oil control [82]
angle measuring system main
arm fault [88]
angle measuring system flex
arm fault [104]
analogue output proportional
valves arm [107]
3 Cleaninfaults Pos 1 [120]
implausible value or SPS
reports encoder mistake or
mistake of the SPS entry.
time fault driving [60]
Many possible causes
The leakage oil movement
takes too long. Defect in the
arm travel (valve, etc.)
Angle encoder reports
implausible value or SPS
reports encoder mistake or
mistake of the SPS entry
Angle encoder reports
implausible value or SPS
reports encoder mistake or
mistake of the SPS entry
SPS reports mistake on the
analog output. Output defect,
not correctly switched, short
or open
This cleaning of panel 1 is
broken up 3 times through
time exceedances of the
cleaning cycle. The panel will
not drive for further cleaning
is set correctly over the code
rail. Possible service call.
Check travel drive using
manual and local automatic
operation, restart automatic
cycle and observe
Read malfunction message
(number) on the FU- display
and read the meaning in the
FU-documentation
Check arm movement using
manual and local automatic
operation, start automatic
cycle and observe
Can only be tested through
experimental exchanges of
the
encoder. Possible service call
Can only be tested through
experimental exchanges of
the
encoder. Possible service call
Check output signal, cable
and
connected FU-entry
Find the cause locally (too
big/heavy/unwieldy cleaning
debris on the rake). Remove
cleaning debris manually or
with another method. Check
the panel with local
automatic operation of free
 procedures.
Table 1.4:Alarms related to Trash Rack Cleaning Machine
1.4 Desilter Gates
Possible malfunction related to Desilter Inlet, Outlet and Flushing Gates are given below:
Malfunction Type Cause of Malfunction
Desilter Downstream
mcb hydraulic pump DES [88] Motor overloaded or defect
Motor overload switch defect
mcb backup pump DES [89] Motor overloaded or defect
Motor overload switch defect
system pressure min Desilter Cable break, hydraulic pump
[94]
or valve defect
24V circuit breaker fall [104] Circuit breaker fall
emergency stop [106] Emergency power-off button
pressed
Desilter 1 Downstream
position measuring system Analog input reports not
outlet gate 1 fault [120] plausible value, senor or
analog input defect.
both end switches outlet gate Limit switch for the end
1[121]
position open/close defect,
manipulated or occupied
through a foreign material.
overload lift outlet gate 1 Pressure switch reports
clearance.
Troubleshooting
Check components, turn back
on
Check components, turn back
on
Check system for cable
break/leakage, check valve
with manual operation
Search mistake, turn back on
after troubleshooting and
acknowledge
Assure that the cause of the
emergency power-off has
beeneliminated, release the
emergency power-off button,
acknowledge
Check encoder signal, entry
card.
Check limit switch, repair, set,
remove foreign material or
replace it.
Check gate movement in
[122] overload lifting. Possible manual operation, possible
inhibited floating debris,
inhibited floating debris.
check possible valve or
pressure switch, set, replace.

overload lower outlet gate 1
[123]
Pressure switch reports
overload lowering. Possible
inhibited floating debris.
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or
pressure switch, set, replace.

time overflow lift outlet gate
1[124]
Lift gate (automatic
operation)does not function,
gate isblocked mechanically,
valvesnags or defect. Limit
switchoccupied or defect.
Check gate movement in
manual operation, possible
inhibited floating debris,
possible valve or limit switch
check, set, replace.

time overflow lower outlet
gate 1 [125]
Lower gate (automatic
operation) does not function,
gate blocked mechanically,
valve snags or defect.
Check gate movement in
manual operation, possible
inhibited floating debris,
possible valve or limit switch
check, set, replace.

both end switches flushing
gate 1 [113]
Limit switch for the end
position open/close defect,
manipulated or occupied with
aforeign material.
Check limit switch, repair, set,
remove foreign material or
replace.

overload lift flushing gate 1
[114]
Pressure switch reports Check gate movement in
overload lifting. Possible manual operation, possible
inhibited floating debris,
inhibited floating debris
check possible valve or
pressure switch, set, replace

overload lower flushing gate 1
[115]
Pressure switch reports
overload lowering. Possible
inhibited floating debris
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or
pressure switch, set, replace.

time overflow lift flushing
gate1 [116]
Gate lowering (automatic
operation) does not function,
gate blocked mechanically,
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or limit
 valve snags or defect, limit
switch occupied or defect.
Desilter 2 Downstream
position measuring system Analog input reports not
outlet gate 2 fault [136] plausible value, sensor or
analog input defect
both end switches outlet gate Limit switch for the end
2[137]
position open/close defect,
manipulated or occupied by a
foreign material.
overload lift outlet gate 2 Lift gate (automatic
[138] operation)does not function,
gate blockedmechanically,
valve snags ordefect, limit
switch occupied ordefect.
overload lower outlet gate 2 Pressure switch reports
[139] overload lowering. Possible
inhibited floating material.
time overflow lift outlet gate Lift gate (automatic
2[140] operation)does not function,
gate blockedmechanically,
valve snags ordefect, limit
switch occupied ordefect.
time overflow lower outlet Lower gate (automatic
gate 2 [141] operation) does not function,
gate blocked mechanically,
valve snags or defect, limit
switch occupied or defect.
both end switches flushing Limit switch for the end
gate 2 [129] position open/close defect,
switch, set, replace.
Check encoder signal, entry
card
Check limit switch, repair, set,
remove foreign material or
replace.
Check gate movement in
manual operation, possible
inhibited floating material,
check possible valve or
limit switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating material,
check possible valve or
pressure switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating material,
check possible valve or
limit switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating material,
check possible valve or
limit switch, set, replace.
Check limit switch repair, set,
remove foreign material or

overload lift flushing gate 2
[130]
overload lower flushing gate
2[131]
time overflow lift flushing
gate2 [132]
time overflow lower flushing
gate 2 [133]
Desilter 3 Downstream
position measuring system
outlet gate 3 fault [152]
both end switches outlet gate Limit switch for the end
3[153]
position open/close defect,
overload lift outlet gate 3
[154]
manipulated or occupied by a
foreign material.
Pressure switch reports
overload lifting. Possible
inhibited floating material.
Limit switch reports overload
lowering. Possible inhibited
floating material.
Lift gate (automatic
operation)does not function,
gate blockedmechanically,
valve snags ordefect, limit
switch occupied ordefect.
Lower gate (automatic
operation) does not function,
gate blocked mechanically,
valve snags or defect, limit
switch occupied or defect.
Analog input reports not
plausible value, sensor or
analog input defect.
manipulated or occupied by a
foreign material.
Lift gate (automatic Check gate movement in
operation)does not function, manual operation, possible
gate blockedmechanically, inhibited floating material,
replace.
Check gate movement in
manual operation, possible
inhibited floating material,
check possible valve or
pressure switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating material,
check possible valve or
limit switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating material,
check possible valve or
limit switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating material,
check possible valve or
limit switch, set, replace.
Check encoder signal, entry
card.
Check limit switch repair, set,
remove foreign material or
replace.

overload lower outlet gate 3
[155]
time overflow lift outlet gate
3[156]
time overflow lower outlet
gate 3 [157]
both end switches flushing
gate 3 [145]
overload lift flushing gate 3
[146]
overload lower flushing gate
3[147]
time overflow lift flushing
gate3 [148]
valve snags ordefect, limit
switch occupied ordefect.
Pressure switch reports
overload lowering. possible
inhibited floating debris.
Lift gate (automatic
operation)does not function,
gate blockedmechanically,
valve snags ordefect, limit
switch occupied ordefect.
Lower gate (automatic
operation) does not function,
gate blocked mechanically,
valve snags or defect, limit
switch occupied or defect.
Limit switch for the end
position open/ close defect,
manipulated or occupied with
foreign material.
Pressure switch reports
overload lifting. possible
inhibited floating debris.
Pressure switch reports
overload lowering. possible
inhibited floating debris.
Lower gate (automatic
operation) does not function,
gate blocked mechanically,
check possible valve or
limit switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or
pressure switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or limit
switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or limit
switch, set, replace.
Limit switch check, repair,
set,foreign material removes
or replace.
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or
pressure switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or
pressure switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or limit

Desilter Downstream Warnings
oil filter glogged DES [186]
Desilter Upstream
mcb hydraulic pump DES Inlet
[8]
mcb backup pump DES Inlet
[9]
mcb oil cooler DES Inlet [10]
oil level min fault [12]
system pressure min [14]
oil temp max fault [15]
24V circuit breaker fall [24]
Desilter 1 Upstream
time overflow raise inlet gate
1[40]
time overflow lower inlet
gate1 [41]
valve snags or defect, limit
switch occupied or defect.
Oil filter contaminated
Motor overloaded or defect
Motor overload switch defect
Motor overload or defect
Motor overload switch defect
Motor overload or defect
Motor overload switch defect
Hydraulic turns of because of
lack of oil
Cable break, hydraulic pump
or valve defect
Hydraulic turns off because Let it cool down
oiltemperature is > approx.
70°C
Circuit breaker fall
Lift gate (automatic
operation)does not function,
gate blockedmechanically,
valve snags ordefect, limit
switch occupied ordefect.
Lower gate (automatic
operation) does not function,
switch, set, replace.
Change oil filter
Check components, turn back
on
Check components, turn back
on
Check components, turn back
on
Check system for leakage
check, refill oil.
Check system for cable
break/leakage, check valves
with manual operation.
Find malfunction, after
troubleshooting turn back on
and acknowledge
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or limit
switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating debris,

both end switches raise /
lower1 [42]
overload raise inlet gate 1 [43]
overload raise inlet gate 1 [43]
overload lower inlet gate 1
[44]
fault position measuring
system inlet gate 1 [47]
Desilter 2 Upstream
time overflow raise inlet gate
2[56]
time overflow lower inlet
gate2 [57]
gate blocked mechanically,
valve snags or defect, limit
switch occupied or defect.
Limit switch for the end
position open/ close defect,
manipulated or occupied with
foreign material.
Limit switch for the end
position open/ close defect,
manipulated or occupied with
foreign material.
Pressure switch reports
overload lifting. possible
inhibited floating debris
Pressure switch reports
overload lowering. possible
inhibited floating debris
Analog input reports not
plausible value, sensor or
analog input defect
Lift gate (automatic
operation)does not function,
gate blockedmechanically,
valve snags ordefect, limit
switch occupied ordefect.
Lower gate (automatic
operation) does not function,
gate blocked mechanically,
check possible valve or limit
switch, set, replace.
Limit switch check, repair,
set,remove foreign material
or replace.
Limit switch check, repair,
set,remove foreign material
or replace.
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or
pressure switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or
pressure switch, set, replace.
Check encoder signal, entry
card
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or limit
switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or limit

both end switches raise /
lower2 [58]
overload raise inlet gate 2
[59]
overload lower inlet gate 2
[60]
fault position measuring
system inlet gate 2 [63]
Desilter 3 Upstream
time overflow lower inlet
gate3 [73]
both end switches raise /
lower3 [74]
overload raise inlet gate 3 Pressure switch reports
[75]
overload lifting. possible
valve snags or defect, limit
switch occupied or defect.
Limit switch for the end
position open/ close defect,
manipulated or occupied with
foreign material.
Pressure switch reports
overload lifting. possible
inhibited floating debris
Pressure switch reports
overload lowering. possible
inhibited floating debris
Analog input reports not
plausible value, sensor or
analog input defect
Lower gate (automatic
operation) does not function,
gate blocked mechanically,
valve snags or defect, limit
switch occupied or defect.
Limit switch for the end
position open/ close defect,
manipulated or occupied with
foreign material.
inhibited floating debris
switch, set, replace.
Check limit switch, repair, set,
remove foreign material or
replace.
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or
pressure switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or
pressure switch, set, replace.
Check encoder signal, entry
card
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or limit
switch, set, replace.
Check limit switch, repair, set,
foreign material removes or
replace.
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or

overload lower inlet gate 3
[76]
fault position measuring
system inlet gate 3 [79]
Table 11.5:Alarms related to Desilter gates
1.5 Screen Cleaning Machines
The possible malfunctions related to Screen Cleaning Machine and its remedial measures are
shown below:
Malfunction Type
mcb hydraulic pump SCM [8]
mcb backup pump SCM [9]
mcb oil cooler SCM [10]
oil level min fault [12]
system pressure min SCM [14]
system pressure min SCM [14]
system pressure min SCM [14]
Pressure switch reports
overload lowering. possible
inhibited floating debris
Analog input reports not
plausible value, sensor or
analog input defect
Cause of Malfunction
Motor overloaded or defect
Motor overload switch defect
Motor overloaded or defect
Motor overload switch defect
Motor overloaded or defect
Motor overload switch defect
Hydraulic turns off due to lack
of oil
Hydraulic turns off due to lack
of oil
Hydraulic turns off due to lack
of oil
Line break, hydraulic pump or
valve defect
pressure switch, set, replace.
Check gate movement in
manual operation, possible
inhibited floating debris,
check possible valve or
pressure switch, set, replace.
Check encoder signal, entry
card
Troubleshooting
Check components, turn back
on
Check components, turn back
on
Check components, turn back
on
Check system for leakage,
refill oil
Check system for leakage,
refill oil
Check system for leakage,
refill oil
Check system for line break /
leakage, valve through
manual operation
oil temp max fault [15] Hydraulic turns off due to oil
temperature > approx. 70°C
24V circuit breaker fall [24] Control fuse fall
emergency stop [26] Emergency shutoff button
pressed
time overflow raise rake 1 Lift lever (automatic
[40] operation)does not function,
leverblocked mechanically,
valvesnags or defect, limit
switchoccupied or defect
time overflow lower rake 1 Lower lever (automatic
[41] operation) does not function,
lever blocked mechanically,
valve snags or defect, limit
switch occupied or defect
both endswitches raise / Gear cam switch for the end
lower1 [42]
position up/down defect
time overflow rake swivel in 1 Lever close (automatic
[44] operation) does not function,
lever blocked mechanically,
valve snags or defect, limit
switch occupied or defect
Let cool
Find mistake, turn back on
after troubleshooting and
acknowledge
Be sure that the reason for
the
emergency off has been
eliminated, unlock emergency
shutoff button, acknowledge
Check lever movements in
the manual operation,
possible inhibited cleaning
debris or remove, possible
valve or limit switch, set,
replace
Check lever movements in
themanual operation,
possible inhibited cleaning
debris or remove, possible
valve or limit switch, set,
replace
Check gear cam switch, repair
or replace
Check lever movements in
themanual operation,
possible inhibited cleaning
debris or remove, possible
valve or limit switch, set,
replace
time overflow rake swivel out
1 [45]
both end switches swivel in /
out 1 [46]
x times slake line during
lower1 [32]
slake line during raise (abort)
1[33]
x times overload 1 [34]
overload with swiveled out
rake 1 [35]
time overflow start hydraulic The hydraulic takes too long
1[38] toturn on
time overflow leak oil control
1 [39]
Screen Cleaning Machine 2
Lever open (automatic Check lever movements in
themanual operation,
operation) does not function,
possible inhibited cleaning
lever blocked mechanically, debris or remove, possible
valve snags or defect, limit valve or limit switch, set,
replace
switch occupied or defect
Limit switch for the end Check limit switch, repair, set,
positions open/close defect, remove or replace foreign
material.
manipulated or occupied by
foreign material
Cleaning lever could not be Check lever in the manual
operation or other large
lowered 3 times in a row,
parts, free up, remove, rope
slackrope switch defect or
and slack rope switch
manipulated
Rope ripped, slack rope Check rope and slack rope
switchdefect or manipulated. switch
Cleaning cycle interrupted 3 Free up lever in the manual
times in a row due to operation, remove other
pressureswitch overload, large parts
lever blockedmechanically
Overload occurs by open Free up lever in the manual
lever, lever blocked
operation, remove other
mechanically
large parts
Can only appear with another
mistake of the hydraulic
The drive in the ground Check lever movements in
themanual operation,
position (automatic
possible inhibited cleaning
operation)does not function,
debris or remove, possible
leverblocked mechanically,
valve or limit switch, set,
valvesnags or defect, limit
replace
switchoccupied or defect
time overflow raise rake 2
[56]
time overflow lower rake 2
[57]
both end switches raise /
lower2 [58]
time overflow rake swivel in 2
[60]
time overflow rake swivel out
2 [61]
both end switches swivel in /
out 2 [62]
x times slake line during
lower2 [48]
Lift lever (automatic
operation)does not function,
leverblocked mechanically,
valvesnags or defect, limit
switchoccupied or defect
Lower lever (automatic
operation) does not function,
lever blocked mechanically,
valve snags or defect, limit
switch occupied or defect
Gear cam switch for the end
position up/down defect
Lever close (automatic
operation) does not function,
lever blocked mechanically,
valve snags or defect, limit
switch occupied or defect
Lever open (automatic
operation) does not function,
lever blocked mechanically,
valve snags or defect, limit
switch occupied or defect
Limit switch for the end
positions open/close defect,
manipulated or occupied by
foreign material
Cleaning lever could not be
lowered 3 times in a row,
slackrope switch defect or
manipulated
Check lever movements in
themanual operation,
possible inhibited cleaning
debris or remove, possible
valve or limit switch, set,
replace
Check lever movements in
themanual operation,
possible inhibited cleaning
debris or remove, possible
valve or limit switch, set,
replace
Check gear cam switch, repair
or replace
Check lever movements in
themanual operation,
possible inhibited cleaning
debris or remove, possible
valve or limit switch, set,
replace
Check lever movements in
themanual operation,
possible inhibited cleaning
debris or remove, possible
valve or limit switch, set,
replace
Check limit switch, repair, set,
remove or replace foreign
material.
Check lever in the manual
operation or other large
parts, free up, remove, rope
and slack rope switch
slake line during raise (abort)
2[49]
x times overload 2 [50]
overload without swiveled
rake 2 [51]
time overflow start hydraulic The hydraulic takes too long
2[54] toturn on
time overflow leak oil control
2 [55]
Screen Cleaning Machine 3
time overflow raise rake 3
[72]
time overflow lower rake 3
[73]
both end switches raise /
lower3 [74]
Rope ripped, slack rope Check rope and slack rope
switchdefect or manipulated. switch
Cleaning cycle interrupted 3 Free up lever in the manual
times in a row due to operation, remove other
pressureswitch overload, large parts
lever blockedmechanically
Overload occurs by open Free up lever in the manual
lever,lever blocked
operation, remove other
mechanically
large parts
Can only appear with another
mistake of the hydraulic
The drive in the ground Check lever movements in
themanual operation,
position (automatic
possible inhibited cleaning
operation)does not function,
debris or remove, possible
leverblocked mechanically,
valve or limit switch, set,
valvesnags or defect, limit
replace
switchoccupied or defect
Lift lever (automatic Check lever movements in
operation)does not function, themanual operation,
leverblocked mechanically, possible inhibited cleaning
valvesnags or defect, limit debris or remove, possible
switchoccupied or defect valve or limit switch, set,
replace
Lower lever (automatic Check lever movements in
themanual operation,
operation) does not function,
possible inhibited cleaning
lever blocked mechanically, debris or remove, possible
valve snags or defect, limit valve or limit switch, set,
replace
switch occupied or defect
Gear cam switch for the end Check gear cam switch, repair
or replace
position up/down defect
time overflow rake swivel in 3
[76]
Lever close (automatic
operation) does not function,
lever blocked mechanically,
valve snags or defect, limit
switch occupied or defect
Check lever movements in
the
manual operation, possible
inhibited cleaning debris or
remove, possible valve or
limit switch, set, replace

time overflow rake swivel out
3 [77]
Lever open (automatic
operation) does not function,
lever blocked mechanically,
valve snags or defect, limit
switch occupied or defect
Check lever movements in
the
manual operation, possible
inhibited cleaning debris or
remove, possible valve or
limit switch, set, replace

both end switches swivel in /
out 3 [78]
Limit switch for the end
positions open/close defect,
manipulated or occupied by
foreign material
Check limit switch, repair, set,
remove or replace foreign
material.

x times slake line during
lower3 [64]
Cleaning lever could not be Check lever in the manual
operation or other large
lowered 3 times in a row,
parts, free up, remove, rope
slack
and slack rope switch
rope switch defect or
manipulated

slake line during raise (abort) Rope ripped, slack rope Check rope and slack rope
3[65] switchdefect or manipulated. switch

x times overload 3 [66] Cleaning cycle interrupted 3 Free up lever in the manual
times in a row due to operation, remove other
pressure large parts
switch overload, lever
blocked
mechanically

overload with swiveled out Overload occurs by open Free up lever in the manual
lever,lever blocked
rake 3 [67] operation, remove other
mechanically
large parts
time overflow start hydraulic The hydraulic takes too long
3[70] toturn on
time overflow leak oil control The drive in the ground
3 [71] Position (automatic
operation)does not function,
leverblocked mechanically,
valvesnags or defect, limit
switchoccupied or defect
Warnings
RCD safety switch fall [168] FI protective switch fall
possible ground connection
or overload
oil level min warning [169] Oil lever too low, possible
Leakage
oil filter glogged SCM [170] Oil filter contaminated
Table 11.6:Alarms related to Screen Cleaning Machines
Can only appear with another
mistake of the hydraulic
Check lever movements in
the
manual operation, possible
inhibited cleaning debris or
remove, possible valve or
limit switch, set, replace
Find mistake and turn back on
Refill oil, Check system for
sealing
Change oil filter
 SECTION B:

MAINTENANCE MANUAL

ANNEXURE M 2

Annexure M 2: Troubleshooting of DC System

These circuits are simple and extremely rugged in design as they consist of only passive
components. In case the charger does not deliver the rated voltage and or current it is required
to check the circuit as per the circuit diagram.
PLEASE ENSURE TO DISCONNECT THE BATTERIES AND LAOD WHILE CARRYING OUT FAULT-
FINDING PROCEDURE.
ONLY IF THE PERSONNEL IS CONVERSANT WITH THE SYSTEM SHOULD THE PROCEDURE BE
CONDUCTED WITH BATTERY AND LOAD CONDUCTED AS THIS MAY RESULT INTO SERIOUS
DAMAGE TO SELF, EQUIPMENT CONNECTED AS WELL AS CHARGER.
Testing procedure of the charger are given below:
1. Physical Testing.
2. Electrical Testing.

2.1 Physical Testing:

Physical Testing of the charger has to be carried to ensure that all the components mounted in
the cubicle as well as on the door of the cubicle are in the healthy condition. Following points
must be followed for the physical check:
1. Turn off the incoming supply i.e. 3 Ф, 415 V, 50 Hz. And remove battery connection +ve, -
ve and 80 % from the terminals.
Caution:
Physical testing of the charger components should not be done under live supply condition. It is
dangerous and accident prone.
 2. Check all the connection for any loose connections this can be done by pulling gently
each wire and after checking this tighten each connection.
3. Check that all the components mounted in the charger cubicle, on the mounting plate is
firmly fixed using proper screw / Nuts and bolts. This was done at the factory but after
transportation, it becomes essential to check their tightness.
4. Each component of rectifier mounted on the top of the mounting plate can be verified
using multimeter.
As shown in the drawing, rectifier bridge consists of six thyristors and one freewheeling diode:
Checking Thyristor using multimeter
a) Anode.
b) Cathode.
c) Gate.
Resistance shown between 1 and 2 = Mega ohms.
Resistance shown between 2 and 3 = 20 to 50 ohms.
This test can be conducted by removing gate wires from the connection and ensuring that
component under test has no electrical connection. Checking diode using multimeter: (Diodes to
be isolated from bridge for this checking
a) Anode.
b) Cathode.
Multimeter used must have diode-checking mode

 When positive probe of multimeter is kept on heat sink and negative on cathode:
Multimeter shows = 0.545 to 0.745 => diode is healthy else diode is failed.
Multimeter shows = 0.000 => diode is faulty.

 When positive probe of multimeter is kept on cathode and negative on heat sink:
Multimeter shows = open indication => diode is unhealthy.
Multimeter shows = 0.000 => diode is faulty.
5. Putting multimeter in continuity mode can test continuity of fuses. This can be done by
removing fuse sockets and putting probes of multimeter across the fuse link and testing
continuity – if buzzing sound is heard from the multimeter than fuse is healthy else fuse
must be rated with similar rating and make.
6. DC / DC Converter is used for power supply of the protection module and it cannot be
tested in cold condition- test to check healthiness of this module will be discussed later.
7. Electronic cards cannot be tested under cold condition. Details for the testing of
electronic card is discussed later.
8. All the fuses can be tested as mentioned point 7.
9. For all the indicating meters, zeroing of the meter is very necessary in cold condition,
meters must indicate zero if not than meters must be calibrated.
10. Turning its knob and checking respective contacts can check all the control switches on
the front doors.
 11. MCBs and input isolation switch also can be tested in similar way by checking continuity.
After performing above-mentioned steps, one can ensure that charger is physically healthy and
can be powered up.

2.2 Electrical Testing:

Follow the Flow chart given below, all major and important checks have been listed. This
will help in troubleshooting as well as providing vital feedback to the service department
of the manufacturer in case it has to be referred to them.
2.2.1 Automatic Voltage Regulator (AVR): (ES-FWFCAVR-5106) (E2 & E3)

 Check the card for loose connections, dry solders and burnt components.
 Check Transformer Primary: 415 V, Secondary: 16-0-16 V power supply and16 V synchronizing
voltages at input terminals. Also,check availability of reference voltage at terminals.
 Check terminal voltages as per the table given below.

Sl. No. Terminal Description Voltage

1 1 R Phase SCR Cathode pulse Pulse

2 2 R Phase SCR Gate pulses Pulse

3 3 R Phase synchronizing signal 16 V AC

4 4 Y Phase SCR Cathode Pulse Pulse

5 5 Y Phase SCR Gate pulse Pulse

6 6 Y Phase synchronizing signal 16 V AC

7 7 B Phase SCR Cathode Pulse Pulse

8 8 B Phase SCR Gate pulse Pulse

9 9 B Phase synchronizing signal 16 V AC

10 10 R Phase Pulse Power Signal 16 V AC

11 11 Y Phase Pulse Power Signal 16 V AC

12 12 B Phase Pulse Power Signal 16 V AC

13 13 R’ Phase Pulse Power Signal 16 V AC

14 14 Y’ Phase Pulse Power Signal 16 V AC

15 15 B’ Phase Pulse Power Signal 16 V AC

 16 16 R’ Phase SCR Cathode pulse Pulse

17 17 R’ Phase SCR Gate pulses Pulse

18 18 R’ Phase synchronizing signal 16 V AC

19 19 Y’ Phase SCR Cathode Pulse Pulse

20 20 Y’ Phase SCR Gate pulse Pulse

21 21 Y’ Phase synchronizing signal 16 V AC

22 22 B’ Phase SCR Cathode Pulse Pulse

23 23 B’ Phase SCR Gate pulse Pulse

24 24 B’ Phase synchronizing signal 16 V AC

25 25 Volt Reference: Potentiometer (TOP) 5.6 V DC

26 26 Volt Reference: Potentiometer (CENTRE) 0-5.6 VDC

27 27 Volt Reference: Potentiometer (BOTTOM) Gnd

28 28 -VE FEEDBACK-

29 29 Current Reference: Potentiometer (TOP) 5.6 V DC

30 30 Current Reference: Potentiometer (BOTTOM) Gnd

31 31 Current Reference: Potentiometer (CENTRE) 0-5.6 VDC

32 32 Current feedback Shunt (Gnd) Gnd

33 33 Current feedback signal 0-75 mV

34 34 -

35 35 -

36 41 Control card power supply 16 V AC

37 42 Control card power supply 16 V AC

38 43 Control card power supply 16 V AC

39 44 Control card power supply Gnd

Table 2.1:AVR terminal voltage test/check

 Check the test point voltages as per the details given below:

Test Point Description Voltage

TP101 60 Deg. Shifted R Phase synch sine wave 8.5 V AC sine

Tp102 R Phase final synchronized square wave +7 V DC

TP103

TP104 R Phase final formed pulse

TP201 60 Deg. Shifted Y Phase synch sine wave 8.5 V AC sine

TP202 Y Phase final synchronized square wave +7 V DC

TP203

TP204 Y Phase final formed pulse

TP301 60 Deg. Shifted B Phase synch sine wave 8.5 V AC sine

TP302 B Phase final synchronized square wave +7 V DC

TP303

TP304 B Phase final formed pulse

TP401 60 Deg. Shifted R’ Phase synch sine wave 8.5 V AC sine

TP402 R’ Phase final synchronized square wave +7 V DC

TP403

TP404 R’ Phase final formed pulse

TP501 60 Deg. Shifted Y’ Phase synch sine wave 8.5 V AC sine

TP502 Y’ Phase final synchronized square wave +7 V DC

TP503

TP504 Y’ Phase final formed pulse

TP601 60 Deg. Shifted B’ Phase synch sine wave 8.5 V AC sine

TP602 B’ Phase final synchronized square wave +7 V DC

TP603
 TP604 B’ Phase final formed pulse

TP1 12 V DC +VE Power Supply wrt Gnd +12 VDC

TP2 12 V DC -VE Power Supply wrt Gnd -12 VDC

TP3 Control Voltage +0.0 to 5.5 V DC

TP4 Pulse inhibit signal -0.7 to 10.0 V DC

TP5 -

TP6 -

TP7 Current feedback signal (Amplifier) +0.125 to 2.5 V DC

Table 2.2:AVR test point voltage check

1. To start with check availability of 12 V DC positive and negative power supplies. If
not available check the availability of 16 V AC at their respective terminals, then
check 32.0 V DC at the diode rectifier bridge and the input of regulator ICs. If both
the inputs are OK and Outputs are not available, the replace respective ICs as they
are defective.
2. Check availability of R, Y, B, R’, Y’ and B’ Phase synchronizing waves, check their
respective transformers on the Transformer.
3. Check Synchronizing voltages at respective terminals whichever is absent check it
respective sync wave at final formed test point.
4. Check reference voltage 5.6 V DC at terminals and observe variation in reference
voltage as per the potentiometer settings.
5. Check current feedback signal Terminal no 32,33 if the DC voltage is not available
then it should be of the order of 0.075 Volts depending on the
2.2.2 Protection: (ES-PROT6C-2106) (E7)

 Check the card for loose connections, dry solders and burnt components.
 Check terminal voltages as per the table given below:

Sl. No. Terminal Description Voltage

1 1 16 V AC Power Supply wrt Gnd 16 V AC

2 2 16 V AC Power Supply wrt Gnd 16 V AC

3 3 Gnd. / Power Supply transformer center 0.0 V

4 5 +12 V DC output of the card power supply +12.0 V DC

 5 5 -12 V Dc output of the card power supply -12.0 V DC

6 6 Over voltage sensing signal 125.0 V DC

7 7 Under Voltage sensing signal 100.0 V DC

8 8 Mains AC fail voltage sensing 16.0 V AC

9 9 Mains AC fail voltage sensing 16.0 V AC

10 10 Charger DC fail voltage sensing 85.0 V DC

11 11 Battery Fully charged voltage sensing 132.0 V DC

12 12 Battery under voltage sensing 100.0 V DC

13 13-16 Over relay changeover Relay O/P

14 17-20 Under relay changeover Relay O/P

15 21-108.0 Mains AC fail relay changeover Relay O/P

16 25-28 Charger DC fail relay changeover Relay O/P

17 29-32 Battery fully charged relay changeover Relay O/P

18 33-36 Battery under voltage relay changeover Relay O/P

19 37 Lamp Test signal 220.0 V DC

20 38 Alarm Buzzer 220.0 V DC

Table 2.3:Protection terminal voltage checks

 Check test point voltages as per the details given below:

Test Point Description Voltage

TP1 12 V DC -VE Power supply wrt Gnd. -12 V DC

TP2 GND/Center tap of power supply Trans. 0.0 V

TP3 12 V DC +VE Power supply wrt Gnd. +12 V DC

TP101-TP601 Error output of the comparator IC +10 V DC to -10 V Dc

Table 2.4: Protection test point voltage check

1. To start with check availability of 12 V DC positive and negative power supplies. If not
available check the availability of 16 V AC at their respective terminals, then check 32.0 V
 DC at the diode rectifier bridge and the input of regulator ICs. If both the inputs are OK
and Outputs are not available, the replace respective ICs as they are defective.
2. Check availability of positive feedback signals at their respective terminals.
3. Check whether reference signal (positive volts as per the setting of reference pot) is
present at resistor R108.
4. Compare magnitudes of feedback and reference voltages at resistor R106, R107.
5. Depending on whether reference or feedback voltage is higher output of comparator
should switch between +10.0 to –10.0 V DC. This in turn will switch ON/OFF the relay. If
this does not occur check IC and replace.
6. If the relay does not change state check Diode D104 and Zenner Z101. And finally check
transistor of last stage Q101.
7. If the collector of transistor changes stated from +12.0 to-12.0 volts, then check Relay and
replace if faulty.

2.2.3 Fuse failure detection card (ES-PROTFFD-4106) (E4, E5, E6, E9 & E10)

 Check the terminal voltages on the card E4 as per the table given below:

Sl. No. Terminal Description Voltage

P1 1,2 Fuse 1 detection System

P2 3,4 Fuse 2 detection System

P3 5,6 Fuse 3 detection System

P4 7,8 NA System

P5 9,10 DC Supply +12 V DC

11-13 Relay 1 set of changeover contacts C/O

14-18 Annunciation relay contacts C/O

19-21 Relay 2 set of change over contacts C/O

Table 2.5:Fuse failure detection card E4 terminal voltage check

 Check the terminal voltages on card E5 as per the table given below:

Sl. No. Terminal Description Voltage

P1 1,2 Fuse 4 detection System

P2 3,4 Fuse 5 detection System

P3 5,6 Fuse 6 detection System

P4 7,8 Fuse 7 detection System

 P5 9,10 DC Supply +12 V DC

11-13 Relay 1 set of changeover contacts C/O

14-18 Annunciation relay contacts C/O

19-21 Relay 2 set of change over contacts C/O

Table 2.6:Fuse failure detection card E5 terminal voltage check

 Check the terminal voltages on card E6 as per the table given below:

Sl. No. Terminal Description Voltage

P1 1,2 Fuse 8 detection System

P2 3,4 Fuse 9 detection System

P3 5,6 Fuse 10 detection System

P4 7,8 Fuse 11 detection System

P5 9,10 DC Supply +12 V DC

11-13 Relay 1 set of changeover contacts C/O

14-18 Annunciation relay contacts C/O

19-21 Relay 2 set of change over contacts C/O

Table 2.7:Fuse failure detection card E6 terminal voltage check

 Check the terminal voltages on card E9 as per the table given below:

Sl. No. Terminal Description Voltage

P1 1,2 Fuse 12 detection System

P2 3,4 Fuse 13 detection System

P3 5,6 NA System

P4 7,8 NA System

P5 9,10 DC Supply +12 V DC

11-13 Relay 1 set of changeover contacts C/O

14-18 Annunciation relay contacts C/O

 19-21 Relay 2 set of change over contacts C/O

Table 2.8:Fuse failure detection card E9 terminal voltage check

 Check the terminal voltages on card E10 as per the table given below:

Sl. No. Terminal Description Voltage

P1 1,2 Fuse 14 detection System

P2 3,4 Fuse 15 detection System

P3 5,6 Fuse 16 detection System

P4 7,8 NA System

P5 9,10 DC Supply +12 V DC

11-13 Relay 1 set of changeover contacts C/O

14-18 Annunciation relay contacts C/O

19-21 Relay 2 set of change over contacts C/O

Table 2.9:Fuse failure detection card E10 terminal voltage check

2.2.4 Earth Leakage Detection: (ES-PROTEL-6106) (E8)

 Check the card for loose connections, dry solders and burnt components.
 Check the terminal voltages as per the table given below:

Sl. No. Terminal Description Voltage

1 1

2 2

3 3 - 0.0 V

4 4 +VE Supply of System under supervision 110 V DC

5 5 -VE Supply of System under supervision 16 V AC

6 6 Earth potential/ Centre point of Resistor network +12.0 V DC

7 7 +24 V DC relay supply 110.0 V DC

8 8 Lamp Test Signal 110.0 V DC

9 9 +VE Leakage Lamp signal 110.0 V DC

 10 10 Alarm Buzzer 110.0 V DC

11 11 -VE Leakage lamp signal 110.0 V DC

12 12 Fault (Reset line) 110.0 V DC

13 13 +ve Leakages Relay N/O -

14 14 +ve Leakages Relay Common -

15 15 +ve Leakages Relay N/C -

16 16 -ve Leakages Relay N/O -

17 17 -ve Leakages Relay Common -

18 18 -ve Leakages Relay N/C -

Table 2.10: Earth leakage detection, E8 terminal voltage check

2.2.5 Earth Leakage Detection: (ES-PROTEL-6106) (E6)

 Check the test point voltages as per the details given below:

Test Point Description Voltage

TP1 12 V DC -VE Power Supply wrt Gnd. -12 V DC

TP2 Reference for +ve leakage 0.6 – 2.0 V DC

TP3 12 V DC +VE Power Supply wrt Gnd. +12 V DC

TP4 Error output of comparator IC U1 +7.0 V to -7.0 V DC

TP5 Leakage sensing potential for IC U1 0.6-2.0 V DC

TP6 Leakage sensing potential for IC U2 0.6-2.0 V DC

TP7 Error Output for comparator IC U2 +7.0 V DC to -7.0 V DC

TP8 12 V DC -VE Power supply wrt circuit -12 V DC

TP9, 10, 11 Transistor Base drives for -ve circuit -

TP12, 13, 15 Transistor Base drives for +ve circuit -

TP16 GND

Table 2.11: Earth leakage detection, E6 terminal voltage check

1. To start with check availability of 8.2 V DC positive and negative power supplies. If not
available check the availability of system voltage DC at their respective terminals, then
check zenners D1 and D2 if not replace defective.
2. Check availability of earth leakage feedback signals at their respective terminals.
3. Check whether reference signal (positive volts as per the setting of reference pot)
4. Compare magnitudes of feedback and reference voltages at input of ICs.
5. Depending on whether reference or feedback voltage is higher output of comparator
should switch between +7.0 to –7.0 V DC. This in turn will switch ON/OFF the relay. If this
does not occur check IC and replace.
6. If the relay does not change state check driver circuit and replace intermediate transistors
if required.
 SECTION B:

MAINTENANCE MANUAL

ANNEXURE M 3

Annexure M 3: Troubleshooting of Digital Governor

Remedy No. Action

1 Change donator

2 Check fitting of donator

3 Check scaling

4 Check Wiring

5 Change Module

6 Change defect item

7 Check controlling device

8 Check hydraulics

9 Removal of jammed impurities

Table 3.1:Actions on remedy numbers

The error and possible cause of errors are shown below:

Error Name of Error Possible Cause Remedy

Actr.DvWg_HVLV.FailFdBck.stVal Position failure Feedback donator wrong 2,3,4

setted,signaldrift,
servo valve wicket
Signaldrift, signalhissing
gate

Actr.Wg_HTGV.FailFdBck.stVal Position failure Feedback donator wrong 2,3,4

setted,signaldrift,
 wicket gate Signaldrift, signalhissing

PT.NW.DO.FAIL_H_NET Failure head of failure of input module AI- 1,4,5

water 6300

Envm.Per_GGIO.PckUp10_Alm.st Failure speed pick Open circuit, donator 1,4,5

up breakdown,failure of input-
Val
module TE-6420
1, Bit 0

Envm.Per_GGIO.PckUp11_Alm.st Failure speed pick Open circuit, donator 1,4,5

up breakdown,failure of input-
Val
module TE-6420
1, Bit 1

Envm.Per_GGIO.PckUp20_Alm.st Failure speed pick Open circuit, donator 1,4,5

up breakdown,failure of input-
Val
module TE-6420
2, Bit 0

Envm.Per_GGIO.PckUp21_Alm.st Failure speed pick Open circuit, donator 1,4,5

up breakdown,failure of input-
Val
module TE-6420
2, Bit 1

PT.NW.DO.FAIL_QT Failure during Open circuit, donator 1,3,5

quick breakdown,failure of input-
module TE-6420
transition
Channel 1, failure speed
sensor 1or speed sensor 2

PT.NW.DO.FAIL_ROTATION Failure rotation Open circuit, donator 1,3,5

breakdown,failure of input-
monitoring
module TE-6420
Channel 1, channel 1 of
TE6420not used

Actr.Wg_HTGV.FailPos.stVal Failure positioning Breakdown of input 1,4,5,8,9

module TE-6450 or output
circuit
module AO-6380,
Open circuit, failure servo-
valve,breakdown Feedback
donator
main control valve or
servo-valve,jammed
impurity
Actr.DvWg_HVLV.FailPos.stVal Failure positioning Breakdown of input ,4,5,8
module TE-6450 or output
circuit MCV
module AO-6380,
open circuit detection,
failureservo-valve,
breakdown offeedback
donator main control
valve

Envm.Per_GGIO.SigAIxx.stVal Failure analogue Open circuit, failure of 4,5

inputmodule AI-6300,
input signal
dropoutperipheral module
PE 00

Envm.Per_GGIO.SigSSIxx.stVal Failure peripheral Breakdown of input 3,5

module TE-6450 or output
devices WG
module AO-6380,
Open circuit, failure servo-
valve,breakdown Feedback
donator
main control valve or
servo-valve

Table 3.2:Maintenance actions

Annexure M 4: Troubleshooting of Hydraulic Governor

4.1 Loss of oil pressure, flow

Type of Malfunction and possible causes Remedial Action

No oil pressure, no oil flow: Rectify the electrical connections

 wrong rotating direction of motor  check pressure gauge and pressure

 wrong indication connection
 too high oil viscosity (oil temperature too  check function of oil circulating pump and
low) heating valve
 pump check/shut-off valve closed or only  open check/shut-off valve
partly open

Short-term oil flow, then no flow.
No flow in spite of rotating motor:
 level switch “too low” was NOT 
switching off the motor and the pump
was emptying the tank
 motor / pump shaft broken
 check function of level switch / automatic
control. Trace oil leakage and repair. Refill
oil.
change pump / motor unit. Repair of pump
/ motor unit by supplier.

Pump is running but pressure too  check function of pressure gauge / switch.
low: Attention: Pressure switch monitors only
the pressure tank pressure, NOT the pump
 pressure gauge or pressure switch defect pressure!
 pressure relief valve of pump is faulty or  check pressure relief valve
wrong adjusted

Oil pressure “LOW” alarm:  refer to actions above

 oil pump or pump relief valve defect
 setting of pressure switch wrong

 oil leakage  correct settings

 SECTION B:
MAINTENANCE MANUAL
ANNEXURE M4
 automatic control faulty
Table 4.1:Loss of oil pressure, flow
4.2 Air bubbles in pressure oil
Type of malfunction and possible causes
Pressure oil contents air bubbles:
 air entering pump suction pipe
 flow resistance in suction pipe too high
 suction pipe only partly below oil level
 pump shaft seal faulty
 pump cover not tight
Table 4.2:Air bubbles
4.3 Oil leakages from oil pump
Type of malfunction and possible causes
Oil leakage from pump shaft:
 shaft seal damaged
 internal drainage line blocked
 major defect of oil pump
Table 4.3: Oil pump leakage
4.4 Noisy Oil pump
Type of malfunction and possible causes
Abnormal noise:
 trace leakage and repair
 check function / signals
Remedial actions
Tighten screw connection of suction pipe
 check if suction pipe is partly blocked
 check oil level “too low” level switch.
Trace oil leakage and repair. Refill
hydraulic oil.
 renew shaft seal ring. Smooth shaft
surface if necessary.
 check O-ring
Remedial actions
 replace shaft seal and smooth possible
grooves on shaft
 clear drainage line
 replace oil pump
Remedial actions
 check suction pipe for tightness
 pump is sucking air
 cavitation in suction pipe
 pump / motor screws loose
 motor or pump defect
Table 4.4:Noise
4.5 Oil Temperature high
Type of malfunction and possible causes
Sump tank oil temperature is rising:
 pump relief valve is misadjusted or defect 
 abnormal oil consumption
 safety relief valve for pressure tank miss-
adjusted or defect
 oil drain valve of pressure tank not fully
closed or leaking
 No cooling water flow not available
Table 4.5:Oil temperature high
4.6 Abnormal movement of nozzle servomotors
Type of malfunction and possible causes
Nozzle servomotors oscillation:
 air in pressure oil system
 proportional valve is twisted
Nozzle servomotors don’t move:
 pilot oil filter clogged
 the following valves are NOT in operating 
position: QSD-valve, start/stop valve, oil 
supply shut-off valve
 throttle check valves for time adjustment
are closed
 clear suction pipe
 tighten screws
 replace motor/pump
Remedial actions
 check pump relief valve
check function of proportional valves with
test equipment and electronic control
signals from governor
 check pressure tank relief valve
 check valve and close or replace
if necessary
 check if isolating valve closed
 check if flow regulation valve closed too
much
 check if solenoid valve working properly
Remedial actions
 vent oil system
 remove proportional valve from hydraulic
block and check if block surface is clean,
flat and smooth. Fasten the proportional
valve by means of a torque wrench.
Fastening torque according to
manufacturer (see brochures).
 check and change filter
 check position of valves
check setting of valves
check valve function, behavior with valve
test equipment
 SECTION B:

MAINTENANCE MANUAL

ANNEXURE M 5

 due to faulty proportional valve

Table 4.6:Abnormal movement of servomotors

Annexure M 5: Replacement of Seals

5.1 Process for Seals of Radial Weir Gates

1. Clean seal base surface on gate.

2. Countercheck the holes of the clamp bars with the holes of the gate.
3. Protect the surface of the gate, so that tools, etc. can´t damage the coat of paint.
Note:The rubber seals are supplied with over length on both sides.
Never cut through the Teflon coated rubber!! check length of PTFE. After a connection is glued, no
further cutting or bending of the rubber gaskets shall be done.
4. Cut the sill seal to final length. (See step Cutting the seals)
5. Adjust the sill seal exactly, use the clamp bar as template and start drilling the holes.
Note: Use special rubber drill LENOX SKU 30001_ 1L (Adjustable pilot bit) + SKU 30010_10L (Drill)

6. The screws can be tightened. (20-30Nm)

Note: Seal every clamp bolt with Terostat MS 935.
(~150 screws can be sealed with 310ml)
7. Cut the one over length of the side seals (next to sill seal), but not to final length. Approx.1cm
beyond/above the sill seal.
8. Glue side seal to sill seal (See step Bonding the rubber gaskets)

9. Adjust the two corner pieces exactly

10. Cut the second over length of the side seal
11. Glue corner piece to side seal
12. Repeat step 7 – 11 for the other side seal & corner piece.
13. Cut overlength of lintel seal but not to final length. Approx.1cm beyond the side seal.
14. Glue lintel seal to side seals (on each side)
15. After the seals are installed and glued, grind/cut the side seals. The end must be exact in one
line with the sill seal

5.2 Process for Seals of Flap Gate

1. Clean seal base surface on gate.

2. Countercheck the holes of the clamp bars with the holes of the gate.
3. Protect the surface of the gate, so that tools, etc. can´t damage the coat of paint.
Note:The rubber seals are supplied with over length on both sides.
Never cut through the Teflon coated rubber!! check length of PTFE. After a connection is glued, no
further cutting or bending of the rubber gaskets shall be done.
4. Cut the sill seal to final length. (See step Cutting the seals)
5. Adjust the sill seal exactly, use the clamp bar as template and start drilling the holes.
Note: Use special rubber drill LENOX SKU 30001_ 1L (Adjustable pilot bit) + SKU 30010_10L (Drill)

6. The screws can be tightened. (20-30Nm)

Note: Seal every clamp bolt with Terostat MS 935.
(~150 screws can be sealed with 310ml)
7. Cut the one over length of the side seals (next to sill seal)
8. Glue side seal to sill seal (See step Bonding the rubber gaskets)

9. Adjust the two corner block pieces exactly

10. Glue corner piece to side seal
11. Repeat step 7 – 11 for the other side seal & corner block piece.

5.3 Process for Seals of Powerhouse, Flap Gate & Downstream Stop log gates
1. Clean seal base surface on stoplog.
2. Countercheck the holes of the clamp bars with the holes of the stoplog.
3. Protect the surface of the stoplog, so that tools, etc. can´t damage the coat of paint.

The rubber seals are supplied with over length on both sides.

4. Cut the sill seal to final length. (See step Cutting the seals)
5. Adjust the sill seal exactly, use the clamp bar as template and start drilling the holes. Use
special rubber drill LENOX SKU 30001_ 1L (Adjustable pilot bit) + SKU 30010_10L (Drill)

6. The screws can be tightened. (20-30Nm)

Note: Seal every clamp bolt with Terostat MS 935.
(~150 screws can be sealed with 310ml)
7. Adjust the side seals exactly (see drawing mention in chapter 6), use the clamp bars as
template and start drilling the holes. Use special rubber drill LENOX SKU 30001_ 1L
(Adjustable pilot bit) + SKU 30010_10L (Drill)
8. Tighten screws as described in 6.
9. Cut the second over length of the side seals (next to sill seal), but not to final length.
Approx.5mm beyond/above the sill seal
10. Glue the connection between the side seals and the sill seal. (See step Bonding the rubber
gaskets)

After a connection is glued, no further cutting or bending of the rubber gaskets shall be done.
11. After the seals are installed and glued, grind/cut the side seals. The end must be exact in one
line with the sill seal.

Alignment must be done acc. sketch above. If necessary, use grease Molykote 55M to ease the
adjustment.

5.4 Process for Seals of Radial Gate Stop log gates

1. Clean seal base surface on stoplog.
2. Countercheck the holes of the clamp bars with the holes of the gate.
3. Protect the surface of the gate, so that tools, etc. can´t damage the coat of paint.

Note:The rubber seals are supplied with over length on both sides.
Never cut through the Teflon coated rubber!! Check length of PTFE. After a connection is glued, no
further cutting or bending of the rubber gaskets shall be done.

4. Cut the sill seal to final length. (See step Cutting the seals)
5. Adjust the sill seal exactly, use the clamp bar as template and start drilling the holes.
Note: Use special rubber drill LENOX SKU 30001_ 1L (Adjustable pilot bit) + SKU 30010_10L (Drill)
6. The screws can be tightened. (20-30Nm)
Note: Seal every clamp bolt with Terostat MS 935.
(~150 screws can be sealed with 310ml)
7. Cut the over length of the lintel seal on both sides
8. Cut one over length (next to lintel seal) of the first corner piece
9. Adjust these two pieces exactly
10. Cut one over length (next to lintel seal) of the second corner piece to final length
11. Cut the remaining over length (next to side seal) of both corner pieces
12. Cut one over length of the side seals (next to corner piece)
13. Cut the second over length of the side seals (next to sill seal), but not to final length.
Approx.5mm beyond/above the sill seal.

14. Glue the connection of the rubber gaskets. (See step Bonding the rubber gaskets
15. Glue the connection between the side seals and the sill seal. (See step Bonding the rubber
gaskets)
16. Adjust the seals exactly, use the clamp bars as template and start drilling the holes.
Note: Use special rubber drill LENOX SKU 30001_ 1L (Adjustable pilot bit) + SKU 30010_10L (Drill)
17. Tighten screws as described in 6.

18. After the seals are installed and glued, grind/cut the side seals. The end must be exact in one
line with the sill seal.

Alignment must be done acc. sketch above. If necessary, use grease Molykote 55M to ease the
adjustment.
4.5 Process for Seals of Pressure Door

1. Clean seal base surface on door.

2. Countercheck the holes of the clamp bars with the holes of the gate.
3. Protect the surface of the gate, so that tools, etc. can´t damage the coat of paint.

The rubber seals are supplied with over length on both sides.
After a connection is glued, no further cutting or bending of the rubber gaskets shall be done.

4. Cut one overlength of lower corner pieces. (See step Cutting the seals)
5. Cut one over length (next to first lower corner piece) of the lower seal.
6. Adjust these two pieces exactly and glue the connection of the rubber gaskets. (See step
Bonding the rubber gaskets)
7. Adjust the first lower corner piece and lower seal exactly, use the clamp bar as template and
start drilling the holes.
Note: Use special rubber drillLENOX SKU 30001_ 1L (Adjustable pilot bit) + SKU 30010_10L (Drill)
8. The screws can be tightened. (20-30Nm)
Note: Seal every clamp bolt with Terostat MS 935.
(~150 screws can be sealed with 310ml)
9. Glue the connection of second lower corner piece
10. Cut one overlength (next to lower corner pieces) of side seals.
11. Glue the connection of the rubber gaskets. (See step Bonding the rubber gaskets)
12. Use the clamp bar as template and start drilling the holes.
Note: Use special rubber drill LENOX SKU 30001_ 1L (Adjustable pilot bit) + SKU 30010_10L (Drill)
13. Cut over length of the upper corner pieces to final length and adjust these two pieces exactly
14. Cut the second over length of the side seals (next to upper corner piece)

15. Glue the connection of the rubber gaskets. (See step Bonding the rubber gaskets)
16. Adjust the seals exactly, use the clamp bars as template and start drilling the holes.
Note: Use special rubber drill LENOX SKU 30001_ 1L (Adjustable pilot bit) + SKU 30010_10L (Drill)
17. Tighten screws as described in 8.
18. Cut one overlength of the upper seal and glue the connection to one upper corner piece.
19. Cut second overlength of upper seal and glue the connection so second corner piece

20. Adjust the seals exactly, use the clamp bars as template and start drilling the holes.
21.
Note: Use special rubber drill LENOX SKU 30001_ 1L (Adjustable pilot bit) + SKU 30010_10L (Drill)
22. Alignment must be done acc. sketch above. If necessary, use grease Molykote 55M to ease
the adjustment.
 SECTION B:

MAINTENANCE MANUAL Annexure M 6: Troubleshooting of Turbine and its

ANNEXURE M6 Auxiliaries

Malfunctions are either

 Detected during inspection tours by the operating personnel or

 Indicated by electrical monitoring units.
Possible causes of such malfunctions and the remedial action to be taken are described on the
following pages.

Sl. No. TROUBLE / POSSIBLE CAUSE RECTIFICATION

1 Abnormal noise

1.1 Rotating parts in contact with Localize area.

stationary parts.
Check the clamping and tightening of parts,
e.g. the roof of the nozzles.

1.2 Loose bolts. Locate area and fasten bolts. After fastening of
bolts secure them with a mechanical lock
(welding point) or other means (e.g. Loctite).

1.3 Deflector partly activated. Check deflector servomotor and feedback

system TEMPOSONIC together with MIPREG.

2 Heavy Vibration

2.1 Unit is running in overload Reduce output to nominal value.

conditions.

2.2 Unbalance of rotating unit. Balancing of the rotating unit.

2.3 Loosening of clamping bolts e.g. Fasten clamps and bolts, mechanical locks.
bearing bracket, bearing body.

2.4 In case of monitoring system is Check function of vibration detector and

applied, vibration detector may be setting, readjust if possible, or replace
faulty. SIEMENS. vibration detector.

2.5 Problems with the bearing gap. Check the nozzles, opening may be unequal.

3 Leakage oil from turbine bearing

3.1 Sealings improperly inserted or Replace the sealing.

 damaged.

3.2 Loosening of clamping bolts. Fasten the bolts.

3.3 Too much oil quantity. Adjust the quantity of oil to specified normal
level. Check if water is in the oil, possibly from
the cooling water system.

4. Turbine guide bearing temperature too high (alarm / trip)

4.1 First action. Stop unit and restart the unit while watching
the temperature rise.

4.2 Failure at cooling water supply Check cooling water system, motor-valves,
system. filters, pumps, and water level in sump pit.

4.3 Bearing oil system faulty, extraneous Check bearing for extraneous parts.
parts blocking oil flow.

4.4 Bearing oil dirty and/or water in oil. Check oil, oil cooler and piping. Analyze the oil
quality for water content, suspended particles.
 purify the oil.

4.5 Wear of bearing segments. Check runout and clearances of shaft. Check
bearing alignment and gap.

4.6 Temperature detectors faulty. Check function. And electrical connections of

the sensors.

5. Leakage from nozzle of deflector

5.1 Sealings improperly inserted or Replace the sealings.

damaged.

5.2 Sealings damaged due to dirt or Replace the sealings.

sand.
Visual control of the surface of concerned
shafts and bushings.

7. Turbine over speed pendulum released mechanically, electrical over speed was not
released.

7.1 Digital governor fault. Check governor functions on the MIPREG and
electrical system, cables, connections, etc.

8. Excessive leakage during standstill of unit

8.1 Needle and/or seat ring eroded or Stop unit, close spherical valve and replace
 damaged. needle and/or seat ring.

9. Failure of measurement systems, bad or no signal / indication of the static pressure

9.1 Pressure transmitter damaged. Measuring the pressure at the measuring

connection with a pressure gauge for check.
Check piping.
Replace the pressure transmitter.

9.2 Pressure taps (orifices) clogged. Flushing the pressure taps and the piping.

9.3 Pressure transmitter or converter in Replace the damaged transmitter or the

terminal box damaged converter in the terminal box

9.4 Electrical fault at control panel Check the analog input signal from the level
transmitter between terminalbox and control
panel.
Check the internal signal at the control panel.
Replace the damaged instrument in the
control panel

Table 6.1:Possible malfunction and remedial measures for Turbine and auxiliaries
 SECTION B:

MAINTENANCE MANUAL Annexure M 7: Nozzle tip De-Assembly Sequence

ANNEXURE M7

0. Assembled condition

1. Remove the protection roof

2. Remove Nozzle Hat including Deflector

3. Pressurize the nozzle servo to close position and keep position

Attention:only the length of stroke

 otherwise spring blocked !

4. Push Pins inside and move Cover bush backward

5. Remove bolts of Needle Tip

6. Remove needle tip
 SECTION B:

MAINTENANCE MANUAL Annexure M 8: Troubleshooting of Main Inlet Valve

ANNEXURE M8 and its Auxiliaries

8.1 Possible malfunctions detected during inspection tours

Type of malfunction and possible causes Remedial action

Open position not reached Check position for proper position

Oil Leakage Check the oil piping/ hydraulic power unit for
tightness

Table 8.1:Possible malfunction detected during inspection tour

8.2 Possible malfunction indicated by electrical monitoring units.

Type of malfunction and possible causes Remedial action

MIV Position <98%

Oil losses on hydraulic piping lines to Search leakage points and eliminate them
servomotors / HPU

Position switch faulty Readjust position switch or replace by a new

one

Penstock valve – Control Unit faulty Check function of control unit and replace
faulty valves, etc.

Servomotor locking device not in unlocked position

Position switch faulty Readjust position switch or replace by a new

one

By-pass service valve position feedback faulty Readjust position switch or replace by a new
one
Position switch faulty

Balanced pressure signal not available Readjust pressure switch or replace by a new
one
Differential pressure switch faulty

Table 8.2: Possible malfunction indicated by electrical monitoring units

 SECTION B:

MAINTENANCE MANUAL Annexure M 9: Replacement of SYNCHROTACT 5

ANNEXURE M9

If the SYNCHROTACT 5 is defective switch it off and replace with new one or put the defective
one after repairing. The Generating Units can be synchronized with the grid in Manual Mode
using the synchrocheck even without SYNCHROTACT. However, the operator has to go to local
panel to synchronize with the grid. The replacement of the SYNCHROTACT is given below:
1. Install new SYNCHROTACT 5 on the Panel.
2. Install the SyncView Software (ABB Sync-View 4.0) in your PC.
3. After installation configure your PC IP address. The IP Address can be in range 192.168.0.X
and where X can be any free IP Address. E.g. 192.168.0.250 or 192.168.0.251…)

Figure 9.1:Showing the configuration of IP address in your PC

4. Now connect your PC to the SYNCHROTACT relay using Ethernet cable as shown below in
Figure 9.2.
Figure 9.2:Connection to SYNCHROTACT using Ethernet cable
5. Now Open the SyncView Software 4.0 and go to communicationChange interface to
Communication over TCP/IP and put TCP/IP address 192.168.0.240

Figure 9.3:Showing the configuration of SyncView software

6. Check the communication between the SyncView software and your PC by clicking on Device
Info and if the connection is OK then you will get following information.
Figure 9.4:Showing Device Info when the communication is successful
7. Now to load the new setting from your PC to the synchrotact relay, go to
ParameterOpenopen the setting file and click open and you will get new setting to the
on your SyncView software as shown in figure 9.5.
Note:You should have the setting given to us during the commissioning by the Original
Equipment Manufacturers.

Figure 9.5:Showing the process to load new settings from your PC

8. Now compare the setting between SyncView and Synchrotact by clicking on
ParameterCompare and you will get following message if both the settings are identical.

Figure 9.6:Showing the settings comparison between the SyncView and Synchrotact
9. Write the setting in the Synchrotact Relay by clicking it on “write” button.

Figure 9.7:Showing writing the settings in relay

Now the SYNCHROTACT relay is ready to use.
 SECTION B:

MAINTENANCE MANUAL Annexure M 10: Troubleshooting of SYNCHROTACT

ANNEXURE M10 5

Code Description Remarks

001 Auxiliary voltage on. After the electronics power supply is connected.

003 SYNCHROTECH selected. After the Start pulse.

004 SYNCHROTECH stopped. After the Stop pulse.

005 Device ready. SYNCHROTECH 5 is ready for operation.

006 Device not ready. SYNCHROTECH 5 is blocked, without error = service

operation, with error = fault.

011 Data change. This event is displayed when the device changes from
READY or OPERATING status into BLOCKED status, i.e.
following a write or blocking command.

021 Adjusting command U+. Higher voltage adjusting command.

022 Adjusting command U-. Lower voltage adjusting command.

023 Adjusting command f+. Higher frequency adjusting command.

024 Adjusting command f-. Lower frequency adjusting command.

025 Release contact closes. Output contact channel 2 (Synchrocheck).

026 Release contact opens. Output contact of channel 2 (Synchrocheck).

027 Paralleling command Issue of a paralleling command by the command generation

contact closes. (In Synchrocheck mode: paralleling release).

028 Paralleling command End of the paralleling command (in Synchrocheck mode: end
contact opens. of paralleling release).

029 Blocking active. Blocking signal to one of the configurable inputs has
interrupted synchronizing process.

030 Blocking cancelled. Blocking signal has released the synchronizing process
again.

050 ΔU outside tolerance If these messages are not desired, they can be blocked by
 band setting the total

051 ΔU outside tolerance Paralleling time t tot to 0.

band Otherwise, the following
should be checked, depending
052 s outside of tolerance on the combination of events:
band
i. Are both measuring
053 α outside of tolerance voltages continually
band present throughout the
entire synchronizing
process (observed LED).
ii. Was the calibration of the
measuring voltages
054 ΔU within tolerance band
carried out correctly?
055 s within tolerance band iii. Is the correct parameter
set active?
056 α within tolerance band iv. Are the voltage and
frequency matcher
057 U1 and U2 above U max functioning correctly?

058 U1 or U2 below U min

059 f1 or f2 outside of fn±5 Hz

060 U1/U2< U0 max and no If SYN is programmed for

release for dead bus. dead bus and at least one
voltage is also<U0max, \but
the release for dead bus
has not been given.

061 No stop command within At least one paralleling Automatic stop signal is not
t tot. command has been given. functioning.
However, the expected
Command circuit is broken
Stop signal has not been
generated.

071 Synchronization fault. Collective alarm following i. Check the limit values for
expiry of total paralleling the parameter.
time t tot. ii. With SYN 5202: check
synchro-check parameters
(channel2) and whether
they match channel 1. Loss
or error of phase in one of
both channels.
iii. Read out other events
 which may have been
displayed at the same
time. Try to identify the
fault on the basis of the
combination.

Table 10.1:Troubleshooting of SYNCHROTACT 5

 SECTION B:

MAINTENANCE MANUAL Annexure M 11: Troubleshooting of 24MVA GSU

ANNEXURE M11 Transformer and 5MVA Auxiliary Station
Transformer

11.1 Troubleshooting

Following table 11.1 shows some of the symptoms, possible causes andremedies in case of
abnormal situations.
If the abnormality is of a major nature, the manufacturer should becontacted at the address
given elsewhere in this Manual. When thematter is referred to the manufacturer it shall contain
the following: -

 Transformer Rating.
 Voltage Rating.
 Manufacturers Indent No. / Serial No.
 Year of Manufacture.
 Date / Time of failure.
 Brief description of the problem.
 Checks done and their results.

11.2 Abnormal Operation Conditions

Trouble Cause Remedy

High Winding/ Oil Over voltage Change the circuit voltage or transformer
Temperature connections to avoid over excitation.

Over current If possible, reduce load. Heating can bereduced

by improving power factor of load.Check
parallel circuits for circulatingcurrents, which
may be caused by improperratios or
impedances.

High ambient Either improve ventilation or

temperature relocatetransformer in lower ambient
temperature.

Insufficient cooling If unit is artificially cooled, make surecooling is

adequate.

Low oil level Top up oil to proper level

Deterioration/ sludge Use filter press to wash off the core and coils.
formation of oil Filter oil to remove sludge
 Short circuited core Testing for exciting current and no load loss.
Ifhigh inspect core and repair. See
ElectricalTroubles, below.

ElectricalTroubles/ Lightning, short Usually, when a transformer winding fails,the

WindingFailure circuit, Overload Oil of transformer is automaticallydisconnected from
low dielectric the circuit by the circuitbreaker.
strength.

Table 11.1:Abnormal operating conditions

11.2 Diagnosis of internal faults

 When the operation of a protective device does not clearly indicate an internal fault, it is
desirable to conduct the preliminary measurements and analysis before dismantling the
transformer.
 Conditions before and after the development of fault should be taken intoconsideration
in arriving at a conclusion.

Sl. No. Check Point Description Criteria

1 Measurement Measurement must be taken afterisolating

of Insulation the transformer from the circuitand
Resistance of cleaning the surface of
Windings insulators.Insulation failures can be
detected bythismeasurement.

2 Measurement When measurement is made in one circuit, Comparison with

of winding other circuits must be kept open circuited. factory test results
resistance This measurement can detect winding
faults.

3 Measurement This can be conducted by applying

of Transformer 230volts, which can be readily available at
Ratio. site. For three phase jobs, measureratios
phase by phase.

4 Measurement Measurement can be made by applying230 If values obtainedare

volts under normal conditions bymaking highercompared to
of No Load
use of locally available power source. This factory test results, it
Current measurement can detectfault in windings indicates faulty
and core. condition.

5 Testing of oil Measure Break Down Voltage,

moisturecontent, tan delta & check for
sludge formation, discoloration and
 unusual smell.

6 Measurement Abnormal increase means deteriorationof Comparison

of Tan Delta of insulation. withfactory test
Windings result

7 Analysis of gas When gas is accumulated in Buchholzrelay. Manufacturer maybe

collected in It should be analysed by contacted foradvice
Buchholz gaschromatograph to check presence
Relay ofcombustible gases.

8 Dissolved Development of internal incipient faultcan

GasAnalysis be judged from the results.Increase in gas
composition to bemonitored at periodic
interval.

Table 11.2:Diagnosis of Internal faults

11.3 Protective Devices

Sl. No. Detective Device Description

1 Pressure Relief When the internal pressure increases beyond the presetvalue
Device of PRD it operates. This may also happen if thebreather
connection is choked. Judgment based on theinspection of
other protective relays is essential

2 Differential Relay
This relay detects the internal defects by comparing theinput
current and the output current of the transformer. Ifit
functions simultaneously it indicates internal fault.Please note
that this relay sometimes operates due to inrush current when
transformer is energized and this isnot an internal fault.

3 Oil Temperature This thermometer gives Alarm when the temperaturerises

Indicator/ Winding beyond the set value. Over loading, insufficientcooling because
Temperature of contamination of fan impellers,stoppage of fans/pumps etc.
Indicator Alarm are to be checked.

4 Over CurrentRelay/ These are intended for detecting faults in power

Earth FaultRelay systemassociated with the transformer. A fault in
thetransformer results in operation of these relays. This
isaccompanied by actuation of protective devices of
thetransformer. Identification of fault should therefore
bemade on the basis of a thorough analysis of thesefunctions.

5 Voltmeter/Ammeter If a sudden change in voltage or current is noted whenthere is

 no abnormality in the power system or anunbalance of voltage
or current is noted betweenphases, the reasons should be
investigated.

6 Human Sense
Human sense can play an important role in detection offaults.
a. Discoloration or odour of insulating oil. If pieces
ofinsulating materials or copper are found in oil, aninternal
fault can be suspected.
b. Abnormal noise or vibration.

Table 11.3:Protective devices

11.4 Valves, Gaskets and Welded Joints

Symptom Possible cause Remedy

Oil Leak Loose joint Tighten the joint evenly, of the leak does not
stop, renew the gasket.

Welding joint Take the help from manufacturer.

Valves can’t be Gland packing notfitted Renew the gland packing and adjust
operated correctly. glandpacking nuts evenly.

Valve spindle bent.Seating Fit new valve spindle. Dismantle valve,

for valve plugcorroded freevalve plug or fit new valve.

Table 11.4:Valves, gaskets and Welded joints

11.5 Pumps

Symptoms Possible cause Remedy

Pump Motor Impeller binding Remove the pump and investigate the
over heated problem

Insulation failure of Motor Remove the pump and investigate the

Winding problems.

Two phase operation Check power supply.

Pump motor Impeller damaged Remove pump and investigate the reason
vibration
Motor bearings worn Remove pump and investigate the reason

Pump bearing bushes or Remove pump and investigate the reason

rings worn
Pump running; Valve not fully open Open the valve fully
but output low
Impeller damaged or worn Remove pump and investigate the reason

Speed too low Check electric supply

Table 11.5:Pumps

11.6 Buchholz Relay

Symptom Possible Cause Remedy

Rate of Electrical Identity of gas Class of Fault inference

gas response
evolutio of relay
n

None Trip None Oil surge Faulty operation

mechanis of oil pump
m
operated Suddenvaporizatio Large masses of
by oil n ofoil at 260~400 metal heated e.g.:
supply °C Earth fault,
shortcircuit not
causing
insulationfailure.

Boiling of water in Simultaneous

exceptional cases occurrence of a
heat producing
fault and entry of
water into the
tank.

Rapid Alarm Air or inert gas Major leak due to Fracture of tank,
operates mechanical fault pipe, or Buchholz
and relaycasing or
repeats faulty
after oilcirculating
releasing pump.
gas

Trip and Hydrogen Thermal Local, very

alarm decomposition of highcurrent, hot
mechanis oil above 400°C spot notinvolving
m insulation,
 operates arcover between
metalparts of
Terminal gearor
terminal to tank.

HydrogenandCarbonmonoxid Thermal Local hot spots

e decomposition of due tovery high
oil and insulation current faultsin
contact with
solidinsulation.E.g
. Insulation
failurefollowed by
arcbetween
insulated
conductors and
earth, short
circuited turnetc.

Medium Alarm Air of inert gas Air leaks or Fracture of tank

operates leakages due to pipe or Buchholz
and mechanical fault relay casing or
repeats faulty oil
within circulating pumps
minutes or
hours Hydrogen Thermal Local hot spots
after each decomposition of notinvolving
release of oil above 400°C insulation,faulty
gas joint/
contacts,core
faults
causingburning,
an incipientfault
not involving
solidinsulationE.g.
Core not
properlyearthed

Hydrogen and carbon Thermal Local hotspots

monoxide decomposition of incontact with
oil and solid solidinsulation.
insulation Low power arc
between
insulated
conductors and
earth, core faults.
 Faultyjoints/
contact. Any
incipient fault
involving solid
insulation

Slow Alarm Air or inert gas Presence of air due Release of

operates to mechanical fault entrappedair
or physical during early life
absorption oftransformer
oftransformer,
crack in tank, pipe
or relay casing,
faulty oil pump

Hydrogen Decomposition of Low current

oil only arching not
involving solid
insulation gassing
caused by high
electrical stress,
corona discharge

Hydrogen and carbon Decomposition of Low energy

monoxide oil and solid arching involving
insulation decomposition of
solid insulation,
creepage through
solid insulation,
oxidation of
insulation

No gas Alarm NA Low oil level Oil level falling

pressure operated below the level of
Buchhol the Buchholz
z relay relay due to oil
leakage

Table 11.6:Buchholz relay

11.7 Properties of Transformer Oil

Sl. No. Nominal Voltage Dielectric Strength of insulating oil (kV)

1 220kV More than 50

Table 11.7:Dielectric strength of insulating oil

Sl. No. Judgement Acid Content of Oil (mg KOH/g)

1 Good Less than 0.2

2 Replace or do filtration 0.3 – 0.5

3 Replace immediately Above 0.5

Table 11.8:Acid content of insulating oil (Neutralization)

Sl. No. Judgement Resistivity of Oil at 90°C (Ω-cm)

1 Good More than 0.1 x 1012

2 Fair 1 x 1011 to 0.1 x 1012

3 Poor Less than 0.1 x 1011

Table 11.9:Resistivity of insulating oil

Sl. No. Nominal Voltage of Transformer Water Content (ppm)

1 Up to 245 kV Class Less than 25

Table 11.10:Water Content

Sl. No. Nominal Voltage of Transformer At 90°C, 40-60 Hz

1 145 kV Class and above 0.2 max.

Table 11.11:Dielectric dissipation factor

11.8: Dissolved Gas Analysis

O2 Oxygen

N2 Nitrogen

CO2 Carbon dioxide

CO Carbon Monoxide
 H2 Hydrogen

CH4 Methane

C2H2 Acetylene

C2H4 Ethylene

C2H6 Ethane

C3H6 Propylene

C3H8 Propane

Nominal value of dissolved Ley Concentration limits in oil of Power Transformer in service (parts
per Million-ppm) is shown in table 11.12.

Status H2 CH4 C2H2 C2H4 C2H6 CO CO2 * TDCG**

Condition 1 100 120 35 50 65 350 2500 720

Condition 2 101~700 121~400 36~50 51~100 66~ 351~ 2500~ 721~

100 570 4000 1920

Condition 3 701~ 401~ 51~ 80 101~ 101~ 571 ~ 4001~ 1921 ~

1800 1000 200 150 1400 10000 4630

Condition 4 >1800 >1000 >80 >200 >150 >1400 >10000 >4630

Table 11.12:Nominal value of Dissolved Gas Concentration

* CO2 is not considered in the calculation for TDCG because it is not a combustible gas
** TDCG means Total Dissolved Combustible Gas
Condition - 1
Total Dissolved Combustible Gas (TDCG) and any individual combustible gasbelow this level
indicate normal operation of the transformer/Reactor. If anygas exceeds the specified level, it
needs investigation.
Condition - 2
TDCG and any individual combustible gas in this range indicate greater thannormal combustible
gas level. A fault may be present. Further monitoring isrequired.
Condition - 3
TDCG and any individual combustible gas in this range indicate a high level ofdecomposition of
cellulose insulation and / or oil.
Condition - 4
TDCG and any individual combustible gas in this range indicate excessivedecomposition of
cellulose insulation and / or oil. Continued operation couldresult in failure of the transformer.
Refer Table 11.13 for recommended sampling frequency and actions.

Note:
A sudden increase in key gases and the rate of gas generation are more important in evaluating
a transformer/Reactor than the amount of gas.
Conditions TDCG level or TDCG Sampling intervals and operating actions for
highest Generation Gas Generation Rates
individual gas Rates
(ppm/day) Sampling Continue normal operation
Interval

Condition 1 720 ppm of <10 Annually / 6 Continue normal operation

normal Monthly
operation TDCG
orhighest 10 ~ 30 Quarterly
condition based
>30 Monthly Exercise caution. Analyze
on
individual gases to find cause.
individualgas
Determine load dependence

Condition 2 <10 Quarterly Exercise caution. Analyze

individual gases to find cause.
10 ~ 30 Monthly Determine load dependence.

>30 Monthly

Condition 3 <10 Monthly Exercise caution. Analyze

individual gases to find cause.
10 ~ 30 Weekly Plan outage. Contact
manufacturer for advice
>30 Weekly

Condition 4 <10 Weekly Exercise caution. Analyze

individual gases to find cause.
10 ~ 30 Daily Plan outage. Contact
manufacturer for advice

>30 Daily Consider removal from service.

Contact manufacturer for advice

Table 11.13:Action based on Dissolved Combustible Gas concentration

 Key Gases Possible Faults Possible findings

H2, possible trace of CH4and Partial discharge (Corona) Weakened insulation

C2H6, possible CO fromageing and
electricalstress.

H2, CH4 (CO if discharges Low energy Pinhole puncture in

involve paper insulation). discharges(sparking) paperinsulation with carbon
Possible trace of C2H6. andcarbon tracking.
Possiblecarbon particles in
oil.Loose grounding of
metalobjects.

H2, CH4, C2H6, C2H4 andC2H2 High energy Metal fusion, (poorcontacts
present in largeamounts. If discharges(arcing). in tap changer orlead
C2H2 is beinggenerated, it connections).Weakened
indicatescontinuance of insulation, fromageing and
arcing. COwill be present if electricalstress. Carbonized
paper isbeing heated. oil.Paper over
heating/destruction if it is in
the arcpath.

H2, CO. Thermal faults less than3000C Discoloration of paper

in an area close topaper insulation. Overloading or
insulation (Paper isbeing cooling problem.
heated) Badconnections. Stray
currentpath and/or stray
magneticflux.

H2, CO, CH4, C2H6 and Thermal fault between 300 °C Paper insulationdestroyed.
and 700 °C Oil heavilycarbonized.
C2H4

All the above gases High energy electrical arcing Same as above with metal
andacetylene in 700°C and above. discoloration. Arcing may
largeamounts. have caused a thermalfault.

Table 11.14:Transformer Fault Types and the gases they produce

Note:Transformers are so complex that it is impossible to put all causes into a chart. Several other
reasons like high current surges due to faults downstream, static electric discharges, multiple core
earthing, sustained operation under over load, over/under voltage etc. may also be seen.
 SECTION C: SAFETY AND WORK PERMIT
SECTION C: SAFETY AND WORK PERMIT
 SECTION C:

OPERATION MANUAL

CHAPTER 1
CHAPTER 1: PERMIT TO WORK-LOCK OUT/
TAG OUT

1.1 Introduction

This procedure is intended to be used for the protection of Personnel while servicing or
performing maintenance on equipment / pipelines / valves / control systems. This is a general
procedure that shall be used as the minimum requirements for isolation of equipment, pipelines,
machines, system from all possible sources of hazardous energy and / or material such as
Pressurized water, Compressed Air, any other process fluid / chemical energy /Mechanical energy
or Electrical energy.

1.2 Scope and field of application

This procedure specifies the mandatory requirements for controlling hazardous energy. It also
describes
i) how to achieve and maintain the security of any isolation made and
ii) releasing the equipment from lockout.
This procedure applies whenever an employee is servicing or performing maintenance activities
on machinery or equipment in a manner which requires the removal or bypass of guards or other
safety devices or in a manner that requires the employee to place any part of his or her body into
an area on a machine or piece of equipment where work is actually performed upon the material
being processed (point of operation) or where an associated danger zone exists during a
machine operating cycle, or in a manner that otherwise exposes the employee to electrical,
mechanical, heat, radiation, chemical gas /liquid or steam hazards in the event the machinery or
equipment or system is accidentally re-energized during maintenance or service work. Here are
some examples;
1. Work on electric motors and circuits.
2. Work on Pumps, valves and seals.
3. Work on air conditioning and ventilation equipment.
4. Work on Cooling oil/water system pipe lines/gauges.
5. Work on permanently wired machinery or equipment.
6. Work on workshop and laboratory equipment.
7. Work on compressed air or gas (chemical) lines.
8. Work on hydraulic/pneumatic systems.
9. Work on elevators/hoists, etc.
Caution: All sources of hazardous energy / materials shall be identified prior to initiating any
lockout / tagout.

Equipment specific procedures shall be made unless all of the following elements exist(s)–
i) The machine or equipment has no potential for stored or residual energy or re-accumulation of
stored energy after shutdown that could endanger Personnel.
ii) The machine or equipment has all energy sources that can be readily identified and isolated.
iii) The isolation of the energy source(s) will completely de-energize and deactivate the machine or
equipment.
iv) The machine or equipment is isolated from the energy source and locked out during servicing or
maintenance.
v) The keys to the locks are under the exclusive control of the Permit Acceptor, Permit issuer and
employee performing the work.
vi) The servicing or maintenance does not create hazards for other Personnel.
vii) There has been no incidence involving the unexpected activation or restarting of the machine or
equipment during servicing or maintenance.
The practices that have been identified here are applicable within Dagachhu Hydropower
Corporation Limited only.

1.3 Responsibilities

 All Shift In-charge/Team leader and their teams dealing in LOTO shall be responsible for
adhering to the procedure during job involving exposure to hazardous energy / materials.
These include the contractors and their work force if availed.
 Plant HOD shall be responsible to ensure that a system is in place to ensure that all concerned
in the plant are trained in LOTO procedure.
 Permit Acceptor shall be responsible to ensure that only trained and authorized people are
deployed for the jobs.
 Person In-Charge/Shift In-Charge (Permit Issuer) shall be responsible for identifying specific
procedures for isolation/discharging / draining / blinding / venting of equipment before
releasing it for maintenance / inspection in their respective areas.
 Maintenance supervisors shall be responsible for arranging / preparing discharge rod/slip
plates / blanks, etc., as per the process requirements and use of Personal protective
equipment while carrying out discharging /blinding / de-blinding activities as per the specific
instructions.
 Person In-Charge/Shift In-Charge Electrical Officer/Technician shall be responsible for
electrical lockout and tag out (Danger).
 Executing Person or Team Leader shall be responsible for provision of Locks.
Note: Refer Annexure S2 for details of Responsibility Matrix

1.4 Policy

Lockout devices and Tagout devices shall be singularly identified; shall be the only device(s) used
for controlling hazardous energy sources and shall not be used for any other purposes.
No Personnel shall perform job on any equipment or machine unless it has been locked out and
tagged out, to prevent inadvertent release of hazardous energy sources.
No device to be operated or moved when a tag, Caution or danger, or lock is attached.
The steps outlined in this procedure shall be considered as the minimum requirements.
Note:- Refer section – 8.0 for exceptions to this procedure.

1.5 Definitions

Affected Person— Any Person who operates or maintains or works on machinery or equipment,
which is subjected to lockout/ tagout.
Authorized Person— A Person trained and authorized in the lockout/tag out procedure to make
and verify isolations.
Note: In some cases, the authorized Person can be the executing Person.
Caution Tag – is placed with intent of warning the affected Person that operation of the device
will cause harm to the equipment / system / machinery/ personnel.
Complex lockout—Lockouts that may involve multiple:

 Crafts/Disciplines
 Contractors/Employers
 Hazardous energy sources
 Lockout points
 People
 Shifts
Control device —a device used to execute a system change by manual, remote, automatic, or
partially automatic means (e.g., push buttons, emergency buttons or stops, selector switches,
and other control-circuit type devices).
Release Tag – is placed only on an energy-isolating device with intent of alerting the affected
Person that operation of that energy-isolating device will cause harm to the life of the Personnel
inside the hazard zone.
Electrical Engineer/Technician — A qualified Person trained and authorized in the electrical
lockout/tag out procedure to make and verify isolations.
Energy-isolating device—a mechanical device that physically prevents the transmission or
release of energy, including but not necessarily limited to, the following:

 A manually operated electrical circuit breaker

 A Fuse
 A disconnect switch
  A manually operated switch that disconnects a circuit from all ungrounded supply
conductors and prevents all poles from being operated independently. (Group Operated
Device)
 A line valve
 Slip plates, blanks, and physical disconnections
 A mechanical block or any similar device used to block or isolate energy.
Executing Person/Maintenance Engineer– Affected Person who is executing the job on the
equipment which is subjected to lockout / tagout.
Operation Engineer /Field Operator— the Person who is responsible for the operation of a
machine, system, or equipment in the field.
Hazardous energy—Any source of electrical, mechanical, hydraulic, pneumatic, chemical,
thermal, nuclear radiation or any other energy that, if not controlled, could cause injury to
Personnel or damage to property and/or environment.

 Electrical hazards are present when conductors or components that may be electrically
energized could cause injury to Personnel or damage to property.
 Mechanical hazards are present when the unexpected start-up of the system, equipment,
or machine, or the release of stored energy while adjusting, maintaining, or servicing
systems, equipment, or machines could cause injury to Personnel or damage to property.
 Process hazards are present when the unexpected release of gases, liquids, or solids
could cause injury to Personnel or damage to property. These hazards can exist during
such tasks as installation, fabrication, servicing, or maintenance of pipelines, vessels, or
associated equipment
Isolation—Separation of the equipment, machinery or area where work is to occur from sources
of hazardous energy or materials in such a way that only a conscious and deliberate act can
restore the connection.
Lock—one of three types of locking mechanisms:

 Discrete—Locks that are different from one another; each can only be opened by one
key.
 Personal—a discrete lock, individually keyed, issued to an individual for his or her use in
securing isolations.
 Series or system—A group of locks that are opened by a single key and are used in area/
complex lockouts. Various sets of locks may be in use; however, only one key can open
any given lock in a particular set.
Locking—placing a lockout device on a hazardous-energy-isolating device at a point of Isolation.
Lockout—Isolation of a source of hazardous energy, including releasing any residual hazardous
energy that might be present, and securing an isolation point by locking it.
Lockout device— A piece of equipment that prevents the unauthorized or accidental operation
of a hazardous-energy-isolating device. Locks are an essential element of a lockout device.
Maintenance - Workplace activities such as constructing, installing, setting up, adjusting,
inspecting, modifying, and maintaining and/or servicing machines or equipment. These activities
include, but not necessarily limited to, lubrication, alignment, cleaning or unjamming of machines
or equipment and making adjustments or tool changes, where the Person may be exposed to the
unexpected energization or startup of the equipment or release of hazardous energy.
Maintenance Engineer – A Person who is solely responsible for the execution of the intended
maintenance activity. Normally he will be the permit acceptor.
Person In-Charge/Shift In-Charge – A Person who is the custodian or owner of the area or
process and or associated equipment. He / She are authorized by the management to exercise his
/ her exclusive rights for the operation and use of the process and or its associated equipment in
the designated area. Also, referred as “Proprietor / Owner” in the Dagachhu Hydropower
Corporation Limited LOTO Standard.
Permit to Work - The written or printed document that is issued by the Owner to execute job as
per Permit to work procedure applicable at Dagachhu Hydropower Corporation Limited only.
Refer Annexure S1 for Permit to Work used at Dagachhu Hydropower Corporation Limited.
Qualified Person— A Person trained and authorized to work with the equipment and who
understands the hazards involved.
Stored energy—Hazardous energy that can continue to exist after equipment is isolated (e.g.,
the hazardous energy contained in springs, flywheels, pressurized fluids or gases, pneumatically
controlled devices, capacitors, or gravity).
Tagging—placing a specific tag on a lock or point of isolation to identify who placed the lock and
when it was placed.
Tagout—Placement of Release tag (Release Order\Release Notice – “HOLD”. “MEN AT WORK”)
(without a lock).
Team Leader— A qualified and authorized Person who shall undertake overall responsibility for a
lockout/tagout to place and keep all hazardous energy sources under lockout/tagout and to
account for all Persons working with him on the job or task. He is normally expected to lead the
executing team at the work location.
Testing —A process in which a qualified Person checks the machine / equipment to verify
whether its performance meets the intended need.
Troubleshooting— A process for identifying malfunctioning components within a system that is
done in both energized and de-energized systems.
Try/trying— proving the effectiveness of isolation by attempting to make a machine, system, or
equipment operate without being inhibited by interlocks or other means that would impede the
“try” step.
Work Permit Issuer -A Person, but not necessarily limited to Person In-Charge/Shift In-Charge,
who is authorized to verify that all conditions for carrying out the assigned job have been met, to
define ongoing precautions to maintain safe working conditions during the work, to authorize
the work to occur, and to cancel the permit.
Work Permit Acceptor – A Person, but not necessarily limited to Maintenance Engineer, who
accepts the work permit and controls the overall execution of the job in the field, in compliance
with permit to work procedure of Dagachhu Hydropower Corporation Limited.
1.6 Permit to Work

The Permit to Work is a written or printed document that is issued by the Owner/DHPC to
execute job as per Permit to work procedure applicable at Dagachhu Hydropower Corporation
Limited only. The Permit to Work should be availed for any maintenance work within Dagachhu
Hydropower Corporation Limited. We use two types of Permit to Work at Dagachhu Hydropower
Corporation Limited and are as follows:
i) Permit to Work through SAP system: For this, permit requester/availer should request the
Permit to Work through their SAP user ID and inform the permit issuer/Shift In-charge
through SAP mail or through any other means of communication. The lockout and tagout
should be done after the permit issuer issue the permit.
ii) Permit to Work in hard copy: It is also mandatory to maintain the Permit to Work in hard
copy as well and it is given in Annexure S1.
The Permit to Work should be closed/cancelled after the maintenance work is completed and
after recommissioning the system/equipment to its original state.

1.7 Procedure of Lockout & Tagout

This procedure covers the minimum requirements for lockout and tagout of energy- isolating
devices to protect any Person from hazardous energy including electrical, mechanical, hydraulic,
pneumatic, or other energy.
This shall be used as a general procedure for isolating all potentially hazardous energy
(lockout/tagout) before energization, start-up, or release of stored energy that could cause
injury. This procedure, when used in conjunction with specific information concerning individual
machines, provides the necessary information for lockout/tagout of machines with multiple
energy sources.
This procedure shall be followed in conjunction with the requirements of the Dagachhu
Hydropower Corporation Limited Safety Manual.

Caution: Specific individual procedures are required for all servicing and maintenance of
equipment, machines or systems requiring lockout/tagout of more than one energy source.

The essential elements of Lockout and Tagout procedure is -

i) Preparation for Lockout / Tagout.
ii) Tagging/Locking/Trying
iii) Restoring Equipment to Service

1.7.1 Preparation of Lockout and Tagout

Before work is started on any equipment, System or process, the Person In-Charge/Shift In-
Charge shall be responsible for Preparation for Lockout / Tagout.
He / She shall ensure that all hazardous energy sources are identified (Chemical, Electrical,
Mechanical or other) to determine which switches, valves or other energy-isolating devices apply
to machinery or equipment to be locked and tagged out.
Where stored or residual energy (such as that in capacitors, springs, elevated machine members,
rotating flywheels, hydraulic systems, water pressure, etc.) may be encountered, identification of
such type(s) of stored or residual energy shall be ensured. Appropriate methods of dissipating or
restraining such energy (by methods such as, but not necessarily limited to, grounding,
repositioning, blocking, bleeding down, etc.) shall be ensured.
For equipment preparation, pertaining to plant operational processes involving line breaks, the
prime consideration shall be of proving that isolations are intact giving a tight shut off.

Caution: Each case must be carefully considered by the Person In-charge/Shift In-charge, taking
into account the hazardous properties of the materials involved and the details of plant design.

1.7.2 Sequence of Lockout and Tagout

 Person In-Charge/Shift In-Charge shall ensure that all the type of energy that the System or
equipment utilizes, shall understand the hazards of the energy, and shall know the methods
to control the energy. In cases where complex lockout or multiple energy sources are
involved the Person In-Charge/Shift In-Charge shall generate an energy source identification
sketch (a computer generated, hand written or in any other form) to properly identify all
energy sources.

 Field operator/Operation Engineer shall ensure the equipment is not in operation and shall
switch off the equipment from LCS/ local Push Button/ASLPA Control System / remote
pushbutton. She/he shall provide an appropriate CAUTION Tag on the LCS or another control
device. (Refer Annexure S4)

 Person In-Charge/Shift in-charge shall submit Release notice tag for isolation of electrical
energy. Operation Engineer shall identify electrical energy source(s). He / She shall switch off
the source(s) and test the absence of voltage to equipment. All such energy isolation points
shall be provided with lockout device (Hasp) and ‘Release Notice’ tag (Refer Annexure S5).
Simultaneously the Maintenance Engineer or Team Leader shall provide his lock on the Hasp
and retain the key to the lock till the job is over. Refer Annexure S6 for recommended LOTO
methods for electrical energy sources. Field Operator/Operation Engineer shall use the
energy source identification sketch wherever applicable and now isolate all energy sources
by operating the valve, or other energy-isolating device(s) so that the equipment is isolated
from its energy source(s). (Refer Annexure S3 for guidelines for positive isolation and special
precautions).

 Field Operator/Operation Engineer shall ensure that stored energy (such as that in springs,
elevated machine members, rotating flywheels, hydraulic systems, and air, gas, steam, or
water pressure, etc.) shall be dissipated or restrained by methods such as, but not necessarily
limited to repositioning, blocking, draining, venting, bleeding down, etc.

 All such energy isolation points shall be provided with lockout device (Hasp) and ‘Release
Notice’ tag. (Refer Annexure S5)

 After energy source(s) isolation, the equipment shall be cleared by /purging / draining /
depressurizing / decontaminating and ensuring that the equipment / line is totally free of
 hazardous material. All such /drain / vent points shall be provided with ‘Release Notice’ tag.
(Refer Annexure S5)

 The Maintenance Engineer or Team leader shall provide the lock on each of the field energy-
isolating device, as per the energy source identification sketch, wherever applicable, and
retain the key to the lock till the job is over.

 After ensuring that no Persons are exposed to any hazard, Field Operator/Operation Engineer
shall remove the CAUTION tag from the LCS or another control device. As a check on having
disconnected the machinery or equipment from the energy sources, the Operation Engineer,
in presence of Maintenance Engineer or Team Leader, shall operate (TRY) the push button or
other control device to make certain that the machinery or equipment will not operate.
‘RELEASE ORDER’ tag shall then be placed on LCS or another control device.

Caution:Return the LCS or other control device to the “off” position after the test. Put the
RELEASE ORDER tag back on till the equipment is restored. “TRY” step shall be attempted with all
interlock / other controls, etc. and no interlock / other controls shall be disturbed till the
completion of the job.

The equipment or machine or system is now locked out and tagged out.

1.7.3 Re-commissioning / Taking back in line, of systems after maintenance

 After servicing or maintenance is completed, Maintenance Engineer or Team leader shall

check that the equipment and the area around the equipment is cleared and equipment
guards, Safety devices, etc. have been reinstalled and ready for intended operation.
 Maintenance Engineer or Team leader shall ensure that all Persons have safely moved out of
the hazardous zone.

Caution: Verify that LCS or other control devices are in “off” position. All blinds/ blocks, etc. shall
be removed prior to removal of locks.

 Maintenance Engineer or Team leader shall remove all locks provided on lockout devices
(Hasps) at the energy-isolating points, including electrical energy source and clear his
‘Release Permit’.
 Field Operator/Operation Engineer shall check & inspect the integrity of the equipment and
remove the Release Notice Tags and Release Order Tags.
 The equipment is now released for restoration into operation according to the restart up
procedure.

1.7.4 Lockout and Tagout Procedure involving more than one Person/group

When servicing or maintenance on any equipment or machine is performed by more than one
Person or more than one group, each group shall utilize a procedure which affords the Person a
level of protection equivalent to that provided by the implementation of a Personal lockout and /
or tagout device.
Each of such group shall have a Team Leader who shall have the identification of each individual
Person (DHPC employee or Contractor employee) working in that group. The Team Leader, on
behalf of each individual Person, shall fill up a written declaration to the Person In-Charge/Shift In-
Charge stating his overall responsibility to place Lockout / Tagout for the group and keep all
hazardous energy sources under lockout/Tagout till the end of the job or task. (Refer Annexure
S7 for Team Leader’s declaration)
The Team Leader shall impart the necessary information to each Person of the various sources of
hazardous energy and the method of isolation. He / She shall inform the group about the location
of energy isolation device. After the required information is imparted, each Person in the group
shall acknowledge their acceptance for LOTO to be placed by the Team Leader on their behalf.
The Person In-Charge/Shift In-Charge shall authorize the Team Leader to provide a Lock on behalf
of his group after receipt of the completed declaration.

Caution: A fresh declaration has to be made if any changes take place to the details of the
submitted declaration. (e.g.– change of job scope, change of equipment, etc.) except change of
Personnel within the group excluding Team Leader.

If multiple group are working on same equipment or machine requiring isolation, then as many
isolation tags as the number of permits shall be generated by the Person In-Charge/Shift In-
Charge. Each Team Leader shall provide his / her lock, on behalf of the group. Unless all locks are
removed, restoration of any energy source shall not be done.

1.7.5 Lockout and Tagout Procedures Involving Shifts

An orderly transfer of Lockout or Tagout devices between Person leaving the workplace and
relieving Person shall be ensured in order to minimize exposure to hazards from the unexpected
energization or startup of machinery or equipment, or the release of stored energy.
Proper information about LOTO on jobs undertaken shall be communicated through operation
log book entries/proper documentation & handing over the keys to the next shift. This
responsibility lies with executing Persons/Team leader of both shifts who shall ensure smooth
carryover of the job to the next shift. Refer Annexure S8 for Record of LOTO Transfer in Shifts.
(Optional to log book entries).

1.7.6 Temporary Removal of Lockout/Tagout Devices

In situations where the energy sources are locked and tagged, and there is a need for temporary
re-energizing for testing / taking trial of the equipment, machine or part thereof, the following
shall be mutually agreed upon between the Person In-Charge/Shift In-charge and the Executing
Persons/ Team Leader:

 Scope of testing

 Testing procedure

 Duration of testing

 Assessment of hazard as an outcome of testing

 Additional precaution to be taken during the restoration of energy, duration of testing

and re-isolation of energy.
In all cases, the temporary removal of Lockout / Tagout devices shall include, but not necessarily
limited to, the following steps:
  Person In-Charge/Shift In-Charge shall ensure that the area in the vicinity of the target
equipment / machinery is cleared.

 Person In-Charge/Shift In-Charge shall ensure that all Persons inside the hazard zone are
informed that equipment / machinery needs to be re-energized for testing / trial.

 Person In-Charge/Shift In-Charge shall ensure that all Persons (all persons in case multiple
groups are working) on the job, safely clear the job to enable testing / trial and remove
their lockout temporarily before moving out of the hazard zone.

 After getting final clearance from Person In-Charge/Shift In-Charge, the executing Person/
Team Leader shall re-energize the equipment / machinery for testing / trial under
‘Operating Permit’ Tag. (Refer Annexure S5A)

 After completion of testing / trial, ‘Operating Permit’ shall be cleared by the executing
Person/ Team Leader. Person In-Charge/Shift In-Charge shall de-energize the equipment /
machinery.
For complex situations (as judged by Person In-Charge/Shift In-charge) the Person In-Charge/Shift
In-charge shall require and ensure that a specific written procedure covering all of the above
points is prepared and reviewed with all Persons involved in the testing.

1.7.7 Maintenance requiring undisrupted energy supply

Where maintenance, repairing, cleaning servicing, adjusting or setting up operations (including

the energy-isolating device itself) cannot be accomplished with prime mover or energy source
disconnected, such operation shall be performed under following requirements.

 The Person In-Charge/Shift In-charge shall issue ‘Caution ‘tag to a qualified Person who
shall keep the machine / equipment (e.g. – Control panel, Remote Control unit, Circuit
Breaker, Switches, etc. from where the machine can be activated) under his exclusive
control throughout the duration of the job.
 The qualified Person shall ensure that all executing Person must be in his clear sight or in
direct communication with him at all times till the duration of the job.
 The qualified Person shall ensure that all executing Person must be beyond the reach of
the machine / equipment part which may move / actuate and cause exposure to
hazardous energy / material.
 If the qualified Person has to leave the operating station, the equipment / machine must
be de-energized till the same or another qualified person resumes control of the
machine / equipment.
 During repairs when the machine / equipment parts are to be adjusted / replaced, the
qualified Person shall ensure that the machine / equipment must be de-energized /
disconnected from its energy source.
 After the job, the qualified Person shall ensure that all executing Person on the job, safely
clear out from the hazard zone and clear the ‘Caution’ tag before testing / trial.

Caution: Each case must be carefully considered by the Person In-charge/Shift In-charge, taking
into account the hazard involved and the details of equipment design and equipment specific
procedure shall be made as needed.
1.7.8 Lockout Devices and Locks

Person in-charge/Shift in-charge shall be the only agency that will control and shall ensure
necessary provision for providing field hasp including hasp for electrical Lockout.
Plant control room shall have a comprehensive procedure of monitoring and control of field
through proper documentation and shift-to-shift communication so that no device(s) remain left
out unnoticed.
All hardware used for hazardous energy control must be durable enough to withstand the
workplace environment and must be used solely for the purpose of control of hazardous energy.
If there is a loss of key, the concerned person shall inform the Person In-charge/Shift In-Charge by
a formal written communication about the facts. The Plant HOD shall be the only approving
authority for breaking any locks of the energy-isolating device.
For ease of identification of the department to which the executing Persons/Team leader is
associated, the locks shall be identified by defined colors as mentioned below-

 Electrical Maintenance Group – Red,

 Mechanical Maintenance Group - Yellow
 Operation Unit – Black,
 Others - Green.

1.7.9 Tagout and Tags

If an energy-isolating device is not capable of being locked out, a tagout procedure (Tagging
system) shall be followed.
Where Tagout procedure (tagging System) is used for hazardous energy control, the Persons
must be fully aware of the following limitations of tags:

 Tags are essentially warning devices affixed to energy-isolating devices, and do not
provide the physical restraint on those devices that is provided by a lock. Tags may evoke
a false sense of security, and their meaning needs to be understood well.
 When a tag is attached to an energy-isolating means, it shall not be removed without
authorization of the authorized Person responsible for it, and it is never to be bypassed,
ignored, or otherwise defeated.
 Tags must be securely attached to energy-isolating devices so that they cannot be
inadvertently or accidentally detached during use. Tags must be legible and
understandable by all Persons, whose work operations are or may be in the area, in order
to be effective.
 Tags and their means of attachment must be made of materials, which will withstand the
environmental conditions encountered in the workplace.
CAUTION Tags shall be provided to indicate that no change must be made to the state of the device /
valve / control unit / etc. (Refer Annexure S5)
RELEASE Tags shall be provided at the point of isolation of Hazardous energy source. (Refer
Annexure S5)
OPERATING PERMIT tag shall be provided for trial /testing operations of the equipment. (Refer
Annexure S5A)

Caution: Either type of RELEASE tags cannot be substituted by CAUTION tags and hence shall be
tagged as per the right intent.

1.7.10 Contractors

Whenever outside servicing Persons (e.g., contractors, vendors, Equipment Service Engineers,
etc.) are to be engaged in activities covered by the scope and application of these procedures,
the Maintenance Engineer shall inform and ensure implementation proper lockout or tagout
procedures.
All outside servicing Personnel (e.g. contractors, vendors, Equipment Service Engineers, etc.)
must comply with all applicable Lockout /Tagout standards or requirements.
Contractor Supervisor shall ensure that their employees understand and comply with the
applicable Lockout /Tagout standards or requirements.

1.8 Exceptions

 Work performed on cord & plug connected portable electric equipment as long as the
equipment is unplugged during servicing & the Person performing the servicing maintains
exclusive control of the plug.
 Lamp replacement job done in non-operational area.

1.9 Review of LOTO Completion

Area owners shall audit their respective areas once every month to identify Lockout / Tagout left
since last audit and identify root cause for non-release. Such cases shall be resolved on case-to-
case basis by registering a target date / regularizing through other established procedures.

1.10 Audit

Multi-disciplinary audit team shall be formed by plant HOD in consultation with the custodian.
Audit shall be carried out on once a month within the plant. The audits must be performed by
Personnel other than the one actually performing work on the equipment at the time of the
audit.
The audit shall be focused on the following aspects

 Knowledge about the Site & Plant level procedure

 Compliance to the Standard & Site level procedure
 Implementation of the procedure, especially procedure under exclusion
 Compliance of Authority
 Documentation & record (including training, etc.)
Record of Deficiencies shall be submitted to Site Head/Unit Head for taking steps to correct
them. Records of such corrective actions (including revision of procedure, training etc.) shall also
be maintained by the plant.

1.11 Training & Record keeping

Personnel must initially be trained on identification of Hazardous energy sources associated with
the job. Specific training including risk assessment for specific jobs shall be conducted.
Authorized Persons (DHPC employee) must receive initial training and special instructions
concerning the scope, purpose, authorization, rules and techniques for lockout/tagout of
hazardous energy sources including, but not necessarily limited to:

 Recognition of the types of hazardous energy sources;

 Intended use of the lockout/tagout procedure;
 Steps for shutting down, neutralizing, isolating, holding and securing;
 Steps for placement, removal and transfer of lockout/tagout devices and the associated
responsibility;
 Requirements for testing to determine and verify the effectiveness of lockout/tagout
devices; and
 Other appropriate measures necessary to protect employees from hazardous energy.
All Persons authorized to perform maintenance of equipment, must understand the purpose and
function of the lockout/tagout program. Maintenance supervisors shall be responsible for
ensuring their people are scheduled to attend training. Division heads/Unit Heads are to ensure
that all Persons in their division (DHPC employee or Contractor employee) have been properly
trained.
Each new or transferred Person shall be instructed about the purpose and use of the
lockout/tagout procedure, as it pertains to them, before they begin their initial assignment.
Retraining is required for all authorized and executing Persons (DHPC or Contractor) whenever
there is a change in job assignment, a change in machines or equipment that presents a new
hazard, or when there is a change in the energy control procedure.
Retraining shall be conducted when there are changes in job assignment; machines, equipment
or processes; or in the LOTO procedures. Retraining shall also be conducted when a periodic
inspection of the effectiveness of this procedure reveals inadequacies in Person’s knowledge or
performance.
A record of all training and retraining shall be maintained. The training record shall include the
name of the employee, level of training, name of the instructor and the date of the training.
Division Head/Unit Head or his nominee will keep all training records on file. The Training records
will be retained indefinitely or until the employee is no longer employed or at the site.
 1.12 Annexures
Annexure S1 Permit to Work

PERMIT TO WORK - LOCK OUT/TAG OUT Page 1

Permit No:
Work on energized equipment or installations / Maintenance activity on any Machine

Reminder: A Permit to Work shall be issued for any work (maintenance, servicing, etc.) where lock out / tag out is required

A. Application

Requested by (company, service, name): Date:

Area: Description of works (attached drawing/sketch as necessary):

Estimated work duration: From: Hours to: Hours

B. Risk assessment (tick adequate risks)

☐ Electrical Hazard☐ Mechanical Hazard ☐ Hydraulic ☐ Pneumatic ☐ Chemical ☐ Others (describe)

……………

C. Isolation Scheme (tick action implemented)

☐ Review of equipment technical ☐ Identification of all energy isolation devices ☐ identification of all lock out
documentation ☐ Identification of emergency devices
☐ Others (describe)………
shutdown devices

D. Precaution to be taken prior to commencement and during work

1) Equipment:

☐ Lock out tags ☐ Insulated steps/platform ☐ Rescue hook ☐ Lock out box

☐ Voltmeter ☐ Others (describe)……

2) Electrical (PPEs):
☐ Electrical safety boots ☐ Electrical safety gloves ☐ Others (describe)…………

3) Other PPEs:

☐ Safety Shoes ☐ Safety glasses ☐ High Visibility jacket ☐ Dust mask

☐ Apron ☐ Welder mask ☐ Mechanical gloves ☐ Manual handling

gloves
☐ Visor ☐ Fiber mask ☐Others (describe)…………

E. Lock out devices applied

Identification of Types of Hazards Potentia Type of Identification

energy isolation l lock out code of lock out
equipment Electrical Hydraulic Pneumatic Mechanical Chemical residual devices device
energy

1. ☐ ☐ ☐ ☐ ☐

2. ☐ ☐ ☐ ☐ ☐

F. Verification before

Do you confirm that the following elements are fully available/implemented?

 All the equipment shutdown by normal stopping ☐ Yes  Adequate rescue means available ☐ Yes
procedure
☐ Yes  All personnel affected by machine/equipment ☐ Yes
 All energy sources isolated
shutdown ☐ Yes
 All energy isolating equipment “Lock out” with ☐ Yes
adequate lock out device notified
☐ Yes
 All energy isolating sources tagged ☐ Yes  Adequate PPE worn by all concerned person
 All potentially hazardous sources or residual ☐ Yes
☐ Yes  All PPEs in good condition
energy purged/ dissipated ☐ Yes
 Verification of effectiveness of isolation ☐ Yes  Work area clear and demarcated
 Nearby workers informed of work to be performed

G. Permit Issue

The work permit has been issued for the works to proceed subjected to conditions specified above.

Name Date and time Signature

Availing Authority

Issuing Authority

DHPC EHS Focal

Person

PERMIT TO WORK – LOCK OUT/TAG OUT Page 2

Permit No:
Work on energized equipment or installations / Maintenance activity on any Machine
H. Lock out device removed

Identification of energy isolation Type of lock out devices Identification code of lock out
equipment device

1.

2.

3.

4.

5.

6.

7.

I. Completion of Work

Do you confirm that the following elements are implemented?

 All works requiring the lock out / tag out are finished ☐ Yes  All tags have been removed ☐ Yes
 All safety devices of the equipment are operational  All personnel affected by
☐ Yes ☐ Yes
machine/equipment switched ON notified
 All lock out devices have been removed ☐ Yes  Nearby workers informed of ☐ Yes
 All energy isolating equipment are operational machine/equipment switched ON
☐ Yes

J. Permit Closure

I, hereby declare that all workers under my charge have been withdrawn from the equipment and advised them not to do any job
further. All the tools and temporary earthings which were provided by me were cleared from the equipment. The equipment is fit for
energisation. The work permit is hereby cancelled.

Name Date and time Signature

Availing Authority

Cancelling Authority

DHPC EHS Focal

Person

Annexure S2
Responsibilities Matrix:

Sl. No Activity Description Responsibility

1 Ensure that equipment / machine / Person In-Charge/Shift In-Charge

system is shut down and cleared
 2 Provision of Hasp on source of Hazardous Person In-Charge/Shift In-Charge,
energy after isolation Maintenance Engineer/Technician.

3 Electrical Isolation request Person In-Charge/Shift In-Charge /

Maintenance Engineer

4 Electrical Isolation of Equipment Person In-Charge/Shift In-Charge

5 Provision of lock on Hasp and retaining Maintenance Engineer / Executing

key till completion of the job Persons/ Team leader

6 Trying (Verifying) effectiveness of Person In-Charge/Shift In-Charge in

isolation. presence of Maintenance Engineer /
Executing Persons/ Team leader

7 Written Request in case Key is missing & Person In-Charge/Shift In-Charge

clearance from Site Head through /Maintenance Engineer / Executing
Division Head Person/ Team leader

8 Authorizing to breaking of lock on source Site Head/Division Head

based on written request

Annexure S3
Guidelines for Positive Process Isolation

 The most positive method of isolation is the complete physical disconnection of the line with
blind flange or blank put on the live end. Where there is work on pressurized hydraulic system
or entry into a vessel, physical disconnection is the mainly recommended method of isolation.
If this method is not reasonably practical, then, as a next best method, the insertion of a slip
plate with the correct size, specific MOC and appropriate pressure rated blind is preferred for
the purpose of authorizing a confined space entry.

 Isolations shall be checked by one of the following methods:

i) By releasing pressure or draining liquid via a suitable vent or drain point. Do not rely on
pressure gauges - pressure should be seen to be released. Check that drain points or
vents are clear and free from chokes. If the isolating valves are holding, flow of material
should stop after pressure is vented.
ii) Where no vent point or suitable drain exists, it may be necessary to open a joint on a
pipeline or item of equipment between the closed isolations. This must be done under a
work permit with extreme care and the joint should be only cracked open until pressure is
fully released and the valves can be closed tight.
Caution: It is not possible to provide specific instructions covering the various ways in which the
equipment can be freed from hazardous process materials before maintenance work can take place.
In some cases, this may be achieved by pumping out and draining to a safe place; in other cases, by
blowing; or in the case of gases by purging or steaming. In some instances, decontamination is
carried out after the section of item can be fully isolated, in other cases it will be necessary to purge
or pump out before valves can be closed and slip plates fitted. Each case must be carefully
considered by the Person In-Charge/Shift In-Charge, taking into account the hazardous properties of
the materials involved and the details of plant design.

 In many situations, remotely operated valves and motor operated valves (MOV) are the only
isolations. Basically, for these on-off type valves the correct procedure is to positively disable
it, by either disconnecting the instrument air supply or remove the actuating signal wires or in
the case of MOVs electrical lockout / tag out is to be ensured.

 Having achieved line/equipment isolation by the closure of single or double isolation valves,
this valve isolation must remain effective until the purpose of the isolation has been achieved
and the Work Permit signed off. To ensure this, the valve or valves must be locked/ tagged in
the closed position or open position in the case of vent/drain valves.

Special Precautions

 For equipment like pump / blowers etc. where shafts / blades may rotate even after handing
over, are to be locked suitably against rotation using locking device before taking up
maintenance work.

 Existing slip plates should not be relied upon for positive isolation since they may be
corroded. They should be removed, inspected & replaced where necessary by new ones.

 Process and service lines, or equipment, e.g., a pump casing, relying on valve isolations must
not be left with open ends. Blanks must be fitted to the open ends immediately after the
section of the line or part of the equipment that is removed.

 Always ensure that slip plates compatible with the process materials confirm to the piping
design standards to which the plant was designed and these should be fitted as close as
possible to the equipment to be isolated. Always ensure that blind detail is entered in the
blind register.

 Where cutting or welding is to take place, the line or equipment must be purged and either
slip plates must be fitted after the section or item has been isolated or the item of the
equipment must be removed and open ends leading to other process equipment blanked off.

 Equipment containing corrosive chemicals must be washed or steamed out, where possible
after depressurizing and draining. Where residual contamination is unavoidable, full
protective clothing should be worn.

 In case isolation is required again due to some problem (like change in DOR), then this
procedure is to be followed afresh.

 For work on an Electrical distribution system, all Lockout / Tagout activities will be the same.
However, to avoid back feeding of power, isolations shall be ensured from all possible paths
(Upstream and downstream).
 While working on electrical installation, after lock out / tag out is done, equipment shall be
discharged safely of all its residual energy. If required, special care may be taken to keep the
terminals earthed till the completion of the job.

 Diesel engine driven / battery operated equipment shall be made inoperable by disconnecting
and removing battery cables safely.

 For isolation of electrical source where lock out provision is absent, physical disconnection of
outgoing power conductors shall be ensured.

Annexure S6
Electrical Isolation Method:

Sr. Electrical Energy Location of LO/TO point LO/TO Isolation method

No. Source

1 220KV source Breakers/Isolators on Lock Out & Switch Off and

respective bay Tag Out Isolate Control
locations /panels Supply and apply
earth switches.

2 33kV and 11kV Breakers/Isolators on Lock Out & Switch Off, Isolate
respective locations Tag Out Control Supply and
/panels Rack out

3 415V Source MCC / PDB feeder Lock Out & Rack out / Fuse
Tag Out removal

4 415V or less Source DB / Power points / Lock Out & Fuse removal
with LO provision Control Panels Tag Out

5 415V or less Source DB / Power points / Lock Out & Switching OFF
without LO provision Control Panels Tag Out power from
MCB/ELCB/ Isolator

6 Lighting circuit LDB Lock Out & Switching OFF

Distribution (230V) Tag Out power from
MCB/ELCB/ Isolator
 SECTION A:

OPERATION MANUAL

CHAPTER 2

7 415V / 230V/110V Socket Lock Out & Removal of plug

sockets Tag Out

8 110V DC MCC / PDB feeder Lock Out & Rack out / Fuse
Tag Out removal

CHAPTER 2: SAFETY AND OCCUPATIONAL HEALTH

2.1 Introduction

Occupational safety and health forms an integral function of a company and is concerned with
protecting the safety, health and welfare of people engaged in work or employment. The
management and employees are responsible and accountable for creating a safe working
environment and adhering to safe working practice.
Occupational health should aim at the promotion and maintenance of the highest degree of
physical, mental and social well-being of workers in all occupations; the prevention amongst
workers of departures from health caused by their working conditions; the protection of workers
in their employment from risks resulting from factors averse to health; the placing and
maintenance of the worker in an occupational environment adapted to his physiological and
psychological capabilities.

2.2 General Safety Rules

Most mishaps are caused by careless or thoughtless acts by workers. Workers must always be
cautious and deliberate in their actions, and always notify their co-workers before carrying out
 works that are potentially hazardous. Unsafe equipment, tools, and conditions must be reported
immediately and corrected. Good house-keeping is also important for safety.
Mishap prevention is a basic responsibility of every worker. All workers have an individual
responsibility to work and act safely at all times and ensure safety of their co-workers. Safety
takes precedence over work production.
Safety rules and regulations are established to protect people and property from injury or
damage.  All employees should adhere to the following general safety rules and should develop a
sense of pride for the safety and health in their respective workplaces.  There is no substitute for
the use of common sense and good judgment when it comes to safety.
i. Each worker shall wear suitable clothing including approved gloves and approved footwear
appropriate for working conditions. Do not wear loose clothing when working on or near
moving machinery. Long hair must be secured under the hard hat
ii. Do not wear metal jewelry (including but not limited to wristbands, watch chains, rings,
bracelets and body jewelry) when working on or near electrical equipment and near
moving machinery
iii. Promptly report all injuries to your supervisor; administer first aid promptly.  (In case of
serious injury, do not move the person until medical aid arrives, unless in a dangerous
location)
iv. Read and observe all signs and warnings
v. If you are in doubt about the safe or proper way to perform a job, get instructions from
your supervisor
vi. Correct or report any unsafe workplace conditions to your supervisor as soon as possible
vii. Report fires immediately, sound the alarm, evacuate the building utilizing standard fire
alarm protocol
viii. Know the location of emergency exits and locations of portable fire extinguishers and
other emergency equipment in the Power House complex. Keep emergency exit paths
clear
ix. All work areas shall be kept free of recognizable hazards.  Material stacking or storage must
be arranged to prevent its falling or creating trip hazards
x. Oily and dirty rags must be stored and disposed of in proper containers
xi. Fluids spilled on floor areas must be cleaned up immediately
xii. Use the right tools for the right job

2.3 Work Site Safety

Maintaining acceptable work site safety involves proper behavior, good housekeeping,
maintenance of protective measures, and avoiding unsafe actions.
Typical unsafe actions are listed as under:
i. Operating without authority
ii. Operating or working at unsafe speeds
iii. Making safety devices inoperative without proper authorization
iv. Using unsafe equipment or equipment unsafely
v. Taking unsafe positions or postures
vi. Working on moving or dangerous equipment
vii. Distracting, teasing, abusing or startling
viii. Failing to use safe personal protective devices
ix. Failing to lock-out energized circuits

2.4 Electrical Hazards

Electrical personnel involved in operating and maintaining electrical systems can be injured and
equipment can be damaged whenever electrical systems and components are not handled safely.
The adoption of safe electrical practices will reduce the hazards to personnel.

2.4.1 Dangers from Electrical Shock and its Effects

Electric shock results from setting up an electric current path within the human body. The current
flows because there is a potential gradient (voltage difference) between an energized object and
the grounded worker.
Remember that it is the current which causes damage to the living tissue and not the voltage.
Low voltage under wet conditions can cause fatal accidents. Contact with high voltage circuit
results in deep burns instantly resulting in disappearance of the protection afforded by the skin
resistance, and hence greater damage.
The value of dangerous currents for various individuals varies according to body constitution. For
women, it is approximately two-third of that for men and for children half of that for men.
Current values and its effects on human beings are given in the table below:

Current Values Effects

1 mA or less Causes no sensation i.e. Not felt

1 to 8 mA Sensation of shock, not painful; individual can let go at will, as

muscular control is not lost

8 to 15 mA Painful shock, individual can let go at will, as muscular control is not

lost

15 to 20 mA Painful shock, muscular control of adjacent muscles lost, cannot let

go

50 to 100 mA Ventricular fibrillation (possible)

100 to 200 mA Ventricular fibrillation (certain): A heart condition that results into
instant death, no known remedy

Above 200 mA Severe burns, severe muscular contractions - too severe that chest
muscle clamps heart and stop it during duration of shock

Table 2.1:Current values and effects

2.4.2 Rescue from Electric Shock

When a person comes in contact with live wires or equipment, switch off the current
immediately. If this cannot be done at once, remove the victim. Do not touch the victim with bare
hands. Use rubber gloves. If these are not available, use a rope, a long piece of cloth, or a
wooden stick to drag the victim. It must be ensuring that whatever used should be dry and non-
conducting. Send for a doctor. Apply artificial respiration, if required.

2.4.3 Dangers from Arcs and Blasts

Arcs result from the passage of electric current through air, when the air fails as an insulator and
serves as a conducting medium for ionized gases. Blasts result when the metal at the arc site
expands and vaporizes. Water expands 1670 times when it becomes steam; copper expands
67000 times when it vaporizes. High energy arcs can be fatal even at a distance of 3 meters.

2.4.4 Lockout and Tagout

Lockout/Tagout (LOTO) procedures apply to the control of energy

during servicing and/or maintenance of machines and equipment.
Control of hazardous energy, establishes the minimum requirements for
the lockout or tagout of energy isolating devices. It shall be used to
ensure that the machines or equipment are isolated from all potentially
hazardous energy, and are locked out or tagged out before employees
perform any servicing or maintenance activities where the unexpected
energization, start-up or released of stored energy could cause injury.  
As part of safe working practices, the lockout/ tagout process requires a circuit de-energized,
tested dead, isolated, tested dead, locked out, tagged, and grounded.

2.4.5 Fire Hazards

Adequate fire prevention measures have been taken for all areas/facilities in
the underground Power House to minimize chances of occurrence of fire.
However, in the event of fire in the underground Power House complex,
following needs to be adhered to:

i. Inform the Fire Officer, Safety Officer and higher authorities immediately about the incident
of fire.
ii. Ensure that all emergency escape routes are clear for passage and sufficient illumination
available.
iii. If the fire is minor, initiate action for putting off the fire with the help of Fire Personnel
deployed in the Power House.
iv. In case of fire, ensure closing of fire dampers in Transformer Chambers, blowers and
ventilation fans to avoid spread of fire.
v. Ensure that all portable fire extinguishers are properly filled and its standard pressure
maintained.

2.5 Personnel Protective Equipment

 Hazards exist in every work place in many different forms such as sharp edges, falling objects,
flying sparks, chemicals, noise and a myriad of other dangerously situations. Controlling a hazard
at its source is the best way to protect workers.
Two types of methods viz. engineering control and work practice control, are used to eliminate
hazards to the greatest extent possible. For example, building a barrier between the hazard and
the workers is an engineering control; changing the way in which workers perform their work is a
work practice control.
When engineering and work practice controls are not feasible or do not provide sufficient
protection, workers must be provided with personal protective equipment (PPE) and ensure its
use. PPE is equipment worn to minimize exposure to a variety of hazards. Examples of PPE
include such items as gloves, foot and eye protection, protective hearing devices, hard hats,
respirators and full body suits.

2.5.1 Head Protection

Protecting workers from potential head injuries is a key element of any safety program. A head
injury can impair a worker for life or it can be fatal. Wearing a safety helmet or hard hat is one of
the easiest ways to protect a worker’s head from injury. Hard hats can protect workers from
impact and penetration hazards as well as from electrical shock and burn hazards.

Hard hats should able to protect workers under following work situations:
i. If objects fall from above and strike, then on the head
ii. When workers bump their heads against fixed objects, such as exposed pipes or beams
iii. When there is a possibility of accidental head contact with electrical hazards
iv. In general, protective helmets or hard hats should do the following:
v. Resist penetration by objects
vi. Absorb the shock of a blow
vii. Be water-resistant and slow burning
viii. Have clear instructions explaining proper adjustment and replacement of the suspension
and headband

2.5.2 Eye and Face Protection

Employees can be exposed to a large number of hazards that pose

danger to their eyes and face. Appropriate eye or face protection
shall be worn by all employees when they are exposed to eye or
face hazards from flying particles, molten metal, liquid chemicals,
acids or caustic liquids, chemical gases or vapors, potentially
infected material or potentially harmful light radiation.
Examples of potential eye or face injuries include:
 i. Dust, dirt, metal or wood chips entering the eye from activities such as chipping, grinding,
sawing, hammering, the use of power tools etc.
ii. Chemical splashes from corrosive substances, hot liquids, solvents or other hazardous
solutions.
iii. Objects swinging into the eye or face, such as chains, tools or ropes.
iv. Radiant energy from welding, harmful rays from the use of lasers or other radiant light (as
well as heat, glare, sparks, splash and flying particles).
Selecting the most suitable eye and face protection for employees should take into consideration
the following elements:
v. Ability to protect against specific workplace hazards.
vi. Should fit properly and be reasonably comfortable to wear.
vii. Should provide unrestricted vision and movement.
viii. Should be durable and cleanable.
ix. Should allow unrestricted functioning of any other required PPE.
Some of the most common types of eye and face protection include the following:
i. Safety spectacles. These protective eyeglasses have safety frames constructed of metal or
plastic and impact-resistant lenses. Side shields are available on some models.
ii. Goggles. These are tight-fitting eye protection that completely cover the eyes, eye sockets
and the facial area immediately surrounding the eyes and provide protection from impact,
dust and splashes.

2.5.3 Foot Protection

Workers shall wear protective footwear when working in areas where there is a danger of foot
injuries due to falling or rolling objects or objects piercing the sole.

2.5.4 Hand Protection

Employees engaged in work where there is a danger of cuts,

slivers, burns, contact with hazardous materials, exposure to heat
and cold etc. shall wear suitable gloves for hand protection.

2.5.5 Hearing Protection

A personal hearing protection device (or hearing protectors) is any device designed to reduce the
level of sound reaching the eardrums. Ear muffs, ear plugs and ear bands are the main types of
hearing protectors.

Ear plug
Ear muff

Noise is measured in units called “decibels”, abbreviated as “dB”. Noise levels can range from 1
dB (near silence) to 60 dB (quiet conversation to 140 dB (a jet engine). Scientific studies have
shown that people exposed to noise levels of 85 dB and above over 8 hours or longer will
gradually lose their hearing over time. If you have to shout to be heard by another person 3 feet
from you, the noise level is probably above 85 dB. Noise levels above 140 dB will cause immediate
hearing loss. Therefore, everyone should wear hearing protection all the time when working
around noise levels above 115 dB. Hearing protection must be worn when employees are exposed
to 8-hour average noise levels of 85 dB or greater.
Some noise levels of commonly used equipment are given as under for reference:

Equipment Noise Level Equipment Noise Level

Back Hoe 85-95 dB Jack Hammer 112 dB

Chain Saw 110 dB Lawn Mower 90 dB

Gun Shot 140 dB Tractor 95-105 dB

Table 2.2:Noise levels of commonly used equipment

Various standards are followed while providing hearing protectors to workers exposed to noise
hazards. The permissible noise exposure as per the Occupational Safety and Health
Administration (OHSA), US are given as under for reference.
 Sound Level Duration Sound Level Duration

90 dB 8.0 hours 102 dB 1.5 hours

92 dB 6.0 hours 105 dB 1.0 hours

95 dB 4.0 hours 110 dB 30 minutes

97 dB 3.0 hours 115 dB 15 minutes

100 dB 2.0 hours

Table 2.3:Sound level and duration

2.5.6 Life Jackets and Safety Belts

i. Employees, who work in a location where there is a possibility of falling into water, shall be
provided with and wear a suitable life jacket or they shall be protected by a fall arrest
system that will hold the employee form falling into water
ii. Employees using boat or watercraft shall wear suitable life jackets at all times
iii. Employees working at heights such as towers and on EOT cranes shall wear safety belts.
The safety belts shall be inspected for strength and healthiness by individuals before
wearing them

2.5.7 Respiratory Protection

Approved respiratory protections must be provided to employees when are

exposed to insufficient oxygen environments, harmful dusts, smokes, gases,
vapors, and sprays. These hazards may cause cancer, lung impairment,
other diseases, or death when appropriate protections are not provided.
Employees must be trained for proper usage and care of the respiratory
protection equipment.

2.6 Tools and Equipment

2.6.1 Hand Tools

All hand tools used shall be of approved make and shall be free from any form of defects.
Defective tools shall be immediately removed from service, tagged and reported to the
supervisor.
For any specific instructions, manufacturer’s manuals shall be referred to.

2.6.2 Ladders- Portable

When the work warrants use of ladders, following basic precautions may be adhered:
i. Suitable fiber glass ladders shall be used while working near energized lines and in locations
which contain live electrical apparatus
ii. Ensure that legs of portable ladders are secured properly to avoid slippage of ladders,
thereby
iii. When extending ladder to working height, both locking dogs on the moving section must
be engaged on a rung
iv. Portable ladders shall not be placed in front of a door that opens toward the ladder, unless
the door is locked, blocked or guarded

2.6.3 Hoisting and Rigging

A designated person shall be responsible for safe loading/ unloading of materials. Proper and
correct use of ropes, chains, cables, slings, jacks, skids and other hoisting and rigging apparatus
shall be ensured. All hoisting apparatus shall be periodically inspected by the Safety Officer for
their strength and defects.

2.6.4 Welding, Cutting and Brazing

The intense light associated with welding operations can cause serious and sometimes
permanent eye damage if welders do not wear proper eye protection. The intensity of light or
radiant energy produced by welding, cutting or brazing operations varies according to a number
of factors including the task producing the light, electrode size and the arc current. As such,
hazards associated with these operations pose an unusual combination of safety and health risks.
Following precautions and safe practices shall be adopted while carrying out welding, cutting or
brazing operations:
i. Welders and their helpers shall wear protection equipment appropriate for the job to guard
the eyes, face, neck and hands when engaged in welding, cutting or brazing operations.
This protection shall include welding helmets, welding caps, insulated gloves, leather
aprons, spectacles or goggles and respirators where required
ii. Welding, cutting or brazing operations shall not be performed in a confined space. Proper
ventilation is required to protect the operator from the evolving noxious fumes and gases
iii. Do not weld on dirty plate or plate contaminated with unknown material. The fumes and
gases which are formed could be hazardous to health. Remove all paint and galvanized
coatings before welding. All fumes and gases should be considered as potentially
hazardous
iv. Keep welding cables dry and free of oil or grease Keep cables in good condition, and, at all
times, take appropriate steps to protect them from damage. If it is necessary to carry
cables some distance from the machines, run the cables overhead, if possible, and use
adequate supporting devices
v. Inflammable materials shall not be carried by welders when engaged in work

2.6.5 Air-Operated Tools

Following precautions and safe practices shall be adopted while using air-operated tools:
i. Air-operated tools shall never be pointed at another person
ii. Air-operated power tools shall be secured to the hose by a positive means to prevent the
tools from becoming accidentally disconnected
iii. Employees shall wear appropriate PPE when exposed to hazards created by dust, metal
cuttings or other substances being blown from equipment, materials or structures by the
use of compressed air, compressed gases or steam
iv. The manufacturer’s safe operating pressure for hoses, pipes, valves, filters and other
fittings shall not be exceeded
v. Air-operated tools shall only be operated in accordance with manufacturers’ instructions
vi. Metal-reinforced hoses shall not be used near energized equipment
vii. Air-operated power tools shall not be used in the proximity of energized lines or apparatus

2.7 First Aid

The Safety Officer shall maintain First Aid Kits at work places and employees shall be familiar with
their location and contents. First aid is intended to be a simple, practical guide for effective action
in time of emergency. Except for minor injuries, professional medical treatment should be
sought.

2.7.1 Work Injury and Mishap Reports

The work site injuries and mishaps are required to be prevented as far as possible by taking
precautionary measures such as use of PPE. However, if such incidents are unavoidable resulting
in any mishaps, then such incidents shall be immediately reported to the Safety Officer.
 References

We have taken references from following Operation and Maintenance Manuals:

1. Alstom Renewable GmbH, Austria, “Hydro Generator – Dagachhu System Manual”.
2. Andritz Hydro GmbH, Austria, “Operation and Maintenance Manual - Turbine”.
3. Andritz Hydro GmbH, Austria, “Operation and Maintenance Manual - Spherical Valve (Main Inlet
Valve)”.
4. Andritz Hydro GmbH, Austria, “Operation and Maintenance Manual - Digital Governor”.
5. Andritz Hydro GmbH, Austria, “Operation and Maintenance Manual - Hydraulic Governor”.
6. Alstom Renewable GmbH, Austria, “ALSPA Control System Operation and Maintenance
Manual”.
7. Converteam GmbH Germany, “Operation and Maintenance Manual - Static Excitation System”.
8. Areva T&D, “Installation, Operation and Maintenance manual for PIX 36kV with vacuum
switchgear”.
9. Electronic Systems India limited, “Instruction and Operation Manual of 110V DC, 440AH Float
cum Boost Battery Charger”.
10. Cummins Power Generation, “Operation and Maintenance Manual – Diesel Generators”.
11. Braun Maschinenfabrik, Austria, “Operation and Maintenance Manual - Gates”.
12. Braun Maschinenfabrik, Austria, “Operation and Maintenance Manual - Screen Cleaning
Machines”.
13. Braun Maschinenfabrik, Austria, “Operation and Maintenance Manual – Trash Rack Cleaning
Machine”.
14. Braun Maschinenfabrik, Austria, “Operation and Maintenance Manual - Desilter”.
15. Alstom Renewable GmbH, Austria, “Electrical Protection Of 220kV OHL 220kV Busbar 5MVA
Auxiliary Transformer – Checklist and directions for operation”.
16. Alstom Renewable GmbH, Austria, “Electrical Protection of Units – Checklist and directions for
operation”.
17. Andritz Hydro GmbH, Austria, “Operating and Maintenance Description of Intake Gate”.
18. Andritz Hydro GmbH, Austria, “Operating and Maintenance Description of Weir Radial and Flap
Gates”.
19. Areva T&D, “Operation and Maintenance Manual – Gas Insulated Switchgear”.
20. Andritz Hydro GmbH, Austria, “Operating and Maintenance of Water control panel for Main
Inlet Valve”.
21. Areva T&D, “Description and Instruction Manual for 24MVA, 11/220 kV, GSU Transformer”.
 Acknowledgement

We sincerely acknowledged all the officials who were involved in bringing first Operation and
Maintenance Manual of Dagachhu Hydro Power Corporation Limited. We also want to thank the
management of Dagachhu Hydro Power Corporation Limited for giving us this opportunity for
bringing up this first Operation and Maintenance Manual. We acknowledge the efforts and
commitments of following officials:
1. Mr. Karma Phuntsho, Chief Executive Officer,
2. Mr. Tashi Dorji, Head, Operation Unit,
3. Sonam Gyamtsho, Assistant Engineer (Mechanical)
4. Pema Wangchuk, Junior Engineer (Electrical),
5. Sonam Tenzin, Junior Engineer (Mechanical),
6. Choedra, Junior Engineer (Electrical),
7. Mon Raj Rai, Junior Engineer (Electrical),
8. Sonam Tshering, Sr. Section Officer (Mechanical),
9. Karma Dorji, Sr. Section Officer (Electrical),
10. Ugyen Tshering, Sr. Section Officer (Electrical),
11. Sherab Thaye, Sr. Section Officer (Electrical),
12. Chening Dorji, Sr. Section Officer (Electrical),
13. Tshechik Wangdi, Sr. Foreman (Mechanical),
14. Pema Dendup, Sr. Foreman (Electrical),
15. Sithar Wangdi, Foreman (Mechanical),
16. Thinley Phuntsho, Foreman (Mechanical),
17. Pema Gyeltshen, Electrician
If there are any discrepancies/ shortfalls/ mistakes/ practical issues in the manual, we would
appreciate if you keep note of it, so that we can incorporate in next the revision.