NORTH SOUTH POWER

COMPANY LIMITED
SHIRORO HYDROELECTRIC POWER STATION

MECHANICAL MAINTENANCE DEPARTMENT

AGM (MECH)

REPORT ON UNIT 411G1 BRAKES REPAIRS.

On 22nd July 2015 a trouble/repairs report was filed on UNIT 411G1 brakes failure to come to
standstill when the unit was shut down with low pressure observed.

CHECKS/TROUBLE SHOOTING.
 Physical checks and response of the brakes when applied and released manually were
carried out.
 Cleaning of the entire generator housing was carried out.
 Isolation of air pressure valve.
 Pressure gauge was used to test the brakes one by one to ascertain the Faulty ones.
 Brakes Nos.1,3 and 12 did not attain the require pressure of 6bars.
 Dismantling of air piping connections of the affected brakes.
 Dismantling of brakes base bolts.
 Dismantling of brakes limit switches.
 Dismantling of brakes lining(pads)
 Unscrewing of brakes spring retainers.
 Removal of Brake spring.
 With the aid of 2tones chain blocks, the piston was removed safely from the brakes
drum.
 Brakes diaphragms were inspected and discovered to be defective.
 The brake drums were also inspected and some fine particles were found.

REPAIRS CARRIED OUT

 The brake drums and pistons were thoroughly cleaned using smooth emery cloth,
solvent and (molten cloth).
 Compressed air was introduced to blow retained particles within the drum and
piston.
  The brake springs and retainers were thoroughly cleaned and blown with
compressed air.
 Cleaning and replacement of new diaphragms seals were carried out.
 Smearing of pistons and inner walls of brakes with TELUS T68 oil to reduce friction
while mounting them back.
 With the aid of chain blocks, the pistons were carefully lowered to the brake drums
with special attention to the diaphragms seals.
 The brake springs were put back into their slots.
 The spring retainers were screwed back to the brake drums.
 The brake pad base were tie to the piston.
 The brakes were carefully mounted back to their positions.
 Reconnections of air piping’s and limit switches.
 The brake pads were finally fixed to their positions ensuring that, they are keyed into
their slots.
 Removal of all working tools/material used from the generator housing.
 General cleaning of the work environment.
 The Permit Holder carried out final inspection of work done.
 Lifting of isolation for test run.
 Brakes were applied and released manually on intervals.
 The brake air supply and brake pressure improved up to 7bars each and all the
12No brakes applied.

CONCLUSION: The unit was surrendered at 1838hrs on 24/7/2015.

TOOLS/MATERIALS REQUIRED FOR THE JOB
 Spanners with opening 13,17,19,24,27,30,36 and 46mm.
 Hammers(big and small),mallets(big and small),flat screw drivers and devices.
 2tones chain blocks.
 Brake tables(iron type).
 Smooth emery cloth and molten cloth.
 Mobile air compressor.
 Chisel, iron bars spirit level
 TELUS68 and electro clean.

ENGR U.I Jalo

For PM (MECHANICAL)