Installation and Commision Report OF MicroHydro power of Nepal

8/11/2019 Installation and Commision Report OF MicroHydro power of Nepal

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Preface

Private or community owned and managed micro-hydropower (MHP) schemes are nowaccepted as viable and least-cost options for manual under-developed and inaccessible mountainareas of Hindu Kush-Himalayan (HKH) region; where local entrepreneurs and/or communitypeople are liely to initiate! manage! operate and maintain such plants" #he technology is simpleand low cost and the implementers/surveyors! designers! manufacturers! installers! etc"! areusually not fully $ualified having e%pertise of desirable level in their respective fields" #herefore!institutional arrangements and properly designed and implemented inputs are needed for thesegroups of professionals (both implementers and operators/managers) in the form of training!manuals and guidelines! bac-stopping! maintenance/repair facilities and now-how" &ithoutsuch interventions the performance and viability of many such plants may not be optimal"

Keeping in view the above needs! ''M* has endeavored to develop and disseminate a seriesof five information manuals on; site survey and layout design! manufacture! -installation!management and operation and maintenance and repairs" #he manuals have been preparedunder a pro+ect titled ,apacity uilding for Mini- and Micro-hydropower *evelopment in the

.elected countries of Hindu Kush-Himalayan egion! Phase 00," #he pro+ect has beenbenevolently supported by the 1orwegian 2overnment lie its predecessor the first phase; and isdesigned and implemented by ''M* in the HKH region of Paistan! 'ndia and 1epal! incollaboration with suitable focal agencies in each country"

#he current manual focuses on the installation! commissioning and handing over of such plantsto the owner-!managers" .ince the educational and technical $ualifications of the installers ofthese plants are liely to be $uite low! this manual has been ept simple and short" #hisapproach inevitably leads to a dilemma as to what to cover and to what depth" 1evertheless! anattempt has been made to reach a correct trade off"

#he original version of the manual was prepared by *.-#echnology *evelopment utwal!1epal; which was e%tensively revised by me and two short-term consultants! Mr" 3+oy Kari andMr" 2irish Kharel of Kathmandu" #he revision is based on recommendations of the 4%perts5onsultation organised by ''M* in 6ebruary 0778 and also on some suggestions of othere%perts" *. did a very good +ob in collecting the basic information and compiling it in oneplace; while the consultants rewrote some chapters to improve the contents and cover someadditional topics" ' myself as well as ''M* are grateful to *. and the consultants for theircontribution"

#his manual is probably first of it5s ind on the sub+ect! &hile every effort is made to mae ituseful for the target group! ie; installers or supervisors of installation process; there is alwayssome room for improvement" #herefore! comments are earnestly solicited in due course frome%perts! implementing agencies and users so that the ne%t edition can be improved"

3nwar 3" 9une+ooordinator MMHP Pro+ect

''M*! 75 1ovember! 0778


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TABLE OF CONTENTS

Page

Chapter 1: Introduction 0

0"0 3bout this Manual 0

Chapter 2: Planning Preparation for In!tallation :

"0 #ools and ther Materials for the .ite

Chapter %: Ci&il Con!truction ?


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Chapter ': In!talling Electro($echanical E#uip$ent B

="0 Machine 6oundations B

=" Machinery 'nstallation B

=": 3lignment B

=":"0 *irect drive 0

=":" elt drives

="< 'nstallation Procedure for Penstoc :

="" 'nstallation Procedure :B

>": 'nstallation of *istribution and .ervice @ines :"< 4arthing :"


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Chapter -: .andling O&er the Plant

7"0 ompletion ertificate

7" 2uarantees


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C.APTE/ I

Introduction

Many areas in the Hindu Kush-Himalayan (HKH) region are least developed and inaccessible;

and the inhabitants live under difficult conditions involving drudgery! deprivation and

degradation of e%isting resources and environment" 4nergy! particularly useful forms of energy

such as electricity! considered to be the crucial ingredient for development both social as well as

economic! is in short supply" #o develop such areas! appropriate energy resources and systems!

along with improved access would be crucial" ecause of difficulties associated with

transportation! it is preferable to develop and use local resources of energy which can be

initiated and managed/operated by the locals themselves"

Power/energy of flowing or falling water! which is usually available in most remote and under-

developed mountain areas! in the micro-hydropower (MHP) range of B" to about 0BB &! can

meet the local needs amicably and cheaply; provided appropriate inputs and methodologies are

adopted and implemented" 4%perience in many developing countries has clearly e%hibited the

viability of this renewable and environment-friendly resource for such areas" However! it has

also been learned that properly designed and implemented inputs such as training! manuals on

various aspects and bac-stopping are vital for the success of such programmes" 3nother

important prere$uisite is involvement! infect lead role by the communities/beneficiaries in the

whole process of planning! fund raising and decision maing; survey; installation and

management and operation" &ithout this complete involvement of the beneficiaries! the chances

of success of the plant in the long run are not bright"

101 Aout thi! ,anual

3fter e%tensive studies consultations and analysis of the current situation in the HKH region!

''M* decided to develop five manuals listed below and three training programmes mainly for

the implementing professionals involved in such private MHP schemes at the grassroots level"

#hese manuals mainly cover the following aspects of private/community owned MHP plants in

the remote areas"

.ite .urvey and @ayout *esign and Manufacture


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'nstallation

Management and peration

epair C Maintenance

#his manual is part of the above series and covers all aspects of installation starting from

pacing and transportation of the e$uipment to the site! to commissioning and handing over the

plant to the owner-manager(s)" #he intended target group is the private sector installers who

may have some e%perience of installation but by using the current manual they should be able to

improve the installation process and deal with the problems and other aspects in a better way" 't

is e%pected that such an installer is at least capable of reading and understanding this manual;

however! he should preferably have some technical $ualification; say! certificate or diploma in a

relevant engineering trade"

bviously! it is impossible to cover all the aspects for all types of different sites and e$uipment"

However! an effort has been made to cover most installation aspects for the micro-siAed plants

especially up to =B & capacity" .ome plants may also have agro processing or other e$uipment

within the powerhouse" However! installation of such an e$uipment has not been covered in this

manual since it is a separate sub+ect" 3lso! instructions are usually provided with such e$uipment

with regard to installation and commissioning"

't is hoped that the information provided in this manual would assist in improving the capabilities

of the installers! without having to undergo e%tensive training; although! there is no doubt that

actual and proper training would further enhance their capacities"

'n addition to pacing and transporting the e$uipment safely to the site! there are three main

components of installation process; ie"! civil construction including weir! intae! canal! forebay!

powerhouse and tailrace; electromechanical installation of turbine! generator! valve(s) and

penstoc; and installation of transmission lines" #hus! this manual mainly covers these

components and their testing and commissioning"


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C.APTE/ 2

Planning Preparation! for In!tallation

onsiderable planning and preparations have to be made! information gathered and e$uipment

identified which is to be taen to the site" Most probably! this would not be the first visit of the

installers to the site" 3t least one or more of the team members should have travelled to the site

and the main village before! where the team has to stay" ontacts with the local lead persons

should also e%ist" #herefore! travelling to the site should not pose a problem" However! the

route for transporting the e$uipment may be somewhat different than for the personnel; some

e$uipment may have to be airlifted and then manually transported! for e%ample" 3lso! the time

of travel and transportation of e$uipment has to be given due thought and suitable choices made"

bviously! a rainy season! harvesting time! festival time or very cold/hot season would not besuitable for woring at the site" 't may also tae between two wees to si% months to complete

the installation; depending upon the siAe of the plant! site remoteness! and whether it is an easy

or a difficult scheme"

riefly! the installation process would include the following"

Pacing and transporting e$uipment and materials to the site and storing it there"

6inalisation of the sites for weir! intae! power canal and its sub-components (eg"! desilting

basins! spillways! crossings! etc)! forebay! penstoc and powerhouse; already demarcated

during the surveys"

Measurement and minor ad+ustment of locations of some components such as the base of

turbine" forebay or intae mouth"

onstruction of all components of civil wors including foundations for the turbine!

generator! agro-processing e$uipment! etc; and construct-'on of support piers! anchor

blocs! etc"

'nstallation of the penstoc pipe and accessories"

'nstallation of turbine! generator! agro-processing units (if provided)D5 and coupling/drive

systems"

'nstallation of transmission and distribution wiring systems"


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#esting C commissioning (starting! testing! measuring output! removing defects)" #raining

the managers and operators"

Handing over the plant and certification"

.ometimes! most of the civil wors would have been completed before the arrival of e$uipment

at the site" 'n other cases! however! it may be convenient to complete the civil wors as well as

installation of the electromechanical e$uipment and transmission system simultaneously and in a

prescribed se$uence"

'f for some reason the installation wor has to be discontinued! ade$uate planning would be

necessary to prevent damage to the installed/constructed components and to the remaining

e$uipment and materials to be stored! including the cement; which can be easily spoiled due to

rain/water or humidity" .imilarly! newly constructed civil wors such as earthen canal may have

to be protected from damage during the monsoon rains or other mishaps"

Esually! two or three persons may travel to the site who collectively possess the re$uisite

e%pertise" However! all may not stay there all the time" #he main e%pertise needed would be in

the field ofF

.ite assessment and survey (to assess geophysical features! changes since last survey and

some measurements of distances! etc");

ivil construction;

'nstallation of electromechanical e$uipment including penstoc;

@aying transmission lines;

ommissioning and testing"

'nformation should also be collected and verified regarding availability and costs of silled and

unsilled labour! constriction materials! etc" 'n addition! locations of a nearest but ade$uate

worshop (say! having welding facilities or other tools)! health care centre and communications

facilities should also be identified in advance! if possible"


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201 Tool! and Other ,aterial! for the Site

3 comprehensive list of tools and instruments to be carried to the site! which may be needed

during the installation must be prepared! preferably in the form of a checlist" #he list should

also include materials to be transported (an indicative chec list is given in 3nne%" " 0)"

3dditionally! all the drawings of the parts/components and their installation instructions must

also be carried to the site; for! weir! intae! canal! forebay! penstoc route! powerhouse! the

mechanical components (eg"! trash racs! e%pansion +oints! etc")! plus specifications and

construction details for various foundations" #he decisions regarding construction materials as

to what needs to be carried and what could be ac$uired aG the site should also be made in

advance (eg"! doors and windows! corrugated iron sheets! wooden beams! steel bars! etc")" .ome

such material can be easily provided or ac$uired by the communities" 'n fact! completion ofmost of the civil wors can be and should be the responsibility of the beneficiary communities or

the entrepreneur"

't is usual that some land/length measurements may also have to be carried out again; eg"! more

e%act measurement of the length of the penstoc" r! sometimes! ad+ustment of the penstoc

length by a few centimeters becomes necessary; for which the base of the turbine or the forebay

may have to be raised/lowered; and this can only be done by measuring the length" .imilarly!

some survey tools such as 3bney or *umpy level would be needed to mar and construct the

power canal! intae and the weir"


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C.APTE/ "

Tran!portation of E#uip$ent to Site

3ctual transportation of the e$uipment is usually not the responsibility of the installers" However!

they may! sometimes! be called upon to advise" #ransportation of the e$uipment to the site also

includes its proper pacing and planning the transportation as well as storage at the site till it is

properly installed" Pacing is an important endeavour to; protect the e$uipment from weather

elements! avoid pilferage/loss/damage during transportation/storage and to mae it easy tc) carry"

'n most instances! the e$uipment may have to be carried manually! for a few meter distance or

$uite a few ilometres (eg"! in 1epal! it may be a few day5s wal)" #herefore! the pacages have

to be of appropriate siAe and weight" 3n e%perienced and trained porter can carry upto >B g for

long hauls on a mountainous trail; while a horse or mule can carry upto 8B g" ut this wouldalso depend on how difficult or dangerous the trail is (eg"! steepness and its width! slipperyness!

etc")" Many components (eg" penstoc pipe sections) need not be wrapped while in other cases

(eg" generator) they have to be wrapped in Polythene sheets or similar material to protect them

from rain water" .ome smaller items would have to be paced together while others (eg" turbine)

may have to be disassembled and paced; otherwise! it may be too heavy to carry manually" #he

penstoc or other long items of more than : meter lengths! may also be difficult to carry" 3ll these

aspects should be given due consideration while" planning the pacaging and transportation" Parts

of some items! which have to be assembled latter! may have to be mared so that they are

correctly reassembled"

Pacing larger units such as a generator C turbine in wooden cartons is usually e%pensive and

inconvenient to carry" However! smaller and delicate items such as electrical instruments! 4@!

switches! insulators for transmission! may be paced in card board or wooden cartons! using

ade$uate anti-impact material such as foam and rain protecting material such as plastic sheets" 'n

some countries such as 1epal! the traditional method of carrying a heavy load is on the bac;

whereas in Paistan for e%ample! people carry the pacages on their head" #herefore! the

following ma%imum dimensions of the pacage are suggested for each of these methods"


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Carring $ethod Per$i!!ile 3i$en!ion! 4c$5

Length 6idth .eight

n the bac =B =B 0B

n head =B =B


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C.APTE/ %

Ci&il Con!truction

%01 Site In!pection and Preparation

ased on the detailed design! the locations of various MHP structures should be verified and then

clearly mared at the site" #his includes placing centre line pegs along the headrace and penstoc

routes and along the boundary of other structures such as the settling basins! forebay! anchor

blocs and the powerhouse"

3t this stage the layout design should be well finalised and additional changes should be

unwarranted" However! a final survey should be carried out to verify that there have been no

changes in the site since the design phase to necessitate relocation of structures" #he layoutshould only be changed if there are ma+or geological changes such as landslides along the

headrace or penstoc routes"

#he site preparation should include clearing the route from the intae to the tailrace" .hrubs and

other vegetation should be uprooted if they can obstruct the construction wor" .imilarly! if some

structures are located along cultivated fields! such fields should be left barren prior to

commencing the construction wor" 't should be noted that a larger area will be re$uired during

the construction phase than the actual area that various MHP structures will eventually occupy"

#his is because ade$uate space would be needed for labourers to wor freely! for storing

construction materials such as stones and sand and for dumping e%cavated soil"

%02 Con!truction Se#uence

#he construction of the scheme should be started from the most critical location; i"e"! where a

slight misalignment or improper orientation may result in significant e%penditure for remedial

measures" Esually the machine foundation in the powerhouse is the most critical location" #his is

because once the machine foundation anchor bolts are set in concrete! the turbine and the

generator locations cannot be read+usted" #herefore! first the machine foundation should be

constructed" #hen wor should commence on the installation of the penstoc pipe from the

machine foundation to the forebay" 4%cept for their final :BB mm height! support piers can be

constructed as the penstoc installation wor progresses upstream including e%pansion +oints at


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given locations as per design" #he final height should be ad+usted once the entire pipe length has

been installed which has been supported by temporary stonewor! wooden plans! or other similar

materials! in order to achieve proper alignment of penstoc pipe and avoid bending stresses while

reaching the end point in the forebay" #he anchor blocs should also be completed after the entire

penstoc pipe length has been installed" #his is because once anchor blocs are constructed! the

penstoc pipe cannot be read+usted"

#he forebay is usually located on an elevated terrace (flat area) at a steep slope above the

penstoc" .ometimes e%cavation on the location is re$uired to provide sufficient area for the

forebay" #hus! some ad+ustment is usually possible of the penstoc pipe length; if the actual

length of the penstoc and the distance at the location do not match" Hence! the forebay should

be constructed after the penstoc pipe reaches this structure"

nce the machine foundation! penstoc and the forebay have been constructed! the logical

se$uence is to continue the construction wor upstream until the location of the intae is reached"

'f the construction wor is commenced in this se$uence! there will be less chances of

misalignment or errors ;"n the elevation of the structures" However! if the survey wor has been

accurate enough and staff at site are well e%perienced! some construction wor can also

commence concurrently" 6or e%ample! different portions of the headrace canal and the settling

basins can be constructed concurrently" However! it should be noted that in this approach if the

elevations of the headrace canal do not match and the downstream section is higher! remedial

measures will be costly"

onstruction wor at the intae and specially the diversion weir should normally start when all

other structures are completed" #his is because the flow can not be diverted for power generation

until all other structures are completed" 6urthermore! there can be additional riss from floods if

the wor at the intae and weir is completed prior to the onset of monsoon but other structures

are still incomplete" .ome retaining wor along the intae ban can still be carried out

concurrently with other structures! provided that the MHP scheme can be commissioned prior to

the onset of monsoon rains"

%0" ,achine Foundation9 Poerhou!e and Tailrace

%0"01 Con!truction of ,achine Foundation


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#he machine foundation should be constructed as follows"

*emarcate the floor area of the powerhouse and the location of the machine foundation as

per the design"

4%cavate the machine foundation pit (as per design) until the re$uired depth is reached and

compact the floor using a manual ram" 'f the pit base is not a roc! then a =B mm stone

soling should be provided above it"

4%cavate the tailrace section inside the powerhouse before commencing the machine

foundation concrete wor" #his prevents any misalignment between the machine foundation

and the tailrace" 1ote that if the tailrace is e%cavated at a later stage there needs to be a gap

of about a wee after the construction of the machine foundation for the concrete to cure"

3lso once the machine foundation and the tailrace section in the powerhouse are completed!

wor on the powerhouse walls and roof can commence" *ue to confined space! it may not

be feasible to construct the powerhouse structure! machine foundation and the tailrace

section concurrently"

Place formwor at the periphery of the e%cavation and arrange the reinforcement and

anchor bars for the base frame as specified in the design" #ile threaded ends of the anchor

bars should be greased and then covered with clean pieces of cloth or plastic sheets so that

they are not damaged while pouring concrete" .ometimes! the base frame can also be

welded to the reinforcement bars and cast into the foundation"

nce the formwor and reinforcement of the machine foundation have been placed! prepare

the concrete mi% at the re$uired ratio (usually 0F0"=F:) and then pour it up to the

generator/turbine base frame level" oncreting wor is discussed further in the ne%t section"

Manually compact/vibrate the poured concrete using long steel rods" nce the re$uired

level is reached! place the base frame for the machines on the concrete so that it fits snugly

over the anchor bars (holes in the base frame are in line with the anchor bars)" #hen tighten

the anchor bolts" #he base frame level should be constantly checed (using a ,spirit level,)

while tightening the bolts" 1ote that the level of the base frame can be ad+usted only while

the concrete is still wet"

Protect the newly poured concrete structure from direct sun and rain for at least < hours"

< hours after the construction of the machine foundation! curing should start by eeping it

moist for at least a wee" #his is usually done by gently pouring water on the concrete


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structure" 3n uncured concrete structure will not gain full strength" *uring hot and dry

weather poring water on the concrete structures may be re$uired twice a day (mornings and

afternoons) to ensure that they gain full strength"

emove the formwors from the machine foundation only seven days after completion of

construction" 1ote that if wood is e%pensive! dry stone walls can also be used for the

formwor" 3lso unlie wooden formwor! such dry stone walls need not be removed" 3

typical machine foundation pit with the reinforcement bars is shown below in 6igure


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3lso note that! the concrete mi% should be poured on the structure within a few hours

after its preparation" oncrete stored over-night looses significant strength and should not

be used at all"

6ig"


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Ese only seasoned wood for doors! windows and trusses"

%0% Ci&il 6or8! for Pen!toc8

%0%01 Pen!toc8 Pipe In!tallation

#he civil wors for penstoc involves installing the pipe and constructing the support piers and

anchor blocs as specified in the design layout" oth of these must be located on original firm soil

and not on bacfill"5 #he procedure is as follows

lear all vegetation along the penstoc route and mar the centre line by fi%ing a tight

string" 3lso mar e%cavation lines for the support piers and anchor blocs"

6i% the turbine along with the manifold and gate/valve (if provided) to the machine

foundation"

.tart the installation of the penstoc from the machine foundation by connecting the first

lin of penstoc (usually a bend) to the turbine manifold and proceed upstream! which is

usually more convenient method" #his avoids any misalignment between the penstoc and

the turbine housing" .ince the turbine needs to be firmly fi%ed to the machine foundation!

there is almost no tolerance at this end after the machine foundation has been constructed"

6urthermore! the pipe sections below the e%pansion +oints can slide down if installation

proceeds downstream from the forebay" 3lso as discussed earlier! minor pipe deviation

can be ad+usted at the forebay wall" -however! such ad+ustment is not feasible at the

machine foundation"

'nstall the e%pansion +oints at the re$uired locations as specified in the design layout (i"e"!

downstream of the forebay and anchor bloc locations)" #ightly pac +ute (or similar

fibre) inside the e%pansion +oint during the installation process to prevent leaage during

the operational phase"

3s the pipe installation wor progresses upstream! construct the support piers at the

re$uired locations"" However! it is recommended that the last 0=B mm to :BB mm height

of the pier be constructed only after the entire penstoc pipe has been installed" #hisallows for some ad+ustment of the pipe till the end" *uring the installation process!

temporary dry stone walls can be used on top of the unfinished support piers"

#he construction of the support piers first involves e%cavating the ground to the re$uired shape as

per the drawings" nce the re$uired foundation depth is reached (usually :BB mm at the


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downstream face and depth varies according to the slope at the upstream face5 the earth should be

compacted using a manual ram" #hen the piers should be constructed in stone masonry in 0F>

cement mortar as discussed belowF

%0%02 Ce$ent ,a!onr 6or8

6or stone masonry in cement mortar! the following is recommended"

.tones should be washed and ept immersed in water for a day prior to construction" *ry

stones do not adhere well on cement mortar and therefore the masonry will have less

strength"

#he ratio of the mortar should not be less than 0F> cement/sand for the construction of

support piers"

Ese good $uality sand and cement as described in sections


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%0' Forea

2enerally the forebay should be constructed after the installation of the penstoc is completed

including the civil wors" #he construction of the forebay involves the following"

3t the proposed location! mar the e%cavation lines for this structure according to the

design as discussed earlier"

4%cavate the ground to the re$uired depth and shape" 1ote that it is important to chec

the floor elevation after e%cavation but before construction" 'f errors are found on the

elevation after construction wor has commenced (and the forebay is higher than the

headrace canal upstream)! remedial wor can be e%pensive"

ompact the earth surface using a manual ram after completion of the e%cavation wor"

#hen construct the structure as per the design" #he forebay and other water retaining

structures are usually built using stone masonry in 0F< cement mortar"

onstruction of cement masonry structure was covered earlier"

' f possible the inside faces (water retaining surfaces) should have dressed stones which

minimiAes the thicness of the plaster" 1ote that once the cement mortar has been

prepared it should be used within -: hours"

3s the masonry wor condenses! install the gates! flush pipes and spillways at the given

locations as per the design"

3fter completion of the gates and masonry wor! plaster the water retaining surface (i"e"

inside surface) of the forebay" 3bout 0 mm thic 0F cement mortar is recommended for

the plaster"

nce the construction of the forebay is completed it should be cured as described earlier"

'f there is a delay between the! masonry wor and the plaster then the structure should be

cured for another < days after completion of plaster"

%0) .eadrace Canal

nce the! canal type (or types for different lengths) has been selected and the siAes wored out!

the actual construction procedure involves the following stages"

.etting out of the course of the canal and maring the centre line with pegs

Preparing the bench for the canal!

6i%ing the e%cavation lines!


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4%cavating the canal!

onstructing/lining the canal"

%0)01 Setting Out the Canal

efore setting out the canal! the availability of the e$uipment and staff need to be ensured" #he

same e$uipment that was used for the detailed survey wor such as an 3bney level or a theodolite

and a tape is usually sufficient for the construction and setting the specified slope of the canal bed"

3 transparent water tube can also be useful in checing the levels of the canal bed at various

locations as the construction progresses"

#he setting out of the canal is done as follows

6irst place pegs along the headrace canal route 0 *epending on the topography! suchpegs should generally be driven at =m to B in intervals along the route" Pegs should be

placed more closely at bends as well as at other important locations such as drops!

beginning and end of crossings! etc"

Place some intermediate pegs or reference pegs +ust outside the canal path using a

leveling instrument" &ith the use of this instrument! the differences in elevation between

these pegs can be calculated" .uch pegs will serve as reference levels for the e%cavation

wor" 3n alternative to this is to paint mars at e%posed rocs +ust outside the canal

path and calculate their relative elevations"

%0)02 Preparation of the Bench

#he bench of a canal is a strip of land of uniform and width and slope" 't is lie a road of

generally constant width and slope at the level of top of the canal" #he bench should be prepared

as follows"

4%cavate a strip of land of even width along the pegs placed earlier on the canal route"

'f there is a possibility of materials being washed down by rain from the slope above orsmall land slips being deposited directly in the canal! increase the width of the bench such

that it is larger than the finished canal top width" #his e%tra width is called the berm; which

stops debris or water coining down the hillside and from entering the canal" .uch e%cess

water should be channelised away from the canal through a proper drainage system" 'f it is

not possible or practical to drain all the e%cess flow away! it may be allowed to enter the


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#he subse$uent readings between intermediate pegs (i"e" reference points) can be noted in

se$uence with similar calculations"

%0)0" Fi;ing the E;ca&ation Line!

nce the canal bench has been prepared! the e%cavation lines need to be set out as follows"

Place pegs along the centerline and the top and bottom widths of the canal (for trapeAoidal

sections)" 1ote that in case of lined canal! the top and bottom widths should include the

side wall thicness as well (i"e"! outside edges of the finished canal)"

9oin the pegs using thin ropes" #hen mar separate lines for the centre line and top and

bottom widths (for trapeAoidal sections) using powdered lime or ashes so that they are

indicated on the ground" 1ote that for rectangular sections! top and bottom width are e$ual

and three parallel lines are sufficient for the e%cavation wor"

hec the dimensions against the design specifications continuously during this process"

%0)0% E;ca&ation of the Canal

#his consists of e%cavating the canal having the re$uired shape and slope according to the design

as described below""

6or rectangular canal! start the e%cavation from the sides down to the re$uired depth"

6or trapeAoidal sections! start the e%cavation at the central part without e%ceeding the

bottom width lines vertically down to the re$uired depth" #hen e%cavate the sloppy sides

without e%ceeding the top width and meeting the bottom width at the re$uired depth"

#hus! the re$uired trapeAoidal shape can be arrived at" #his method of e%cavation

minimises the use of construction materials and the need to bacfill" 3lso! note that side

walls of a trapeAoidal cement masonry canal are more liely to crac if constructed on

bacfill" 't is also helpful to prepare a wooden frame matching the cross sectional shapeof the canal to chec it continuously as the e%cavation progresses" #his involves

constructing a wooden frame of the re$uired trapeAoidal shape using rectangular stics"

hec the canal bed slope fre$uently using a leveling instrument" 1ote that an

inaccurate slope can be very costly" 'f the slope is less than re$uired! the canal will not

have the capacity to convey the design flow" .imilarly! if the slope is steeper than


24/67

re$uired!" the velocity" may e%ceed the ma%imum value for the canal type and start

eroding it"

%0)0' Con!truction of the Canal Lining

nce the e%cavation wor has been completed! the construction of the lining of the canal can

commence if provided for in the design" 'f an earthen canal has been chosen! all that is re$uired is

to trim the side walls and bottom width at some places where the e%cavation wor has been poor"

However! if a masonry lined canal has been chosen! then this will re$uire collecting stones!

dressing/siAing them and then placing them at the e%cavated surface according to the design"

6or stone masonry in cement mortar canals! the following is recommended"

#he minimum thicness for bed and side walls should be 0=B mm since thinner walls re$uiremore stone wor of the lining (dressing C siAing) and may not have the re$uired strength"

#his also applies to stone masonry in mud mortar canals"

.ince this is a water retaining structure! the ratio of the mortar should not be less than 0F mm where #a is ambient temperature of penstoc"

#herefore! the gap between the pipe ends should be about B mm when the e%pansion +oint -is

being installed"

'0%0%01 Po!itioning the Pipe in the E;pan!ion =oint

#he procedures for setting the e%pansion +oints while installing it are different for a bolted type

design and a welded type design"


34/67

Bolted tpe de!ign

.ince the distance between the flange of e%pansion +oint and the pipe end is small; the gap is

accessible and can be measured easily (6ig" ="0:)" 3fter the correct gap has been set by moving

the pipes a%ially! the pacing is placed and the stay ring tightened" #he ne%t length of penstoc

pipe is then bolted on to the e%pansion +oint"

6elded tpe de!ign

'n a welded design the setting is more difficult because the gap is not accessible and it cannot be

measured directly" 3s shown in 6ig" ="0< the gap ,2, is the difference between the ends of

lengths ,3, and ,," #he pipe is mared at the re$uired length before fitting the stay ring" #he

e%pansion +oint flange is then positioned over the i-nar and the stay ring tightened"


35/67

'0%0%02 In!talling the Pac8ing

4nsure that the place where the pacing will be placed is clean and greased or oiled" .$ueeAe one

end of the pacing rope into the gap between the inner and outer sleeves" Mar this point so that

the number of turns of pacing can be counted" #he pacing should be pushed firmly with a

suitably siAed piece of wood until it reaches the retaining ring" ontinue placing the first round of

pacing firmly against the retaining ring" epeat until about five turns have been completed and

then cut it" Place the stay ring against the pacing and tighten the bolts"

'0' Control! and In!tru$entation

'f an 4lectronic @oad ontroller (4@) is fitted the controls and instrumentations are an integral

part of the 4@ panel" 3ll the meters should be ad+usted to Aero" 3ll connections should be

checed to ensure that they are tight and correctly done" #he ballast load should be B morethan the ma%imum output of the generator and its resistance should be checed to ensure that it is

functioning properly and that there are no short circuits"


36/67

C.APTE/ )

In!tallation of Tran!$i!!ion Line!

)01 Step! efore In!talling Tran!$i!!ion Line!

't is usually necessary to resurvey the transmission route and plan for difficult features and

obstructions! eg"! landslide Aone! gulley crossings! trees! ground clearance! cultivated land! etc"

#he following should be the main consideration while finalising the routes"

hoose short C straight route"

alculate the re$uired number of poles! for the given length and use pegs for maring the

location of pole pit"

'f the wooden poles are proposed in design then select hard wood straight poles" #he depth of pole length should be about one meter underground and bitumen paint

should be applied to the buried portion to prevent rotting"

#he poles should have siAes indicated in #able >"0 below"

Tale )01 Si? Three Pha!e 11 8?

Height of pole > m ? m 8 m

*iameter of pole 0= mm 0=B nun 0?= mm

2round clearance " 0"

'nsert the pole base in the pit; ensuring that after erection the pole should be in line with

other poles and vertical; chec verticality with plum bob"


37/67

6ill up the pit with earth C stones and compact well"

'nstall stay wires on the poles at every bend! first and last pole and on the pole having a +umper

(6ig" >":)

.tart to unroll wire and lift the end up to the pole carefully; the wire should not be over lapped

during pulling (6ig" >""=)" #he sag in the

cable can be measured by level instrument but it is not possible in all cases"

4%cessive tension on the conductor should be avoided which may cause it to brea"

*uring installation of transmission lines! the ends of two wires may be connected using

the following procedure (see also 6ig" >">)"

pen all strains of both ends of the conductors"

ring two ends together! overlapping by at least :BB mm and twist each strain

with another from the opposing conductor"

&rap the remaining length of strands around the +oint and pass the last position

underneath another strand to give the +oint a smooth! tight and unbreaable

finish"

*uring installation of transmission lines! safety belts should be used and necessary

information regarding the safety aspects should be provided to the installers"


38/67

3fter completing erection of transmission lines all routes should be checed! for ground

clearance! road clearance! compaction of pole pits! stay wires! etc" 3nticlimbing devices

and 5*anger5 boards should be installed on each pole"

)0" In!tallation of 3i!triution and Ser&ice Line!

*istribution lines bring power from the transmission line to service wires supplying the

consumers" #he installation procedure for distribution lines is similar as for transmission lines"

'f these lines are to pass through a village! appropriate ground clearance! and distance from the

houses should be provided and stay wires installed wherever necessary"

#he service line brings electrical power from distribution line to the premises of individual

consumers" 't can be pulled by hand from pole to each house" 1ormally flat twin sheathed solidaluminium conductors are used! so e%cessive tension in the wire should be avoided" #he wire

should be fi%ed to the pole and connected to the distribution line by wrapping around it three

four times" 't may also be tied to the pole to avoid e%cessive stress at the +oint"

)0% Earthing

4arthing is the process of providing path to e%cessive electricity and voltage caused by short

circuit or lightning to earth and preventing damage to e$uipment and personnel" 't may be

classified into the following two systems"

.ystem earthing means connecting the neutral points of generators and transformers to the mass

of earth" 4$uipment earthing mean s connecting the outer casing or supporting structure of all

live electrical e$uipment to the general mass of earth"

4arth connections should be provided at the following points"

1eutral of the all power systems such as generators! transformers! etc"

4arth terminals of each lightning arrestor"

#he frame of generator! motor! 4@! ballast! transformer! control/instrument panel! etc"

3ll metal casings or coverings containing or protecting any electric supply or apparatus

#he armouring of underground cable"

#he metallic poles and towers of overhead lines"


39/67

#he system and e$uipment earthing should be made separated by minimum distance of ten

meters"

3 good earthing should have very low resistance; it should thus be made in an area! where the

earth is normally moist; for e%ample! near a canal" .alt and coal are used to further reduce earth

resistance"

)0%01 Earth electrode!

3 plate or pipe of copper or 2' driven into the ground and connected to an electrical system or

e$uipment is called the earth electrode" 5#he number and type of earth electrodes re$uired per

installation depend upon the factors such asF type of soil! the type and capacity of the installationor e$uipment! the value of the re$uired earth resistance! etc" oughly! following siAes of earth

electrodes are recommended for MHP installations"

Tale )02 /eco$$ended SiBB long % >BB wide % :"0= thic

2' plate 7BB long % 7BB wide % :"0= thic

2' pipe :8 dia" =BB long

't is recommended to use copper wire for copper electrodes and 2' wire for 2' electrodes

having the 8 .&2 siAe (


40/67

inclined to the vertical having same length and inclination should not be more than :B degrees

with the vertical"

Pipes or rods should be one piece" 'f it is necessary to reduce the depth of burial of an

electrode! this must be done without increasing the resistance" #his is achieved by using a

number of rods or pipes and connecting them together in parallel" #he distance between two

electrodes in such cases should preferably be not less than twice the length of the electrode"

#he earth wire should now be +oined at the top of the pipe by drilling a hole in the pipe and the

earth wire should be tightened there with a brass nut and bolt" efore doing so! the copper earth

wire should be scraped in order to mae good contact between the wire and the pipe"

Plate Electrode!

Plate electrodes may be made of galvanised iron or steel having the minimum siAes as shown in

#able >"" Plate electrodes should be buried such that the top edge is at a depth of not less than

0"=B m" below the surface of the ground"

&hen resistance of one plate electrode is higher than the re$uired value! two or more plates

should be used in parallel! the two plates being separated from each other by not less than eight

meters"

#he plates should preferably be set vertically" Plate electrodes should be used only when the

current carrying capacity is the main consideration! as for e%ample in the power house"

#he earth wire should now be +oined at the top of the plate by drilling a hole there and the earth

wire should be tightened there with a brass nut and bolt" efore doing so! the copper earth wire

should be properly scraped (6ig" >"8)"

)0' Lightning Arre!tor!

*uring storms! high voltage of lightning can come in contact with transmission and distribution

lines! which would transmit across the coils of generator and its body! causing a short circuit and

damage" #herefore! earthing needs to be provided for this high voltage to discharge before - it


41/67

gets to generator! via a lightning arrestor! which is connected between phase and earth" 'n case

of three-phase transmission! separate arrestor is needed for each phase and earth as shown in 6ig

>"7" 6or low-tension transmission B"= L lightning arrestor will do the +ob but higher voltage

rating is re$uired for high-tension transmission"

#he lightning arrestor should be installed as close to generator as possible! usually at the first

pole outside the powerhouse" 'f the transmission line is more than a ilometer long! one

lightning arrestor should be installed for every ilometer"


42/67

In!tallation Procedure

hec whether the lightening arrestor is as per the specification"

Mount a frame on the pole and fi% lightening arrestor on it (6ig" >"7)" 'f more than one

lightning arrestors are to be used! the distance between two arrestors should be at least

0BB mm"


43/67

C.APTE/ *

Co$$i!!ioning and Te!ting

ommissioning and testing of a MHP provides a system for checing that all the components of

the MHP are functioning properly as per the design and/or specified by the supplier" #he

commissioning and testing procedure also provides a record of the operational status of the

plant at startup which is a useful reference for the future" More practically! some problems may

be encountered when the plant is operated for the first time" #hese problems! whether in the

civil wors or in the electromechanical e$uipment! must be removed completely! before the plant

is put into normal operation"

*01 Co$$i!!ioning Procedure

#he commissioning procedure should begin 1@ after all the installation wor has been

completed and checed" #he commissioning report must have a list of all the items to be

checed or tested" 3longside the items! their condition and whether this condition is satisfactory

or whether it needs to be rectified! must be mentioned" @iewise! with the test results! the data

obtained! calculation of results (eg"! efficiency) must be noted along with whether or riot this

meets the specifications"

*0101 Cleaning the Pen!tor8

*uring penstoc installation some debris would inevitably have been dropped into the penstoc

while it was being assembled" #his debris must be removed before running the turbine otherwise

the turbine will be damaged"

#he penstoc valve should be closed and the penstoc partly filled with water in order to flush

the debris to the bottom from where it can easily be removed" #he debris -will collect behind the

valve"

#he water should then be drained by opening the valve or turbine vane +ust enough to allow the

water to drain very slowly" 3fter the water has drained out the debris can be removed in the

following ways"


44/67

'f a gate valve is installed; by removing the top half which houses the spindle and gate"

y removing the valve (in case of butterfly valve) and/or turbine adaptor"

y removing the turbine cover"

*0102 Chec8! Before Starting

efore starting the plant the whole system from the weir and intae to the end of the

transmission line must be inspected to ensure that there is no damage or possibility of breaup!

especially in the canal" #he following must be checed and/or carried out to ensure as follows"

Inta8e

'ntae and trashrac are clean"

#he intae gate operates properly"

Canal

#he canal is cleared of stones and dirt"

#here are no cracs or drainage to the canal" epair cracs or damage if any"

3e!ilting

#he flushing valve opens and closes properly"

*esilting basin is cleared of all debris"

7ate!@!toplog!

#hey operate properly"

Pen!toc8 Support!@anchor!

3ll nuts on the penstoc straps are tightened properly"

#here is no damage to supports/anchor blocs and the base of the anchor blocs/supports

have not been eroded" epair as re$uired"

#he drainage arrangements around the anchor blocs/ supports are not bloced or

damaged" epair as re$uired"

Pen!toc8

3ll bolts are tightened properly"

#he penstoc has not sagged at any point" econstruct the affected support piers if

re$uired"


45/67

#he paint wor is intact" epair as necessary"

Turine

#urbine is well mounted and in good condition"

orrosion protection and painting are o"

#he ball bearings are well lubricated"

#he shaft is turning smoothly! there is no noise or vibration"

#urbine-alternator alignment is o"

3ll the nuts C bolts are properly tightened"

Poer tran!$i!!ion

oupling is aligned properly! no loose bolts

elt is aligned and tightened to correct tension

Alternator

3lternator is well mounted and in good condition"

orrosion protection and painting is o"

#he ball bearings are well lubricated"

#he shaft is turning smoothly! there is no noise or vibration"

#urbine-alternator alignment is o"

1o loose or untightened bolts"

#he ventilation system is not bloced"

#he stator windings to terminal are properly connected"

3ll cabling is o" and fi%ed well

1ame plate has correct information"

'nsulation resistance is o"

ontinuity of each grounding circuit throughout the system is o"

Control Panel!

Panels are properly fi%ed! doors and locs function properly" Painting is o"

4arthing is done properly! screws and terminals are tight"

3ll cabling! connections! terminals and wiring are o" and there are no loose connections"

2eneral cabling layout is o and there is no damage"

@abels are well fi%ed! have correct e%pression and are readable"


46/67

&iring diagrams are available"

Tran!$i!!ion@di!triution

esistance of all earthing systems is within limits (usually less than =B) #here is no

e%cessive sag of any section"

#he ground clearance of all transmission lines is satisfactory" #he lightning protection

system is in place"

#he connections to the transformer are properly tightened"

#he transmission line is clear of trees and branches" ut off any branches or trees that

are too close (within meters of the transmission line)"

3ll service wires are properly connected"

3ll poles are undamaged! vertical and fi%ed properly" 3ll inflators are undamaged"

3ll connections to the insulators are properly made"

3ll +oints and splices in the transmission are properly made"

3fter all the checs have been completed! and are considered to be satisfactory! the waterways

should be filled slowly with water to test all overflow systems and for slippage or leaage" 3ll

gates! stoplogs! flushing valves must be operated in this situation to ensure that they function in

their normal operating condition" hec to see whether the penstoc leas"

#his test should be carried out for a period of at least < hours while the canal remains full and

some flow is spilling from the forebay" *uring this time the system must be monitored to chec

for any leaages of water from the car-al and the forebay" 't must also be checed to see that no

damage has been caused by the overflowing water"

*02 Co$$i!!ioning and Perfor$ance Te!t!

3fter all the above tests have been carried out the system is ready for commissioning"

pen the main valve or turbine valve .@&@ to start rotating the turbine" #he turbine is

allowed to run at a low speed! with the generator connected! while ensuring that there are no

unusual sounds! vibrations or behaviour"


47/67

'f any unusal sound or odd behaviour is noticed then shut down immediately" #he problem(s)

should be investigated! identified and rectified before the tests are resumed (eg"! misalignment!

loose nuts/bolts! leaages! etc")"

'ncrease the turbine speed gradually until normal operating speed is attained" 3llow the turbine

to operate at this speed! with the generator e%citation 1 and with no load or a very small load!

for about two hours" *uring this time! constantly monitor the e$uipment particularly for

e%cessive temperature rises in the bearings and alternator windings"

'ncrease the load on the machines in steps of B per cent until ma%imum output is reached" 3t

every load step the system must be allowed to reach a steady state (ie" theme are no fluctuations

and flow as well as output is constant) and normal running condition before readings are taen"

&hile the machines are running! continue monitoring for unusual sounds! vibrations and odd

behaviour"

*0201 Perfor$ance Te!t

3fter- operating the machines at different loads as described above! a performance test should be

carried out by taing the readings of the machines and the outputs at different loads" 6ollowing

are recommended to be measured and recorded"

6low (if possible)! pressure at the penstoc outlet! turbine speed! bearing temperature! alternator

temperature at different points! alternator voltage and current on all phases! e%citer voltage and

current and voltage drop across transmission line lengths on each phase"

#he different readings should be taen at steps of B increase of the rated power output of the

plant" 'n cases where an 4@ is installed the power output may be increased by increasing the

water flow" #he 4@ automatically switches on the ballast to maintain the correct speed" #he

tests can be continued using the ballast load but it is advisable to use an e%ternal load as it will

provide visible evidence to the customer that the re$uired output has been produced" 6or

e%ample in a 0B & plant! 0B one & heaters could be used; and for plants of 0- &! 0B-B

'& bulbs could be used"


48/67

3 sample format of the test results is given in 3nne%" =" 1.

*0" /ectifing Fault!

*uring the commissioning -tests it is possible that! for various reasons! some problems are

encountered in the functioning of the plant! or! some faults are detected" #he severity of the

problem must be decided and action taen as one of the following"

*0"01 Seriou! Prole$!

.top further commissioning wor until the problem is fully rectified" .uch problems are broadly

of two types"

.afety related" 3ny conditions which! if not rectified and the e$uipment is operated! could lead

to in+ury! loss of life! or serious damage to the infrastructure and e$uipment of the plant"

E;a$ple!:

'nade$uately built spillway which could cause erosion to anchor blocs/supports or to land"

#ransmission wires that can be touched by a person while standing on the ground"

3ny situation that causes electrical cables to overheat"

Operational #hese are cases which prevent the full output of the plant from being produced

and have an adverse effect on the plant life in the long term! if it is continued to be operated"

E;a$ple!:

loced or restricted canal which prevents the re$uired flow

apid and high rise in temperature of bearings or generator windings

4%cessive vibration

esonance speed that is close to the operating speed

*0"02 Ordinar Prole$!

#hese are the problems that can be rectified straight away or later and will not hinder the

commissioning wor which can continue"


49/67


50/67

*0% Endurance Te!t

3fter the performance tests have been completed the e$uipment should be run continuously for a

period of at least < hours at full load to find out if the machines are able to give ontinuous and

trouble-free service" *uring this test the machinery should be continuously monitored for the

following"

4%cessive vibration and noise"

verheating of mechanical and electrical components"

@oss of output"

*eviations in fre$uency! voltage! current"

'f any of the above Problems occur then the cause of the problem must be found and rectified

before further tests are done or before the commissioning and handover is done"

3fter completing the endurance test successfully! the plant is almost ready to be handed over to

the owner-manager(s)" However! it would be advisable that the owner-manager and operators

continue operation of the plant for an additional -: days under supervision of the installers"

#he plant should be started! stopped! load(s) applied/removed and flow varied! while

continuously monitoring the output! instruments and overall behaviour (noise! temperature!

vibration! leaage)" #his would lead to more confidence about the performance of the

e$uipment and the plant operators would also have received some on-the-+ob training"


51/67

C.APTE/ +

Training ,anager! Operator!

't is necessary that the manager and operators for an upcoming plant be selected/appointed by

the community/entrepreneur before the process of installation begins; so that these two or three

persons participate in the installation process fully" #his would increase their nowledge about

the names! shapes! characteristics and functions of various parts of the electromechanical

e$uipment in particular" #hey should be taught through actual practice instructions and

e%planations! the assembly and disassembly of various components (eg"! bearing housing to

chec/replace a bearint


52/67

asic boo-eeping"

#he operator is almost lie a bus driver" 4ven a minor carelessness on his part may result in a

serious breadown and/or bodily harm" #herefore! the importance and conduct of this training

should be taen seriously by the all concerned"


53/67

C.APTE/ -

.anding O&er the Plant

#he final step in the installation process is the handing over of the plant to the owners or the

manager C community representatives" #he installers must demonstrate to the recipients that

the installation as been completed satisfactorily in accordance with the specifications provided;

that the plant was producing the rated power and woring satisfactorily in all respects land that

it was liely to perform satisfactorily in all respects in future also" 'n addition! both installer and

the recipient must sign and eep copies of some formal documents with regard to the

satisfactory performance! handing over and the guarantees for future"

-01 Co$pletion Certificate

#he completion certificate is usually needed by the installer to get his funds released from some

other funding agency such as a ban; whereas the guarantee(s) from the manufacturers and the

installers are needed more by the owner-recipient; so that he can oet services and parts to be

replaced if something goes wrong during the guarantee period" #hese two types of documents

must be written in clear and precise language to avoid any ambiguity" 3n indicative proforma

shown in 3nne%" 7"0 may be used for the final certification" #he manufacturer/installer must also

provide all drawings! catalogues! figures! setches! maps! a copy of feasibility study and a well-

prepared and useful operation and maintenance manual to the owners"

-02 7uarantee!

#wo or more guarantees may have to be provided by the manufactures! installers and suppliers

of e$uipment! depending upon where the e$uipment has been ac$uired and by who"

#he manufacturers)! for e%ample! would have to provide guarantees for a prescribed period (eg"!

one year)! that the e$uipment would be repaired free of charge including replacement of parts if

the machine or a part/unit fails within this period; e%cept if the failure is caused by improper or

careless use 5 of the e$uipment by the operators" Esually! the guarantee is also provided for the

-arts/components obtained from the maret or from other manufacturers such as penstoc pipes!

bearings! bearing housing! couplings! belts! etc"


54/67

.imilar guarantees should also be provided about the civil wors (if constructed by a

contractor/installer) and about the transmission and distribution lines"

3 sample guarantee document is shown below which may be modified! rewritten or Enproved to

accommodate all the relevant components or units" #his guarantee is meant for the turbine!

generator and coupling system; but other items can also be added"


55/67

7uarantee

#he following e$uipment supplied/manufactured by NNNNNN" is hereby guaranteed by the

undersigned for a period of 0 months; if it breas down or fails to perform satisfactorily to

produce the rated output" #he supplier/manufacturer hereby undertaes to repair such parts and

replace the faulty parts! so that its performance gives the rated outputs" #his guarantee!

however! would be void if the failure of a component was caused by improper

handling/operation! carelessness or an accident"

(0) NNNNN (type) turbine NNNNN & capacity! NNNNN mm dia" rotor!

NNNNN bearings manufactured by NNNNN (ountry)" .haft diameter

NNNNN mm! bearing housing NNNNN (type! mae! country)"

() 2enerator NNNNN (type)! NNNNN phase NNNNN (rpm) with

brushes/brushless! with/without 3L NNNNN (manufacturer name and country)!

capacity NNNNN L3! NNNNN

(:) Pulleys NNNNN mm dia C NNNNN mm dia; NNNNN mm shaft dia" and

NNNNN mm dia"! NNNNN (material); having NNNNN grooves NNNNN

(type) ey"

(


56/67

Anne; 201

Li!t of Tool! and Other ,aterial! for In!tallation of ,.P Sche$e

Particulars e$uired heced #ic when

paced

emarses 1o

,echanical

.panner sets (ing and pen)

.lide wrench

.crew driver sets (Philips and plain)

Hammer

Pipe wrench

6ile set (ound C 6lat)

.teel ruler

Measuring tape (:B m)

@evel (.pirit C .tring)

Hand drill machine

.mall bench vice

Lice grip

3llen ey set

Punches for maing holes

2rease gun

aring puller

&ire rush

Hac saw

4mery papers (different grades)

Paint brush

*ifferential chain

*reep pin

.$uare

Portable welding machine


57/67

Electrical

ommon pliers

1ose pliers

&ire cutter

@ine tester

.afety belt for climbing the pole

2as solder

rimping tool

&ire puller

Multi-meter

6re$uency meter

Libration meter

'nsulation tester

Ci&il

#ri s$uares

row bar

.trings

MasonOs trowel

.howel

Hammer

.pirit level

hiselPic

oring rods

3bney level

#heodolite

Plum bob

*ynamiteOther ,aterial!

ement (1eeded $uantity)

.ealing materials

*oors! windows

orrugated iron sheets

@intels

6uses (different siAes)

allast heaters (if not available with 4@)


58/67

Anne; '01

/ecord Sheet for Perfor$ance Te!t! for ,.P Turine 7enerator

#urbine typeFontroller typeFated output

Micro hydro Pro+ect4fficiency/utput test results

*ateF#est done byFPage of

."1o"

@oad (&) Loltage! L urrent! ' #urbineopening

6low'/s

#urbine.peed(PM)

1et head(m)

Poweroutput (&)(Lr% 'rG Ly%'yG Lb% 'b

verall4fficiency

0

:

?

emars


59/67

Anne; -01

A Propo!ed Profor$a for .anding O&er and Ta8ing o&er a ,,.P

Plant 4Co$pletion Certificate5

To e filled the authori!ed repre!entti&e of the In!taller0

A0 7eneral Infor$ation

Plant 1ameF NNNNNNNNN"" ated apacity (&)F NNNNNNNNNNN"

.tream 1ameF NNNNNNNNN"" L*F NNNNNNNNN"" *istF NNNNNNNN

Plant @ocation (describe) NNNNNNNNN""NNNNNNNNN""NNNNNNNNN

NNNNNNNNN""NNNNNNNNN""NNNNNNNNN""NNNNNNNNN"""

wner nameF NNNNNNNNN"" @ead Person F NNNNNNNNN""NNNNN

(ecipient)

B0 Co$pletion of Ci&il 6or8!

&eir constructed es/1o" #ype F NNNNNNNNN"" @ength (m)F NNNNNNNNN""

*istance between weir and intae mouth (m)F NNNNNNNNN""

'ntae type F NNNNNNNNN"" .iAe F NNNNNNNNN"" (m)

anal type F NNNNNNNNN"" J .ection F NNNNNN @ength (m) NNNNNNN

3re length sections of different types Q es/1o" *escription and length NNNNNNNNN""

NNNNNNNNN""NNNNNNNNN""NNNNNNNNN""NNNNNNNNN"""

*esign flow (@/s) NNNNNNNNN""

ontrol 2ate type C .iAe F NNNNNNNNN""NNNNNNNNN""NNNNNNNN"

*esilting basins (1o")F NNNNNNNNN"" .iAe F NNNNNNNNN""NNNNNN""""

onstruction typesF NNNNNNNNN"" @ocationF NNNNNNNNN""NNNNNN"""

6lushing .ystems F es/1o" 1oF NNNNNNN"" onstruction typeF NNNNNNNNN""

.pillwaysF 1o" NNNNNNNNN"" onstruction typeF NNNNNNNNN""NNNNN

2ate providedQ es/1o" 2ate type and .iAeF NNNNNNNNN""NNNNNNNN"""

6orebay siAe (@ % & % H! m) NNNNNNNNN""NNNNNNNNN""NNNNNNN""

#rash rac type and siAe NNNNNNNNN""NNNNNNNNN""NNNNNNNNN"


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NNNNNN""NNNNNN""NNNNNN""NNNNNN""NNNNNN""NNNNN"""

6orebay C its accessories performing satisfactorityQ es/1o"

'f no! describe problem and solution NNNNNN""NNNNNN""NNNNNN""NNNN


's penstoc and its accessories performing satisfactorilyQ es/1o"

'f no! describe problem and solution NNNNNN""NNNNNN""NNNNNNNNNN""


C0 In!tallation of Electro($echanical E#uip$ent

#urbine type NNNN otor dia" (m) NNNNNN ated capacity (&) NNNNNNNN

ated speed (rpm) NNNNN unaway speed (rpm) NNNNNNNNNNNNNNNN"earing type NNNNNNNN .iAe NNNNNNNN Manufacturer NNNNNNNN"""

Te!t /e!ult! 4Turine5

's turbine properly installedQ es/1o" 'f no! describe problem and remedy NNNNN"""

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN"

&as rated speed achievedQ es/1o" 'f no! suggest remedy NNNNNNNNNNNNNN"""

&as rated power achievedQ es/1o" 'f no! describe problems and remedies NNNNNNNN


3ny other problemQ es/1o" *escribe C suggest remedies NNNNNNNNNNNNNN""


7enerator

#ype NNNN .ingle/three phase" ated L3 NNNN! ated speed (rpm) NNNNNNN

ated voltage (v) NNNNNN 3LQ es/1o" #ype NNNNNNNNNNNNNNNN

Manufacturer C ountry NNNNNNNNNNNNNNNNNNNNNNNNNNNN

2enerator properly installedQ es/1o" 'f no! describe problem and remedy NNNNN""


4@ ProvidedQ es/1o" #ype NNNN Manufacturer and ountry NNNNNNNN

oupling/Pulley siAes NNNNNNNN .peed ratio NNNNNNNNNNNNNNNN


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elt types C siAes NNNNNNNNNNNNNNNNNNNNNNNNNNNNNN"""

Power #ransmission type (if different) NNNNNNNNNNNNNNNNNNNNNN""

ontrol Panel 'nstruments and 1o" provided (*etails) NNNNNNNNNNNNNNNN""


Main switch type NNNNNNNN 6uses type C 1o" NNNNNNNNNN

ver-voltage cutout NNNNNNN ver-current cutout NNNNNNNNN

4arthing system (describe) NNNNNNNNNNNNNNNNNNNNNNNNNNN"

3ll instruments and indicatorrs woring properlyQ es/1o

'f no! describe problem C remedy NNNNNNNNNNNNNNNNNNNNNNNN""

Te!t re!ult! 47enerator5

&as rated electrical power achievedQ es/1o" 'f no! describe problem C solution NNNNN""NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN"

4@ tested and operatedQ es/1" M/M operated C testedQ es/1o"

&hole circuit tested within powerhouseQ es/1o" e%plain problem and remedy NNNNNN"



3ny misalignmentQ es/1o" 'f es! describe NNNNNNNNNNNNNNNNNNNN

3ny vibrationQ es/1o" 'f es! describe NNNNNNNNNNNNNNNNNNNNN"""

3ny high temperature Q es/1o" 'f es! describe NNNNNNNNNNNNNNNNNN"

3ny loose beltsQ es/1o" 'f yes! describe NNNNNNNNNNNNNNNNNNNNN"

4ndurance test doneQ es/1o" *uration (hrs") NNNNNNNNNNNNNNNNNNN""

'f no! describe problem and remedy NNNNNNNNNNNNNNNNNNNNNNN""

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

3ny problem during earthing continuity checs for generator! 4@! control panelQ es/1o"

*escribe problem (if any) and remedy NNNNNNNNNNNNNNNNNNNNNN""


's fre$uency meter installed es/1o" 'f es! fre$uency range (HA) NNNNNNNNNNN"

*escribe problem with fre$uency (if any) and remedy NNNNNNNNNNNNNNNN

*" #ransmission @ine 'nstallation


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Main transmission line length (m) NNN &iring system single/three phase! three/four wires

poles 1o" NNNNNN #ype NNNNNNNN .iAe (@ % & % H) NNNNNNN

&ire siAe NNNNNNNNNNNN Manufactures NNNNNNNNNNNNNN"

@ightening arrestors! 1o" NNNNNNNNNN #ype NNNNNNNNNNNNNNN"

ranch #ransmission/*istribution lines! 1o" NNNNNNNNNNNNNNNNNNNN"


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(i) (ii) (ii)

@engths of each branch NNNNNNN NNNNNNN NNNNNNN

&ire siAes NNNNNNN NNNNNNN NNNNNNN

.ingle/three phase NNNNNNN NNNNNNN NNNNNNN

@ightening arrestors; 1o" NNNN"" Poles! 1o "NNNNN 'nsulators! 1oNNNNN

#est esults

Have all wires been inspected/tested for proper installation including +ointing! continuity and

resistance! sagging! etcQ es/1o" *escribe problem (if any) and remedy NNNNNNNNN"


Have any other problems been noticed with wires! poles! nearby trees! buildings! etcQ es/1o"*escribe problem and remedy (if any) NNNNNNNNNNNNNNNNNNNNNN""


E0 Training

#raining conducted for prospective operators and managers during 'nstallation and

ommissioningQ es/1o" 'f no! describe problem and remedy/'f yes! give details NNNNN""



3dditional training during the first supervised operational phase conductedQ es/1o" 'f no!

describe problem and remedy/'f yes! give details NNNNNNNNNNNNNNNNNN""


*escribe the overall assessment of training absorbed by the personal to gain satisfactory

e%pertiseQ NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

Le&el of e;perti!e gained 4Tic85

Person 1ame .atisfactory 3cceptable @ow 1egligible

Manager NNNNNNNNN NN NN" N""" NN

perator 0 NNNNNNNNN NN NN" N""" NN

perator NNNNNNNNN NN NN" N""" NN


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perator : NNNNNNNNN NN NN" N""" NN

*escribe reasons for low or negligible gains and suggest remedy NNNNNNNNNNNN


F0 O&erall Certificate of Sati!factor Co$pletion of all A!pect! of In!tallation Proce!!

ertificate that all the aspects of the 'nstallation process have been completed satisfactorily in

accordance with the agreed specifications" 3ll the defects and problems encountered during the

commissioning phase have been removed and no problem is anticipated in future" #his certificate

applies to the following completed components"

Co$pleted Co$ponent! Signature In!taller Signature /ecipientivil wors

4lectro-mechanical 4$uipment

#ransmission @ines

ommissioning C #esting

#raining

ertified further that all the relevant documents including; operations and maintenance manual!

drawings! specifications (eg"! for bearings)! maps/setches and feasibility/survey report; have

been provided to the owner/manager/authorised recipient"

NNNNNNNNNNN""

.igned by another prominent village leader *ateF NNNNNNN""

1ame! Position C 3ddress NNNNNNN""NNNNNNN""NNNNNNN""NNNN""


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NNNNNNNNNNN""NNNNNNNNNNN""NNNNNNNNNNN""NNN"""

NNNNNNNNNNN""

D0(.igned by 3uthorised epresentative of 'nstallers) *ateF NNNNNNNNNNN""

1ame! Position and 3ddress NNNNNNNNNNN""NNNNNNNNNNN""NNN"

NNNNNNNNNNN""NNNNNNNNNNN""NNNNNNNNNNN""NNN""

D0 1ote" 'f different aspects have been completed by different in installers (eg"! civil wors!

transmission lines) then they should all sign at such spaces introduced in a modified

proforma"


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/eference! and Further /eading

@auter+ung! H"! and .chmit! 2"! 0787" RPlanning for 'ntae .tructuresO" *eutsches Sentrum for

4ntwiclungstechnologien (23#4)! 2#S! 4schborn! 2ermany"

'nversin! 3"! "! 078:" RMicro-Hydropower .ourcebooO" 143 'nternational 6oundation!

&ashington *""

Harvey! 3"; rown! 3"; Hettiarachi! P"; and 'nvesin! 3"! 077:" RMicro-Hydro *esign ManualO"

'ntermediate #echnology *evelopment 2roup ('#*2)! E"K"

&altham! M"! 077

Documents

Installation and Commision Report OF MicroHydro power of Nepal