MICRO PROJECT ON

‘Develop Maintenance Procedure for Preventive and Predictive

Maintenance of a Typical Hydroelectric Power Plant and Its
Components’
Course: Power Plant Engineering

Course Code: 22566

Academic Year: 2021-2022
Semester: 5I

NAME ROLL No. ENROLLMENT No.

Ayush 2031 1901410298

Kshirsagar

Name of Micro Project Guide: Mr. S. C. Chikurde

All India Shri Shivaji Memorial Society’s Polytechnic

Kennedy Road, Near RTO, Pune-411001

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 All India Shri Shivaji Memorial Society’s Polytechnic, Pune-01

Institute Code: 0141

CERTIFICATE
Certified that this micro project report titled “Develop Maintenance Procedure for

Preventive and Predictive Maintenance of a Typical Hydroelectric Power Plant

and Its Components” is the bonafide work of Ms. Ayush Kshirsagar Roll no. 2031

of Third year diploma in Mechanical engineering for the course: Power Plant

Engineering Course code: 22566 during the academic year 2021-22, who carried out

the micro project work under my supervision.

Mr. S. C. Chikurde
Name & Signature
Subject teacher

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 Acknowledgement

I would like to express my special thanks to my teacher Mr. S. C. Chikurde &

signature course teacher as well as our principal Mr. S. K. Giram who gave me the
opportunity to do this project on the topic “Develop Maintenance Procedure for
Preventive and Predictive Maintenance of a Typical Hydroelectric Power Plant
and Its Components” helped me in doing a lot of research. Secondly I would like to
thank to my friends who helped me a lot in finalizing the project within a limited
period.

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 INDEX

Sr. No. Content Page No.

1. Micro Project Proposal 6

2. Rationale 8

3. Aims/Benefits of the Micro Project 6

4. Course Outcome achieved 8

5. Literature Review 8

6. Actual Methodology Followed 8

7. Actual Resources Used 9

8. Output of the Micro Projects 10

9. Skill Developed / Learning outcome of the Micro Project 10

10. Applications of the Micro Project 16

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 ANNEXURE I

Micro Project Proposal

“Develop Maintenance Procedure for Preventive and Predictive
Maintenance of a Typical Hydroelectric Power Plant and Its
Components”
1.0 Aims/Benefit of the Micro Project (Minimum 30-50 Words):
Report On Model Of Hydroelectric Power Plant.

2.0 Course Outcomes Addressed:

C22566.a. Identify various components hydroelectric power plant systems.
C22566.b. Estimate economic parameter of power plant

3.0 Proposed Methodology

(Procedure that will be followed to do the micro project- in about 100-200 words):
1. Finalize the topic
2. Find and Collect information
3. Arrange information
4. Proof read the information
5. Review from the teacher
6. Edit project report as per the suggestions of the teacher
7. Proofread and finalize the report
8. Submission of the report

4.0 Action Plan:

Sr. Planned Planned Name of Responsible

Detail of Activity
No. Start date Finish Date Team Members

1. Finalize the topic 01.10.2021 01.10.2021

Ayush Kshirsagar
2. Find and Collect information 02.10.2021 03.10.2021 Ayush Kshirsagar
3. Model Making 04.10.2021 08.10.2021 Ayush Kshirsagar
4. Arrange information 09.10.2021 10.10.2021 Ayush Kshirsagar
5. Proofread the information 11.10.2021 11.10.2021 Ayush Kshirsagar
6. Preparation of PPT 12.10.2021 12.10.2021
Ayush Kshirsagar
7. Review from the teacher 13.10.2021 13.10.2021
Ayush Kshirsagar
Edit project report as per the
8. 14.10.2021 14.10.2021
suggestions of the teacher Ayush Kshirsagar

9. Proofread and finalize the report 15.10.2021 15.10.2021

Ayush Kshirsagar
10. Submission of the micro project 16.10.2021 16.10.2021
Ayush Kshirsagar

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5.0 Resource Required:

Name of
Sr. No. Specification Qty. Remark
Resource/Material
To collect the information about
1. Internet 1
hydroelectric power plant.

2. Computer To make report 1

To take printout of micro project

3. Printing machine 1
report

4. Book To Collect information 1

Name of Team Members with Roll No’s:

Sr. No Name of Students Roll No

1 Ayush Kshirsagar 2031

Mr. S. C. Chikurde
(Name and Signature of faculty)

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 ANNEXURE - II

Micro Project Report

“Develop Maintenance Procedure for Preventive and Predictive Maintenance of a
Typical Hydroelectric Power Plant and Its Components”

1.0 Rationale (Importance of the project, in about 30 to 50 Words.):

Preventive maintenance (PM) is the regular and routine maintenance of equipment and assets
in order to keep them running and prevent any costly unplanned downtime from unexpected
equipment failure. A successful maintenance strategy requires planning and scheduling
maintenance of equipment before a problem occurs.
2.0 Aims/Benefits of the Micro Project:
Hydropower, otherwise known as hydroelectric power, offers a number of advantages to the
communities that they serve. Hydropower and pumped storage continue to play a crucial role
in our fight against climate change by providing essential power, storage, and flexibility
services. Below are just some of the benefits that hydropower can provide as the United States
transitions to 100% clean electricity by 2035 and net-zero emissions by 2050.

3.0 Course Outcomes Achieve

C22566.a. Identify various components hydroelectric power plant systems.
C22566.b. Maintain hydroelectric power plant and its components

4.0 Literature Review:

Power Plant Engineering by- Vinod Thombre

https://youtu.be/21DWPZOv4SA

https://www.thehindubusinessline.com
https://www.wikipedia.com

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 5.0 Actual Methodology Followed
(Write stepwise work done, data collected and its analysis (if any). The contribution of
individual member may also be noted.) :

Sr. No./
Date Time Work Done
Hour

1. 01.010.2021 5.00pm-6.00pm Finalized the topic for micro-project

Started collect information for micro
2. 02.05.2021 5.30pm-6.30pm
project
Collected material necessary to make
3. 03.05.2021 7.00pm-8.00pm
model
4. 04.05.2021 6.30pm-7.30pm Made the turbine using acrylic sheet

5. 05.05.2021 8.30pm-9.30pm Inserted the rotating shaft in turbine

Made the structure using PVC pipe for
6. 06.05.2021 7.15pm-8.15pm
turbine
Connected the motor and turbine using
7. 07.05.2021 6.15pm-7.15pm
moving belt
8. 08.05.2021 4.30pm-5.30pm Connected motor and LED using wire

9. 09.05.2021 12.15pm-12.45pm Started making report

Done with arranging information and
10. 10.05.2021 5.30pm-6.30pm
inserting pictures of mode in report.
11. 11.05.2021 7.15pm-8.15pm Proof read the report
12.05.2021
12. 6.30pm-7.30pm Made PPT
Reviewed the report and model from
13. 13.05.2021 8.15pm-9.15pm
teacher
Made the changes as per teacher
14. 14.05.2021 5.15pm-6.15pm
suggestion
Proofread and finalize the report after
15. 15.05.2021 12.15pm-12.45pm
making changes in report
16. 16.05.2021 3.00pm-3.30pm Submitted the micro-project

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5.0 Actual Resource Required:

Sr. Name of
Specification Qty. Remark
No. Resource/Material
1. Acrylic Sheet To Make the turbine 3

2. Spoke To make rotating Shaft of turbine 1

3. C.D - 6

4. Motor 200rpm 1

5. PVC Pipe To make structure -

6. Led - 1

7. Wire To connect light and motor -

8. Rubber Belt To connecting turbine and motor 1

9. Blade To cut the pipe 1

10. Insulation tape For wire connection 1

6.0 Outputs of the Micro project (Presentation of data, findings, drawing etc.):

Hydroelectricity Power

Hydroelectricity, or hydroelectric power, is electricity produced from hydropower. In 2015,

hydropower generated 16.6% of the world's total electricity and 70% of all renewable electricity,
[2]
 and was expected to increase by about 3.1% each year for the next 25 years.
Hydropower is produced in 150 countries, with the Asia-Pacific region generating 33 percent of
global hydropower in 2013. China is the largest hydroelectricity producer, with 920 TWh of
production in 2013, representing 16.9% of domestic electricity use.
The cost of hydroelectricity is relatively low, making it a competitive source of renewable electricity.
The hydro station consumes no water, unlike coal or gas plants. The typical cost of electricity from a
hydro station larger than 10 megawatts is 3 to 5 US cents per kilowatt hour.[3] With a dam and
reservoir it is also a flexible source of electricity, since the amount produced by the station can be
varied up or down very rapidly (as little as a few seconds) to adapt to changing energy demands.
Once a hydroelectric complex is constructed, the project produces no direct waste, and it generally
has a considerably lower output level of greenhouse gases than photovoltaic power plants and
certainly fossil fuel powered energy plants (see also Life-cycle greenhouse-gas emissions of energy

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sources).[4] However, when constructed in lowland rainforest areas, where inundation of a part of the
forest is necessary, they can emit substantial amounts of greenhouse gases.
The construction of a hydroelectric complex can cause significant environmental impact, principally
in loss of arable land and population displacement. They also disrupt the natural ecology of the river
involved, affecting habitats and ecosystems, and the siltation and erosion patterns. While dams can
ameliorate the risks of flooding, they also contain a risk of dam failure, which can be catastrophic.

How it Works:

The flow of water produces hydroelectricity:

Falling water produces hydroelectric power

The theory is to build a dam on a large river that has a large drop in elevation (there are not many
hydroelectric plants in Kansas or Florida). The dam stores lots of water behind it in the reservoir.
Near the bottom of the dam wall there is the water intake. Gravity causes it to fall through the
penstock inside the dam. At the end of the penstock there is a turbine propeller, which is turned by the
moving water. The shaft from the turbine goes up into the generator, which produces the power.
Power lines are connected to the generator that carry electricity to your home and mine. The water
continues past the propeller through the tailrace into the river past the dam. 

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A turbine and generator produce the electricity:

"A hydraulic turbine converts the energy of flowing water into mechanical energy. A hydroelectric
generator converts this mechanical energy into electricity. The operation of a generator is based on
the principles discovered by Faraday. He found that when a magnet is moved past a conductor, it
causes electricity to flow. In a large generator, electromagnets are made by circulating direct current
through loops of wire wound around stacks of magnetic steel laminations. These are called field
poles, and are mounted on the perimeter of the rotor. The rotor is attached to the turbine shaft, and
rotates at a fixed speed. When the rotor turns, it causes the field poles (the electromagnets) to move
past the conductors mounted in the stator. This, in turn, causes electricity to flow and a voltage to
develop at the generator output terminals."

Pumped storage: Reusing water for peak electricity demand:

Demand for electricity is not "flat" and constant. Demand goes up and down during the day, and
overnight there is less need for electricity in homes, businesses, and other facilities. For example, here
in Atlanta, Georgia at 5:00 PM on a hot August weekend day, you can bet there is a huge demand for
electricity to run millions of air conditioners! But, 12 hours later at 5:00 AM. Not so much.
Hydroelectric plants are more efficient at providing for peak power demands during short periods
than are fossil-fuel and nuclear power plants, and one way of doing that is by using "pumped
storage", which reuses the same water more than once.

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Pumped storage is a method of keeping water in reserve for peak period power demands by pumping
water that has already flowed through the turbines back up a storage pool above the power plant at a
time when customer demand for energy is low, such as during the middle of the night. The water is
then allowed to flow back through the turbine-generators at times when demand is high and a heavy
load is placed on the system.
The reservoir acts much like a battery, storing power in the form of water when demands are low and
producing maximum power during daily and seasonal peak periods. An advantage of pumped storage
is that hydroelectric generating units are able to start up quickly and make rapid adjustments in
output. They operate efficiently when used for one hour or several hours. Because pumped storage
reservoirs are relatively small, construction costs are generally low compared with conventional
hydropower facilities.
The reservoir acts much like a battery, storing power in the form of water when demands are low and
producing maximum power during daily and seasonal peak periods. An advantage of pumped storage
is that hydroelectric generating units are able to start up quickly and make rapid adjustments in
output. They operate efficiently when used for one hour or several hours. Because pumped storage
reservoirs are relatively small, construction costs are generally low compared with conventional
hydropower facilities.

India’s Hydropower Potentials

Hydropower is key to fulfill India’s renewable energy ambitions for electricity generations. But
contractual conflicts, environmental concerns and financial constraints play spoilsport

Project status
India has an estimated hydropower potential of 1,45,320 MW, excluding small hydro projects
(SHPs). At the end of February 2020, installed capacity was about 45,700 MW. Several hydroelectric
projects (HEPs) in India are languishing due to contractual conflicts, environmental litigations, local
disturbances, financial stress and unwilling purchasers. Only about 10,000 MW of hydropower could
be added over the last 10 years. In a bold move, the Government of India accorded renewable energy
(RE) status to large HEPs in March 2019, enabling new HEPs to receive concessions and green
financing available to RE projects. Courtesy the Draft Electricity (Amendment) Bill 2020,
hydropower purchase obligation (HPO) may appear to become a reality soon. However, a better
option is re-engineering of the power market to treat hydropower as a peaking and grid-balancing
power, and also to distribute its higher tariff over the entire energy consumption on a prorate basis.

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Hydropower potential is located mainly in northern and north-eastern regions. Arunachal Pradesh has
the largest unexploited hydropower potential of 47 GW, followed by Uttarakhand with 12 GW. As
water and water power are State subjects, the construction of HEPs is often delayed due to conflicts
among riparian States — the Subansiri HEP is a prime example of this. Unexploited potential is
mainly along three river systems — the Indus, Ganges and Brahmaputra (see Chart). India has several
international issues across these river systems. Like electricity, hydropower should also be brought on
the concurrent list to formulate uniform policy and process for faster development.

Clearance issues
Environmental clearance would remain necessary for HEPs. Several HEPs were dropped or had their
design and capacity modified due to environmental considerations. Parameters like e-flow, free flow
stretch, eco-sensitive zone, impact on wild flora and fauna are now better defined. Therefore, the
hydropower potential including pumped storage hydropower, should be reassessed using modern
technology and environmental considerations. Thermal projects do not require techno-economic
clearance (TEC) from the Central Electricity Authority (CEA), but for HEPs with capital expenditure
above ₹1000 corer, the concurrence of the CEA is required. Site-specific changes required during
construction also need approval. Clearance is given in consultation with the CWC, and takes an
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inordinately long time. Processes must be revisited to reduce the time taken for the TEC. A unit of the
CWC may be co-located within CEA itself.

Hydropower projects are more than engineering ventures. They have large-scale socio-economic and
environmental implications. HEPs often encounter geological surprises during construction. The land
acquisition process is elaborate, requires public hearing and approval of the Gram Sabha. Forest
clearances take time. Resettlement and rehabilitation (R&R) issues are not only sensitive but also
entail substantial cost. It has been experienced that projects do not envisage adequate cost on these
items at the approval stage. Subsequent arrangement means cost and time overruns. Adequate R&R
cost should be made integral part of the project cost. The project management team should also
include experts from social science, environment as well as communication. If HEPs could be
allocated after obtaining requisite clearances on the pattern of Ultra Mega Power Projects, it would
avoid undue delay and cost overrun.

Financial aspects
HEPs are located in difficult and inaccessible sites. They require the development of roads and
bridges for project implementation. Roads and bridges provide higher opportunities for the
development of neighboring areas. Hence, the Government of India has decided to give budgetary
support for them. However, the process to grant financial support needs to be streamlined. Large
HEPs perform flood moderation also, but they do not get any grant unless declared a national project
by the Ministry of Water Resources. The Ministry of Power has now decided to support flood
moderation. These measures would certainly make the cost of power workable.

HEPs have debt-equity ratio of 70:30 and their tariff is designed to recover debt in the initial 12 years.
This frontloading of tariff makes hydro energy unviable. The government has now allowed debt
repayment period and project life as 18 years and 40 years respectively, and has also introduced an
escalating tariff of 2 per cent annually to reduce the initial tariff.

Requisite changes in tariff regulations are required to operate them. Though the tariff can be
rationalized, it may not address cost and time overrun. Geological surprises, R&R issues and
environmental factors result in several unforeseen situations not envisaged in the construction
contracts, and lead to unnecessary arbitration, litigation, and delays in implementation. Delayed or
deferred payments incapacitate contractors financially. Therefore, a robust and reliable mechanism
for quick resolution of contractual conflicts must be contrived in the system to fast-track
implementation of HEPs.

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  Working Model of Hydroelectric Power Plant:

7.0 Skill developed / Learning outcome of the Micro-Project:

a)To work in time.
b) How to contribute in a group project.
c) To make the report
d) How to collect and edit information to make report
e) How to Prepare model

8.0 Applications of the Micro-Project:

Hydroelectric power plant helps in generating Eco friendly Energy.

They help in creating Recreational Facilities. It also helps in flood
Risk management. The water from the dam is used for agriculture
Irrigation facility

Mr. S. C. Chikurde
(Name and Signature of faculty)

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