Operation and Maintenance Manual: Dordi Khola Hydro Electric Project

OPERATION AND
MAINTENANCE
MANUAL
Dordi Khola Hydro Electric
Project
30 May 2021
Prepared by Entura Hydro Tasmania India
Pvt Ltd ‐ Corporate identification number‐
U74140DL2006FTC156829
t/a Entura, Unit 3A, 3rd Floor, Plot No. FC‐24,
Film City, Sector‐16A, Noida District Gautam
Budh Nagar, Uttar Pradesh‐201301, India

Entura in Australia is certified to the latest version of ISO9001, ISO14001, and OH&S ISO45001.

©Entura. All rights reserved.
Entura has prepared this document for the sole use of the client and for a specific purpose, as expressly stated in the document. Entura
undertakes no duty nor accepts any responsibility to any third party not being the intended recipient of this document. The information
contained in this document has been carefully compiled based on the client’s requirements and Entura’s experience, having regard to
the assumptions that Entura can reasonably be expected to make in accordance with sound professional principles. Entura may also
have relied on information provided by the client and/or other parties to prepare this document, some of which may not have been
verified. Subject to the above conditions, Entura recommends this document should only be transmitted, reproduced or disseminated
in its entirety.

Operation and Maintenance Manual ‐ Dordi Khola Hydro Electric Project Revision No: 0
E302970 30 May 2021
Document information
Document title Operation and Maintenance Manual
Dordi Khola Hydro Electric Project
Client organisation Himalayan Power Partners Ltd
Client contact Mr Guru Prasad Dhakal
ConsultDM number E302970
Project Manager Vibhor Gupta
Project number P508547
Revision history
Revision 0
Revision description
Prepared by Vibhor Gupta
Reviewed by Praveen kumar/D Gogoi
Approved by Kavish Bibra
(name) (signature) (date)
Distributed to Mr Guru Prasad Dhakal Himalayan Power Partners

Ltd
(name) (organisation) (date)

E302970 30 May 2021

This page is intentionally blank.
4
E302970 30 May 2021
Contents
1. Introduction 1
2. Facilities and Equipment involved in the Operation and Maintenance of Hydro Electric
Project 3
2.1 Hydro Electric Project 3
2.1.1 Civil structural facilities 3
2.1.2 Hydro‐mechanical works (to be confirmed by HM vendor) 3
2.1.3 Power/ energy generating equipment 3
2.1.4 Powerhouse auxiliaries 4
2.1.1 132kV Switchyard 4
2.2 Transmission lines 4
3. Operation of Hydro Electric Project 7
3.1 General 7
3.2 Operation of Civil Structures 7
3.2.1 Checklists for waterway facilities 7
3.2.2 Checklists for civil works 8
3.3 Operation of Hydro Electric Project Facilities/ Equipment 8
3.3.1 Basic operation 8
3.3.2 Operation, in case of emergency 12
3.3.3 Other operations 13
3.4 Filling of water conductor system (WCS) 13
3.4.1 Pre–fill checks 13
3.4.2 During filling of water conductor system 16
3.4.3 For emptying the water conductor system 17
3.4.4 Precautions before entering the Tunnel after emptying 18
4. Maintenance of Civil Structures 19

4.1 Diversion structure 19
4.1.1 Maintenance of aprons 20
4.1.2 Impervious floors 20
4.1.3 Retrogression 20
4.2 Power intake 20
4.3 Desilting arrangement 20
4.4 Water conductor pipe 21
4.5 Headrace tunnel 21
4.6 Rock trap in tunnel 22
4.7 Surge shaft 22
4.8 Steel lined tunnel/ pressure shaft 23
4.9 Valve house 23
4.10 Penstock 23
4.11 Powerhouse 24
v
E302970 30 May 2021
4.11.1 Maintenance of the powerhouse building 24
4.11.2 Maintenance of area around powerhouse 25
4.11.3 Transformer yard 25
4.12 Tailrace channel 25
4.13 Switchyard 25
4.14 Specific inspection of civil structures 25
5. Maintenance of Hydro‐Mechanical Works 27
6. Maintenance of Electro‐Mechanical Works, Switchyards, Transmission Line and Sub‐
Station 29
7. Requirements for Effective Operation and Maintenance 31

7.1 Manpower planning and arrangement 31
7.2 Training program for operation & maintenance 32
7.3 Planning and arrangement of spare parts, consumables, tools and testing
equipment 33
7.4 Logging and reporting 33
7.4.1 Logging 33
7.4.2 Reporting 34
7.5 Equipment labelling 35
8. References 37
Appendices
A Format for Monthly Report of Power Plant Operation and Maintenance
B Typical Format for Reporting
List of figures
Figure 7‐1: Typical organization charge for plant operation and maintenance 32
vi
E302970 30 May 2021
1. Introduction
Dordi Khola Hydro Electric Project (HEP) is a run‐of‐the river project having an installed capacity of 27
MW by utilizing the design discharge of 15.28 m3/s and rated head of 199.51 m.
The Dordi Khola is one of the major tributaries of Marsyangdi River and is a perennial river having six
glaciers at the upper catchment in Himalayan Ranges contributing sustainable flow even during dry
season.
In 2012, Entura Hydro Tasmania India Private Limited (Entura) has been appointed technical
consultant for review of the existing Feasibility Report, preparation of updated Detailed Project
Report and Tender Design of Dordi Khola HEP and it was successfully completed in 2013‐14.
Subsequent to the completion of the above task, Entura has been entrusted with the assignment to
Detailed Design and Project Management for Dordi Khola HEP.
The project comprises of an ungated weir with two gated sluice bays, side intake, feeder pipe,
surface desilting basins, WCP intake, water conductor pipe (WCP), headrace tunnel, vertical surge
shaft, pressure shaft, valve house, surface penstock, and surface powerhouse. The major project
components are located on the right bank of Dordi Khola. The discharge is convey through feeder
pipes to desalting basins. Thereafter, water conductor pipe followed by headrace tunnel convey the
discharge to pressure shaft/ penstock via surge shaft and finally to powerhouse. The water after
generating power is discharged back into Marsyangadi River.
All the structures are designed in accordance with Indian standard codes and/or internationally
recognised codes and references. The standard life of a hydro project is assumed to be about 100
years. Therefore, Dordi Khola HEP would require proper operation and maintenance of the civil,
electrical and mechanical components to ensure proper functioning and guarantee estimated
generation annually.
After commissioning of the project, a systematic operation and maintenance plan should be followed
at site. Proper knowledge of machineries, working of the project, prior experience in similar other
projects may be required for the personnel involved in operation and maintenance of the project.
This report deals with operation and maintenance of civil structures. For trash rack, gates, hoists,
valves and E & M equipment, relevant O &M manual provided by suppliers shall be followed.

1
E302970 30 May 2021

2
E302970 30 May 2021
2. Facilities and Equipment involved in the Operation and
Maintenance of Hydro Electric Project
The list of facilities and equipment involved in the operation and maintenance of Dordi Khola Hydro
Electric Project is presented below:
2.1 Hydro Electric Project
2.1.1 Civil structural facilities
 Approach roads
 Diversion structure; water operations including downstream release requirements and
consideration of prior water rights,
 Intake and feeder channel,
 Desilting arrangements,
 Water conveyance system including surge shaft and pressure shaft/ penstock,
 Valve house, and
 Powerhouse complex including tailrace and switchyard.
2.1.2 Hydro‐mechanical works (to be confirmed by HM vendor)
 Trash racks and stop logs,
 Various gates such as intake gates, sluice gates, desilting basin outlet gates, silt flushing gates,
draft tube gates
 Lifting devices (cranes/hoists).
 Steel liner for feeder pipe, water conductor pipe, pressure shaft and penstocks.
2.1.3 Power/ energy generating equipment
 Mechanical
o Turbines and its auxiliaries,
o Governors and associated OPU (Oil Pressure Unit) and guide apparatus, and
o Main Inlet Valve (MIV)
o Penstock protection valve
 Electrical
o Generators and auxiliaries,
o Excitation system,
3
E302970 30 May 2021
o D.G. Set and A.C. auxiliary supply,
o D.C. supply, batteries and battery charger,
o Start up and synchronous panel, control panel, and
2.1.4 Powerhouse auxiliaries
 Cooling water system,
 Ventilation system,
 Lubrication system,
 Drainage and dewatering system,
 EOT crane,
 Air compressor system,
 Lighting system, emergency supply system,
 Medium voltage switchgear
 MV overhead lines
 Power and control cables
 Station earthing, lightning protection,
 Protection and relay system
 Communication & SCADA system,
 Fire detection, fire‐fighting and hydrant system, and
 Indoor and outdoor illumination system
 Distribution transformers
 Safety tagging and safety interlocks.
2.1.1 132kV Switchyard
 Switchyard structure,
 Busbar system,
 Transformers,
 Switchyard equipment such as circuit breakers, isolation switches, C.T., P.T., safety devices /
alarms, and
 Outgoing lines.
2.2 Transmission lines
 Right of way,
 Length, voltage and point of connection/ inter‐connection,
 Overhead conductors,
4
E302970 30 May 2021
 Poles/ towers, pole anchors,
 Insulators, cross‐arms, jumpers.
 OPGW cables

5
E302970 30 May 2021

6
E302970 30 May 2021
3. Operation of Hydro Electric Project
3.1 General
Operation and maintenance of hydro electric project must aim at reducing failure rate by ensuring
smooth operational levels of the power utility. This can be done by adopting timely preventive
maintenance schedule regarding all vital areas of the power project.
3.2 Operation of Civil Structures
Dordi Khola HEP is purely run‐of‐the‐river type scheme. And its operation to be carryout in such a
way that it generate full capacity during wet season, while at the time when the water availability is
low (i.e., during dry season), the generating equipment needs to be assigned for scheduled
maintenance, and that way energy production from such plants could be maximized over a year.
The consideration of downstream water release requirement as per the prevailing laws and
regulations particularly during low water period is a must along with abiding the prior water use
entitlements (if any) during water operation.
By operation of associated civil structure facilities, it is to be understood that it is the operation of
gates, lifting mechanisms, etc. fitted in the structures for regulation and control of water flows. The
gate needs to be operated following the flood hydrographs established during design phase. Failing
to achieve these objectives, particularly, if the sluice bay gate could not be opened at the time of
flood, disaster could happen due to flooding, at the same time creating problems due to sediment
accumulation at the intake zone. Similarly, desilting basin forms an important part of hydro electric
project as it is the silt tank that determines the wear and tear on the turbines. It is, therefore, wise to
keep the desilting basin in good condition particularly during rainy season, when the silt flows are
highly concentrated. The collected silt should be removed as and when necessary; if not, it will
collect up to a limit and any excess will pass into the turbine. The gates of the desilting basin need to
be operated to carryout maintenance work in the desilting basin. Silt flushing gates shall be operated
to flush the deposited sediment in order to reduce abrasion of the waterway, penstock pipe,
hydraulic turbines, etc., and eventually to achieve stable and efficient operation of the hydroelectric
project.
3.2.1 Checklists for waterway facilities
The general checklists for operation of civil works are as follows;
 Damage of structures;
 Sediment accumulation in front of the intake;
 Sediment & debris accumulation in the reservoir;
 Suspended trash at trash rack screens;
 Silt accumulation in the desilting basin;
 Debris and silt deposition in desilting basin.
7
E302970 30 May 2021
3.2.2 Checklists for civil works
 Reservoir water level at Intake;
 Discharge in the river;
 Water level downstream of the weir;
 Water level in the forebay d/s of desilting basin at WCP intake;
 Silt level in the desilting basin;
 CCTV video are available in intake site and powerhouse
 Tail water level.
3.3 Operation of Hydro Electric Project Facilities/ Equipment
The operation of hydro electric project is intended not only to generate electric power by rotating
generators but also to control generation equipment and to supply electricity of stable quality to
consumers, keeping good condition of all facilities related.
The operation of hydro electric project comprises:
 Operation of hydro‐mechanical works such as gates, stop logs, valves, etc. to regulate the
discharge through turbines
 Operation of generating equipment such as turbines and generators, and
 Synchronization into a Grid (Power supply system).
A number of checks are to be done particularly before starting the machine. The general checklists
for operation of Dordi Khola HEP are as follows:
3.3.1 Basic operation
3.3.1.1 Check points before starting operation
Before starting operation, operators must check the following items, and confirm if facilities are in
good condition for operation. Especially in cases after long‐term suspension of operation, they
should check them carefully.
For mechanical works (to be confirmed by HM vendor)
 At sluice bay, check:
o Position of sluice gate;
o Power supply to gates.
 At intake, check:
o Position of intake gate;
o Power supply to gates.
 At desilting, check:
o Position of desilting gates;
8
E302970 30 May 2021
o Power supply to gates;
o Position of silt flushing gate;
o Power supply to flushing gate.
o Silt level monitoring system
 At PPV, check:
o Position of valve;
o Power supply to valve.
 At power plant, check: (to be reviewed and updated by EM suppliers)
o PPV fully open and control circuit/ power circuit healthy;
o PPV emergency closure system from powerhouse is OK with PPV creep detector;
o Reservoir water level OK;
o Draft tube gates fully open;
o AC power for various pump operation;
o Various interlocks and start permissive satisfied;
o level and pressure in common OPU (Oil Pressure Unit) system;
o Penstock/spiral casing dewatering valves are closed;
o Draft tube. dewatering valve is closed;
o position of strainer valves/motorised valves ensure water flowing in cooling pipes;
o MIV maintenance seal open;
o MIV service seal open;
o top cover drain system okay;
o Oil levels in GLOP (generator lube oil pumps) is OK, pumps are OK;
o Generator bearing temperature oil level ;
o penstock pressure and pressures at spiral casing after opening of MIV (Main Inlet Valve),
OPU, cooling water, bearing water pressure and oil pressure for brakes;
o Ensure that brakes are not applied before starting of the machine;
o Ensure that generator stator heater is not ON before starting of the machine;
o Check protection relay tripping commands and reset;
o Ensure generator ventilation system OK before start of units.
 At tailrace, check:
o position of gate;
o Power supply to gate.
For electrical works (to be confirmed by E & M supplier)
 General checklist:
9
E302970 30 May 2021
o DC system;
o Grid power;
o DG set power,
o Event logger, and
o Disturbance logger.
 Check list for generator:
o brake system;
o cooling water for bearings;
o generator fire‐fighting, if applicable;
o AVR condition, DC/AC supply for field flashing;
o oil levels in bearing, IR values, jack position, and
o Generator lube oil pumps system;
 Check list for transformers:
o firefighting system, deluge valve system healthy;
o transformer Buchholz relay;
o oil level in conservator, colour of silica gel, and
o IR of winding and core, BDV (Breakdown Voltage) of transformer oil.
o PPM of transformer oil.
o WTI/OTI readings.
 Check list for switchyard:
o SF6 gas pressure in case SF6 breakers are used;
o earthing switch position;
o Isolator position‐close, Breaker position‐off, and
o Line isolator position.
o Various permissible interlocks of breakers and isolators
o Protective relay healthy
o Communication system healthy
o Visual monitoring of busbars, connectors whether any visible flashover taking place
o Earthing system
3.3.1.2 Starting operation (to be confirmed and updated by E & M supplier)
After checking the above items, the turbine and generator are okay for operation. The procedure of
starting operation is as follows:
 For intake gate opening, check intake gate power supply and hoisting system, give raising
command and check gate position in raised condition. Check gate status in powerhouse
control room display.
10
E302970 30 May 2021
 Monitor reservoir water level to be displayed in powerhouse control room.
 Ensure PPV and draft tube gate fully open.
 For Inlet valve opening, put oil pumps on ‘auto’ mode, open bye‐pass valve manually or give
opening command to by‐pass auto valve, check water pressure on spiral side, and then give
opening command to inlet valve on equalized pressure.
 For turbine operation, put oil pumps on ‘auto’ mode to maintain required pressure in pressure
accumulator, check availability of accumulator system , open cooling water for bearings, open
shaft seal water, put brake on ‘auto’ mode, unlock guide vane lock (as applicable), fix GV
(Governor) opening limit, and put machine on ‘auto’ mode.
 For generator operation, select AVR Auto/Manual mode as required, keep firefighting system
operative (where provided), switch on DC/AC supply for excitation flashing, at 30% of
generator voltage DC supply from battery cuts off, at 90% speed switch on generator
excitation (if not on auto), start machine on ‘Auto’ or ‘Manual’ mode as required (to be
updated by EM supplier).
 For synchronization, check grid voltage and frequency, check generator voltage and frequency,
reduce or increase generator voltage & frequency to match with line voltage & frequency, put
synchroscope in ‘ON’ position. .
 In lieu of the above “step by step method” of starting and synchronising of units, auto
synchronising facility may be used for single command synchronisation of units (to be updated
by EM supplier).
 For checks after synchronizing and taking load, refer instructions and operation manual of EM
supplier.
 For ramping up of loads, refer instructions and operation manual of EM supplier and load
acceptance criteria already defined in transient study.
3.3.1.3 Role of operators during operation (to be confirmed and updated by E & M supplier)
Operators must control equipment in order to supply electricity of good quality keeping equipment
normal and safe as follows:
 Control the inlet valve or guide vane so that voltage and frequency are within the regulated
range.
 Check vibration and noise of equipment, and then stop operation if necessary.
 Check temperature of equipment
 Check any abnormal condition of equipment, and then stop operation and take a measure if
necessary.
 Record results of operation and condition of equipment according to fixed format.
3.3.1.4 Stopping operation (to be confirmed and updated by E & M supplier)
In order to avoid runaway of the turbine and the generator for a long time, the procedure of
stopping operation is as follows:
 Cut load switch off (load rejection)
 Close the inlet valve and/or the guide vane
11
E302970 30 May 2021
 Close the inlet valve and the guide vane completely
 Close the intake gate (if required)
When load is suddenly cut owing to an accident, operator must close the inlet valve or the guide
vane immediately to avoid runaway of the turbine and the generator. In that case governor
emergency closure command shall be initiated.
3.3.2 Operation, in case of emergency
3.3.2.1 In case of flood
In general, hydro electric project can be operated even in case of flood. However, when the river
starts carrying lots of mud and silt and there is possibility that the same may enter into facilities,
operation of the plant should be stopped and the intake gate and tailrace gate should be closed.
In this period, the drainage and dewatering system in powerhouse shall be kept always in operational
mode.
CCTV video shall be monitored continuously at powerhouse control room for the weir site,
intermediate reservoirs, tailrace water levels etc. After flood, operators must inspect all facilities, and
try to recover operation as soon as possible.
In addition, in case of partial flood but with heavy silt (say >2000 PPM) the intake gates has to be
closed to avoid choking of the desilting basin. Water level at weir site and tailrace outfall can be
referred to categorise the flood and necessary safety measures may be taken.
3.3.2.2 In case of earthquake
Since an earthquake affects all facilities of plants, operators must inspect facilities after a big
earthquake as follows:
 Check damage to civil structures
 Misalignment of the shaft of the turbine and the generator
 Ensure that the main power transformers are always locked with locking pads
 All panel foundations, fixings are adequate
 Damage of other electrical equipment
 Others damages
3.3.2.3 In case of shortage of water
There is an applicable range of water discharge for each turbine. Therefore, a turbine should be
operated within the range. The power plant should basically be designed according to water
discharge in the dry season. However, in case of shortage of water that is beyond our expectations,
operators must stop operation because continuous operation under such conditions will damage the
turbine. For the same, operational instruction and manual of EM supplier shall be referred.
12
E302970 30 May 2021
3.3.2.4 In case of accident
In case of accident, operators must stop operation, investigate the cause of it, and then try to
recover operation as soon as possible. Operator’s roles are as follows:
 Inform the accident to the person in charge immediately.
 Investigate accident in detail.
 Look into causes of accident.
 Recover operation as soon as possible if operators can prove the causes and if they can repair
it themselves.
 Contact makers or suppliers of equipment and request them to repair it if operators cannot
find out the causes of accident and they cannot repair it themselves.
3.3.3 Other operations
3.3.3.1 Flushing of sand/silt accumulated in front of intake
If sand/ silt deposition reaches the intake level, sand/silt will be carried into waterway system and it
will affect the penstock and turbine blades. Therefore, in order to prepare against outflow of sand,
silt and debris during flooding, operators must keep the intake approach clean. For this purpose,
operators should flush or remove sand/silt that has settled in front of the intake through opening the
sluice bay gate.
3.3.3.2 Control of intake water
Volume of intake water changes according to change of water level of river. Normally excess water
should be spilled out at escape structure, which is located downstream of desilting basin. The excess
water for long time would wash out the spillway. Therefore, operators must control the intake gate
so as to avoid too much water spill.
3.4 Filling of water conductor system (WCS)
3.4.1 Pre–fill checks
Before commencement of filling operation, it shall be ensured that all construction materials, labour
and departmental personnel are cleared from the entire water system. It shall also be ensured that
the instruments needed for observation before filling, during filling and after filling are installed at
required places and are in working order. Before actually filling the system, the following checks shall
be exercised:
3.4.1.1 General checks before filling of water conductor system
The following works are to be completed and the supervising engineer shall truly endorsed:
 Confirm that all works in the weir intake, desilting basin, water conductor pipe, headrace
tunnel, pressure shaft, penstock, powerhouse, tailrace and all associated structures completed
in all respect.
 Check that hillside drainage is appropriate and that drains are clear of debris and vegetation.
13
E302970 30 May 2021
 Baseline survey shall be taken of monuments or significant features to be used for short‐ and
long term measurement
 The measurement must be taken using appropriate equipment.
 Emergency closure systems (ECS) must be complete, dry tested and functional. Such
equipment are gates, valves or other similar apparatus that are designed to close (manual or
automatic) under flow conditions and to stop water from flowing downstream.
 The interior of the water conductor system should be inspected, to ensure construction debris,
tools are removed and all personnel have vacated the system.
 The exterior of the system have been inspected to ensure all manholes have been closed.
 Communication and clearances with the start‐up engineer/supervisor must be signed off to
verify that the system is ready for watering‐up.
3.4.1.2 Intake structure
 Trash rack and air vent shall be cleaned and its cleaning device shall be checked. In case the
trash rack cleaning machine (TRCM) is not installed, the racks shall be inspected manually.
 Gates (service/ emergency) shall be checked for their seals, tracks, guide and smooth
operation of gates. Filler valve shall also be checked.
 Hoisting arrangement shall be checked for proper operation.
 Automatic system for operation and alarms shall be checked.
 A telephone/wireless set shall be provided at gates with trained crew posted for operation of
gate.
3.4.1.3 Desilting basin
 It shall be thoroughly inspected; all the construction material/ equipment shall be removed
and cleared of all extraneous material.
 Gates shall be checked for their seals, tracks, guide and smooth operation of gates.
 Silt flushing pipe shall be checked and cleaned.
 Silt flushing gates shall be checked for their smooth operation.
 Air escape arrangement shall be clear of any obstruction.
3.4.1.4 Head Race Tunnel
 HRT shall be thoroughly inspected and all the construction material / equipment shall be
removed and the tunnel cleared of all extraneous material such as left over concrete lumps
projections, protruding dowels etc. These should be ground smooth.
 It shall be repaired, wherever required preferably with resin‐based hardeners.
 It shall be ensured that all cold joints are properly treated and the holes for grouting be sealed
perfectly and surface ground smooth.
 It shall be ensured that contact grouting has been done in the prescribed reaches and shall be
in accordance with the design requirement.
14
E302970 30 May 2021
 It shall be ensured that consolidation grouting has been done in the prescribed reaches and
shall be in accordance with the design requirement.
 It shall be ensured that all the instruments required for observation before filling, during filling
and after filling have been installed at required locations and are in proper working order.
 Drainage holes and dewatering pipe, wherever provided shall be checked and it shall be
ensured that these are functioning properly and there is no particle flow.
 It shall be ensured that proper arrangement for gradual filling and dewatering are functioning
properly.
 It shall be ensured that there is no obstruction in the air vent pipes, wherever provided and
around outlet and inlet pipes.
3.4.1.5 Valve House
The following checks shall be carried out on valves before filling operation is started:
 All hydraulic and electrical systems should be checked
 The air inlet valve and vacuum breaking valves should be cleared for overflow of any water.
 The drain from the valve house should be cleared for overflow of any water.
 The communication between valve house and powerhouse shall be tested.
 The control system from the control room to the valve house shall be checked and tested for
proper operation
3.4.1.6 Powerhouse
 All pre‐commissioning tests in the dry stage shall be completed in all respects and certified by
the manufacturer and the erection agency.
 The staff required for the operation of power plant shall be in position and assume their
specific duties.
 Adequate number of spare dewatering pumps shall be in position at various floors of the
powerhouse.
 All drainage and dewatering stops provided during the construction shall be removed and
tested against full tailrace level.
 All drainage and dewatering pumps shall be checked and kept in operational condition.
 Turbine seals shall be tested and checked for prefect sealing.
 Inlet valve seals shall be tested and checked for prefect sealing.
 Alternate source of power supply for operating all the auxiliaries in the powerhouse shall be
ensured 24 hrs.
 Electrical Overhead Traveling Crane (EOTCs) shall be tested and in good operating condition.
 All vacuumed valves, air release valve, and drainage valves shall be tested.
 The security staff and security arrangement shall be completed to restrict the entry of
unauthorized persons in the powerhouse.
15
E302970 30 May 2021
 The staff for operation and maintenance of the powerhouse shall be in position and full
complement shall be detailed on shift duties before initial filling starts.
3.4.1.7 Tailrace Channel
After dry testing of draft tube gates, following systems in powerhouse be checked for proper
functioning.
 Operation of draft tube gates under water,
 Cooling water system for powerhouse,
 Emulsifier pump in the powerhouse, and
 Drainage and dewatering system
In case of any malfunctioning, the tailrace may be emptied and refilled after rectifying the defects.
3.4.2 During filling of water conductor system
The water conductor system shall be filled at very slow rate so that the internal pressure builds up
gradually so that the surrounding rock/ strata gets sufficient time for stabilization and also not to
allow any scope for air to get entrapped, compressed and then released. In case of gated
arrangement, the leakage on gates shall be checked and ascertained for efficacy of the seals.
Procedure of filling water into the waterway system is as follows:
 System must be set up to provide effective communication with inspection crew, start‐up
engineer and all other operators.
 The filling should be done during the daylight hours. This is to provide safety to the personnel
involved in the operation and inspection. It also allows better visibility so that problem areas
can be identified and acted quickly. If possible, 4 – 6 hours of daylight should be available after
completion of filling. During the night‐time hours, intake gates and ECS must be closed for
safety reasons.
 Confirm all gates and valves except intake gate and PPV are open.
 Silt flushing gate of desilting basin in closed position.
 All the manhole in closed position.
 Close all drain valve of all three MIVs
 Close all MIVs
 Close the drain valve of PPV
 Marginally open PPV
 Open the intake gate partially to allow small volume of water.
 Open the flushing gate of the desilting basin for cleaning once desilting basins are half filled.
 Close the flushing gate after cleaning of the desilting basin.
 Penstock gradually filled @ 5% of the design discharge from downstream end
 Filling will continue in day time and stopped in night
16
E302970 30 May 2021
 Drain valve of the penstock opened to clean the penstock and then closed after cleaning.
 Filling will resume next day till we reach water level of PPV
 After filling up the penstock, water level is maintained by closing intake gates. The penstock is
monitored for at least 24 hours for any leakage.
 Pressure at MIV will be checked and recorded every hour to see any loss of pressure
 If no pressure drop is recorded over a period, penstock will be declared as ok then headrace
tunnel is filled in stages. Sufficient time (minimum 24 hours) is given to check any leakage from
HRT at every stage.
 As per guidelines, filling rate of each stage shall be considered as 10 m of head per day to be
filled with a rate of 5% of design discharge. However, being a small tunnel, 10 meter of head
per day would be comparatively high rate of filing. As per Indian standard and international
filing procedure, total length of tunnel shall be divided in number of pre‐determined stages to
be filled say 5 to 6 stages so that excessive tension in the lining is avoided, The steps may be
worked out on the basis of known properties of the surrounding rock mass.
 A waiting period of at least 48 hrs shall be allowed between first and second steps of filling and
of at least 24 hrs between each subsequent steps of filling to get the surrounding strata
surcharged with water.
 Water levels in the surge shaft shall be recorded concurrently during the filling operation.
 At the end of each step of filling, the intake gates shall be closed and water levels in the surge
shaft shall be observed every hour. The loss of water from tunnel around surge tank and
leakage through machine inlet valve shall abo be noted.
 After filling the headrace tunnel, water level is maintained by closing intake gates. The tunnel
is monitored for at least 24 hours for any leakage.
 Pressure at PPV will checked and recorded every hour to see any loss of pressure.
 If no pressure drop is recorded over a period, headrace tunnel will be declared as ok then
water conductor pipe is filled in stages similar to penstock.
 Pressure at PPV will checked and recorded every hour to see any loss of pressure.
 If no pressure drop is recorded over a period, water conductor pipe will be declared as ok
then.
 Desilting basin and feeder pipe get filled @ 5% of design discharge and reservoir water also
raised to full reservoir level.
 After reservoir is filled to FRL, downstream apron may be checked for any seepage or leakage.
Seepage from surface works and underground works is again checked. If seepage found to be
more than 5 litre per second per km (based on Norwegian experience) then the water
conductor system need to be dewatered gradually and proper measures should be taken to
arrest seepage/leakage.
 Rate of filling should be maximum 5% of design discharge.
3.4.3 For emptying the water conductor system
If quantity of leakage or any other situation warrants emptying the tunnel or entire water conductor
system, following procedures and precautions shall be adopted:
17
E302970 30 May 2021
 Close all the intake gates.
 Emptying of the WCS shall be done through the penstock drain arrangement / turbine.
 Before emptying the system through the turbine, it shall be ensured that the discharge is just
sufficient to run the machine at no load and the Generator is not connected.
 Rate of emptying of the tunnel shall be slower than the rate of filling; Emptying of the tunnel
shall be done in steps. In no case, the number of steps in emptying shall be less than the
number of steps followed in filling. The number of steps may be increased if a smaller
discharge is to be passed through the machines.
 The desilting basin can be drained through silt flushing gates.
 Suitable waiting period shall be allowed between each step of emptying.
3.4.4 Precautions before entering the Tunnel after emptying
For emptying the water conductor system, water can be released from the silt flushing gates and also
through the penstock, which is to be decided keeping in view all the inter‐related aspects. Following
precautions should be ensured before entering the tunnels after emptying.
 Do not enter the tunnel without carrying personal monitoring equipment and availability of
breathing apparatus within reach. Under no circumstance, less than two persons shall enter or
move in any section of the tunnel.
 Send an advance party with gumboots, raincoats and torch light for a distance of 500 m (or
less if they feel uneasy) only and report back. Depending upon the condition of water and
slush, regular inspection either on foot or on a vehicle with spotlights mounted on it may be
carried out.
18
E302970 30 May 2021
4. Maintenance of Civil Structures
This section describes the periodic inspection checks that are recommended for the maintenance of
different civil components. The project comprises of following civil components.
 Diversion structure
 Power intake
 Desilting arrangement
 Water constructor pipe
 Headrace tunnel
 Rock trap in tunnel
 Surge shaft
 Steel lined tunnel/ pressure shaft
 Valve house
 Penstock
 Powerhouse
 Tailrace channel
 Switchyard
4.1 Diversion structure
The diversion structure comprises of un‐gated weir with two sluice bays towards intake. Inspection
of weir is necessary just after rainy season by means of underwater lamps and sounding rods. In
addition, detailed inspection in stages should be carried out after drying the upstream floor and
aprons by isolating the portion to be inspected once in every five years. The repairs as found
necessary as a result of inspection should be carried out well before the on‐set of the next rainy
season.
There may be leakage through contraction joints/ construction joints or cracks in the concrete and
seepage from cutting slopes of wing walls, which needs to be checked and repaired suitably.
Dordi Khola reservoir is a small reservoir, which extends about 1km upstream of the weir axis. Unless
maintenance is carried out regularly probability of the reservoir getting filled with silt and debris
cannot be avoided. Therefore, regular sluicing of the reservoir during monsoon should be done every
year.
(Note: Sluicing is an operational technique in which sediment‐laden inflows are released through a
dam before the sediment particles can settle at the bottom, thereby reducing the trap efficiency of
the reservoir. This is accomplished in most cases by operating the reservoir at a lower water level
during the flood season in order to facilitate sufficient sediment transport capacity (turbulent and
19
E302970 30 May 2021
colloidal) through the reservoir. After the flood season, the pool level is raised to store relatively
clear water.)
4.1.1 Maintenance of aprons
The soundings of the area should be taken every year after rainy season in order to assess scour.
Launching of aprons and remedial measures, if necessary should be taken. Downstream apron would
require particular attention.
4.1.2 Impervious floors
A thorough inspection of upstream and downstream floors should be done after rainy season.
Careful inspection of the joints of the stone sets is very important for structure located in boulder
reaches of the river. While minor repairs can be done under water, major repairs should be carried
out by isolating the area.
4.1.3 Retrogression
Retrogression of river bed can be expected on the downstream of the structure. As such, soundings
of this area should be taken just after rainy season and scour holes as and where detected should be
filled with suitable size stones or with mass concrete.
4.2 Power intake
The intake structure is provided at the start of the feeder channel with bulkhead gate. Civil
maintenance of intake structure involves maintenance of the following:
 Check deposition of silt or debris in front of Intake. Sudden start of one or two machines may
suck the debris in front of the intake and choke the trash rack and other areas of water
conductor system.
 Check all welds, nuts and bolts, corrosion and carry out requisite repairs /rectification, if any
defect is noticed.
4.3 Desilting arrangement
The desilting basins should be inspected before the onset of rainy season and silt found within the
tank should be removed by flushing or manually. Any vegetation found in the interior or the exterior
surfaces of the structure should be pulled out along with roots and the damage caused by the
vegetation promptly repaired. The gate / valves of the flushing pipes should be checked and their
proper functioning ensured. The silt flushing pipe carrying the flushing discharge back into the river
should also be inspected. They should be cleaned and any damage found therein should be rectified.
The desilting basins, flushing pipes, gates and the surface drains should be inspected immediately
after rainy season. Any silt deposition should be removed and any structural damages should be
rectified. The silt parts per million (ppm) of the water diverted into the intake of the system should
be checked at least two times a day during rainy season and the water conductor system should be
closed if the ppm exceeds 3500 ppm. The limit of the ppm can be confirmed after having an
experience of 3 to 4 years of operation of the desilting basin or from similar catchments.
20
E302970 30 May 2021
The trash rack installed downstream of the collection pond will need maintenance. All the water
borne vegetation and floating debris is prevented from entering the pressurised water conductor
system. During rainy period it may be necessary to clean even twice a day.
At the intake downstream of collection pond, there must be an adequate air vent pipe downstream
of the service gate.
4.4 Water conductor pipe
The water conductor pipe has been concrete cased along its entire length and provided with access
so that it could be inspected from inside, necessary repairs could be carried out and any deposited
silt could be removed.
Furthermore, longitudinal drains provided on the hill side along the pipe should be cleared of all
debris, stones etc. well before the onset of rainy season. The hillside should also receive inspection
to ensure that no large boulders are being undermined and are becoming a potential danger, in
which case they may be broken into harmless sizes or underpinned with concrete pads
4.5 Headrace tunnel
A tunnel should receive comparatively frequent inspection especially during its early life say at the
end of the first year’s use and again after two more years. As a result of these inspections it should
be possible to forecast the period that may reasonably allowed to lapse until the next inspection may
well be five year.. However, if any rock or concrete pieces are detected in the turbines, the water
conductor system should be closed immediately from the intake, tunnel dewatered at a slow pace,
duly inspected and damaged portions repaired. The maintenance foreman must be fully acquainted
with the procedure and with details of the time that should be taken over emptying and filling.
When emptying/dewatering a tunnel, it must be borne in mind that natural ground water and water
that has seeped out of the tunnel into the rock will tend to return to the tunnel; hence if pressure in
the tunnel is allowed to fall too rapidly, external pressures may cause serious damage to tunnel
linings.
A tunnel can usually be filled a little more quickly than it is emptied, but reasonable time should be
given for stresses to distribute themselves and for temperatures to settle down. The rates of filling
must be slow enough to ensure that there is no violent surging, resulting in the trapping of air and
roof slapping. It is quite easy to do serious damage to the tunnel roof by filling too quickly.
As there is a steel penstock at the downstream end of the tunnel, the early stages of filling should be
carried out with the utmost care so that the penstock is stressed gradually and is not subjected to
violent temperature changes.
The maintenance gang will play an important part in the tunnel inspection and should be equipped
with powerful electric or paraffin pressure lamps giving a diffuse light and not a beam. A complete
and accurate record should be made of all apparent damage to the tunnel lining; even small faults
may increase very quickly and become serious, and any points where water is seeping or running into
the tunnel should be noted. Clear chainage markers in the tunnel are of great assistance in locating
defects, for comparison after each inspection.
If on inspection, it is found that some remedial work is necessary, it is usual, unless the work is very
obviously of a vital nature, to refill the tunnel and continue generation of power until all the
21
E302970 30 May 2021
necessary stores, tools, etc., have been got together, and until the area generation program has been
adjusted to allow for a prolonged shut‐down of the tunnel concerned. It is unwise to start on the
repair with incomplete stores and equipment in the hope that the balance will be forthcoming. The
planned approach leads to better and more economical work, and affords the opportunity of adding
minor repairs to the major program, including the cleaning out of sumps, repainting of the main gate,
etc.
Minor faults in concrete linings usually appear at the vertical joints of shutters, at the joints between
side walls and inverts, and in any “cold joints “that may have occurred during placing of the lining.
The usual minor faults that occur in a tunnel lining can well be dealt with by the maintenance gang
and largely consist of patching concrete. Patching by means of mortar is virtually useless; defective
concrete should be cut away to an ample depth and replaced by concrete placed against shutters.
Large patches should be reinforced with steel rods drilled and grouted into the sound surrounding
concrete or rock. Any deterioration of the concrete lining that is obviously a purely surface
deterioration may be patched with gunite (a mixture of cement, sand and water) provided the area is
not great.
Excessive leakage into the tunnel may well indicate a point of leakage from the tunnel when it is full;
such places should be dealt with by pressure grouting, on completion of which the grout holes should
be carefully plugged with a fine concrete, not with a pure mortar. While the tunnel is empty, the
opportunity should be taken of inspecting the main gate; if a bulkhead or emergency gate is provided
upstream of it, this should be lowered and sealed, so that the upstream face of the main gate and its
guides may be inspected and attended to as necessary.
Most mountain waters produce an organic growth of one type or another on the concrete lining of
tunnels; this fine slimy weed‐like substance will in the course of time become sufficiently thick to
have a material effect on the hydraulic characteristics of the tunnel, and its roots will affect the
concrete lining. These algae must therefore be cleared away periodically. If the tunnel can be held
out for a considerable time, perhaps during some major repair, and can be sufficiently ventilated,
these organic growths will dry out, when they may be hosed off the tunnel walls quite readily. The
humid conditions which exist in most tunnels and the cost of laying out mains often preclude the use
of this method, though it is the best, and resort must then be made to brushing with stiff brooms.
Immediately before refilling the tunnel, a methodical inspection must be made to ensure that no
tools have been left behind. It is remarkable how easily a wheel barrow, shovel, or length of scaffold
tube hides itself away in a dark tunnel. Great care must be taken to ensure that all men are out of
the tunnel, and a strict system of working passes should be employed if any large number of men is
to enter the tunnel on the day it is to be refilled.
4.6 Rock trap in tunnel
All the maintenance measures suggested for headrace tunnel are applicable for rock trap. It is
advisable to clean the deposited material in the rock trap when tunnel is emptied for maintenance.
4.7 Surge shaft
Normally the surge shaft does not require much maintenance. Still it should be inspected once in a
year and any damage, if noticed, should be repaired.
22
E302970 30 May 2021
4.8 Steel lined tunnel/ pressure shaft
At inspection time, the steel lining should be looked at with a view to discovering any signs of
bulging; any sign of water entering the lining should be treated at once by drilling through it, grouting
under pressure, and finally making good the lining by welding. During the grouting process, the steel
lining must be carefully watched to ensure that it is not buckled by the grout. Steel lining should be
tested with a tap hammer periodically to ensure that no voids have been developed between it and
its concrete backing; any large areas of void should be grouted.
It is extremely difficult to prepare steel lining for painting once the tunnel has been in use, as the
humid atmosphere will tend to keep it damp so that the paint will not adhere.
4.9 Valve house
Civil works of valve works does not require much maintenance. However, it should be inspected once
in a year for water seepage from the walls and any damage, if noticed, should be repaired. After
heavy rain storms the surrounds of the valve house, the access road and the stormwater trenches
must be checked for storm damage and washaways.
The slope protection works in the vicinity of valve house should be inspected and repaired, if
required during periodic maintenance.
4.10 Penstock
Penstock require more attention externally than internally. Expansion joints, and sliding pedestal
bearings should be inspected regularly, and the latter should be kept clear of grit and paint during
any repainting or touching up of the pipeline.
Small rusty areas should be thoroughly cleaned, and periodically the whole pipeline should be
repainted.
Furthermore, the hillside should also receive inspection at the same time as the penstock to ensure
that no large boulders are being undermined and are becoming a potential danger, in which case
they may be broken into harmless sizes or underpinned with concrete pads
 A visual observation of exposed penstocks should be performed through a monthly walk down.
The interior and exterior surfaces of penstocks should be visually examined every 2 to 3 years
to note the condition of the linings and coatings.
 Check for signs of deterioration and distortion, saddle supports, anchor/ thrust blocks,
expansion joints and bolted sleeve fixed joints.
 Appurtenances include trifurcations, transitions, bends, tees, elbows, and reducers may be
particularly susceptible to vibration, aging, and lining loss. Check for damage to the lining,
cracked welds, loose or missing rivets, damage from cavitation, broken tie rods, and heavily
corroded areas
 Penetrations are manhole, filling line connection, etc. Check for damaged or missing parts,
cracked welds, cracked or broken castings on valve bodies, broken or missing bolts and rivets,
heavy corrosion
 Check to verify that drains are in working condition and are not leaking.
23
E302970 30 May 2021
 Check for ground movements, water related effects, surrounding slopes for rock falls or
landslides.
4.11 Powerhouse
A well maintained, neat and tidy machine hall, service bay, control block, office spaces, toilets etc.
not only prolong the life of the structure but increase the efficiency of the working personal. Apart
from periodic patch repairs, cleaning, white washing, distempering, painting etc., the following areas
require special attention as detailed below.
4.11.1 Maintenance of the powerhouse building
 Machine hall floor and service bay area: These areas of powerhouse bear a lot of wear and
tear. As such the floors of these areas need continuous maintenance in the form of patch
repairs, replacement of floor tiles etc. Tiles provided on these floors should be heavy duty type
and a good amount of such tiles should be kept ready in the stores for immediate replacement
of damaged ones.
 Generator foundations: The generator foundations are subjected to continuous vibrations
due to running of the machines. In case of cracks are observed in the foundations cracks may
be monitored for their tendency to widen. If such tendency is noticed, suitable remedial
measures should be taken by way strengthening and repairing of that portion. The machine
nuts and bolts are liable to loosen. Check all nuts and bolts, corrosion and carry out requisite
repairs /rectification, if any defect is noticed.
 EOT crane rails: The bolts and welds holding the EOT crane rail may become loose due to
constant travelling of the crane. These should be checked yearly and tightened/rectified
accordingly.
 Roofing: Roofs, gutters and downpipes need special attention before and after the rains. A
leaky roof may be very much dangerous as well as injurious to the electrical & mechanical
equipment. Sufficient quantity of water proofing materials must be kept ready in the stores so
that no time gets wasted in their procurement. All gutters, down pipes and drains should be
repaired and cleaned before rainy season.
 Control room: Control room roof slab joint sealant must be checked on an annual basis (Before
the summer rains) by means of watering the roof with a hose and checking for leaks inside the
control room, and especially above the switchgear, inside the control room. Control room
doors seals must be checked for dust proof. The septic tank for the control room must be
pump regularly to prevent spillage of row sewer into the tailrace.
 Battery room: Battery room walls and floors are subjected to the action of acids and acid
fumes. In case of damage, it should be replace immediately.
 Generator pit: Check for any cracks developed (if any) along the construction joints in walls
around the generator pit and subsequent leakages from these cracks into the generator pit. If
any cracks are observed, the cracks should be filled with suitable filler material to avoid any
leakages.
 Maintenance of hand rail, staircase and gratings: Check all welds, nuts and bolts, corrosion
periodically and carry out requisite repairs /rectification, if any defect is noticed.
24
E302970 30 May 2021
4.11.2 Maintenance of area around powerhouse
The precincts of the powerhouse must be kept neat and tidy. The entrance of the powerhouse must
be kept closed and should be accessible to authorised staff only. After heavy rain storms the
surrounds of the powerhouse, the access road over the structure and the stormwater trenches must
be checked for storm damage and washaways.
The slope protection works in the vicinity of powerhouse should be inspected and repaired, if
required during periodic maintenance.
4.11.3 Transformer yard
The fencing of the transformer yard must be check regularly (weekly) for any damage and repaired.
Check the functionality of the drainage around the transformers and also check that the stone is
clean and surrounds is kept clean.
4.12 Tailrace channel
Due to rise and fall in water levels at the junction of the river with tailrace, scouring of river banks
can occur. This needs to be observed periodically and if any scouring is observed, remedial measures
in the form of boulder dumping, stone pitching etc. should be undertaken.
4.13 Switchyard
The slope protection works at switchyard should be inspected periodically and repaired, if required.
Vegetation in and around the switchyard should be checked and cleaned periodically. Approach
roads from powerhouse to switchyard should be made proper. The drainage system in the
switchyard and cable trench should be checked periodically.
4.14 Specific inspection of civil structures
The specific maintenance check of civil structures and of surrounding protection works / areas for
crackers, settlements, instabilities, etc. needs to be carried out after monsoon, earthquake and/or
flash floods in order to take timely the remedial measures. Similarly, monitoring of discharge at all
the streams before and after water filling should be done.
25
E302970 30 May 2021
5. Maintenance of Hydro‐Mechanical Works
The major hydro‐mechanical equipment to be covered by routine maintenance are sluice bay gates,
intake gates, trash racks, penstock protection valve, main inlet valves and draft tube gates. Apart
from these, other HM works like steel liner for feeder pipe, water conductor pipe and penstock,
desilting gates, and lifting arrangement shall also be covered for periodic maintenance.
The maintenance schedule (such as weekly, monthly, quarterly, annual maintenance schedule) of all
these facilities shall be provided by HM contractor/ supplier.
27
E302970 30 May 2021

28
E302970 30 May 2021
6. Maintenance of Electro‐Mechanical Works,
Switchyards, Transmission Line and Sub‐Station
The maintenance schedule of following facilities shall be provided by EM contractor/ supplier for
weekly, monthly, quarterly, annual maintenance schedule.
 Maintenance of hydro‐turbine & auxiliaries
 Maintenance of generator & auxiliaries
 Maintenance of power transformers
 Maintenance of electrical and mechanical balance of plants
 Maintenance of switchyards, transmission lines and sub‐stations

29
E302970 30 May 2021

30
E302970 30 May 2021
7. Requirements for Effective Operation and
Maintenance
The following are the basic requirements to ensure effective operation and maintenance:
 Manpower planning and arrangement.
 Training program for operation & maintenance.
 Planning and arrangement of spare parts, consumables, tools and testing equipment.
 Logging and reporting.
 Equipment labelling.
7.1 Manpower planning and arrangement
In order to ensure all structures and equipment are operated and maintained in a safe and efficient
manner, planning and management of manpower needs to be done well in advance preferably
during the pre‐commissioning of the project. The manpower required will be based on following
factors:
 Type of project.
 Number of shifts.
 Location of the project.
Run‐of‐the‐River type of scheme demands more manpower than for dam type because of the spread
of hydraulic structures. Similarly, if the numbers of shifts are more there will be more need of
manpower. For remotely located plant, there may be a need of additional staff for the support
services such as transport, maintenance of residences, drinking water supply, etc. However, the
manpower can be kept minimum by employing a multidisciplinary force such as an engineer with
experience in civil and electro‐mechanical work or technician with driving experience and by
employing local labour during requirement of additional work. The guiding factor is safety of
equipment and manpower. Similarly, the contractual work such as civil maintenance, welding and
fabrication, etc. may be awarded on annual basis to keep work force low.
In selecting manpower e.g. for a position of plant in‐charge or plant manager a person having basic
degree in electrical with experience in civil and mechanical works is most suitable while for testing
engineer, he/she should be familiar with all equipment testing to take decision in case of any fault on
electrical equipment such as generator, transformer and switchgear. For the technician, a technician
level certificate holder with hands on experience in electro‐mechanical work such as diesel
generating (DG) plant, electrical installation, hydraulic equipment, electrical panel, PLC panels, cable
work, etc. Typical organization charge for plant operation and maintenance is presented in Figure
7‐1.
Keeping in view that the private hydropower plants will be handed over to the Government of Nepal
(GoN) after a designated period of Operation and Maintenance of the plant, the GoN staff to be
31
E302970 30 May 2021
deployed for O&M need to be trained at least for a duration of one year before the end of License
Period.
Figure 7‐1: Typical organization charge for plant operation and maintenance
7.2 Training program for operation & maintenance
Each employee must receive training to meet the responsibilities of their position. New or
transferred employee is required to familiarize themselves with facility reference documents, facility
system, policies and procedures. The plant manager selects which facility–specific or other training
programs personnel must attend to be qualified to operate or use the facility. The plant manager
may authorize training exemptions based on assessment of the individual’s experience (Note that the
exemptions must be documented). Annual training (continuing type) to ensure the staff is proficient
in the knowledge and skills needed to perform their duties. Training must be provided sooner if there
is a change in job assignments, change to systems or processes, or a change in procedures. The
remedial type of training must be provided when there is a reason to suspect deficiencies or
inadequacies in the employee’s knowledge or skills.
The method of training could be:
 On‐the‐job: The primary mode of training for the facility is through on‐the‐job training.
 Training must be carefully supervised and controlled to avoid mistakes.
 Instructor‐led: Classroom or in the field.
 Computer–based: Online or other.
 Required Reading: Assignments require signatures by the employee to indicate that they have
read and understood the document.
32
E302970 30 May 2021
The contents of training should, in general, be safety, theory (electrical, mechanical and operation
principles), and knowing and understanding of operation limits.
The knowledge and skills should be evaluated and the assessment methods must be documented.
The training program needs to be reviewed annually and recommendations are to be made for any
changes or improvements.
7.3 Planning and arrangement of spare parts, consumables, tools and testing
equipment
For effective maintenance, it is necessary to list out all required ordinary and special tools, spare
parts, consumables and testing equipment along with assessment of the quantity and arrange the
same in a timely manner in advance so that time is not lost in re‐commissioning the plant after the
shutdown. Ordinary tools and parts include different type and sizes of screw drivers, pliers, spanners,
hammers, etc., while the special type of devices and parts is required during assembly or dismantling
of machines. For example, rotor lifting device and endless slings, pole turning device, shaft lifting
device, rotating device and slings for alignment, shaft extension pieces and so on. These are not
required for day to day maintenance; as such these should be properly stored and secured.
Necessary maintenance, if required, must be carried out on these devices in time. Slings should be
stored duly coated with preservatives as recommended by the manufacturers.
7.4 Logging and reporting
7.4.1 Logging
A station log needs to be maintained at each facility in the Control Room. The station log contains
chronological record of all operating and maintenance activities and events which provides a
reference for future use. Operation and maintenance personnel use these information to evaluate
present and past plant status. The station log may be paper, electronic or a combination of both. The
station log documents are following:
 Staff on duty
 Operations of waterway equipment including gates and , valves.
 Communications involving plant operations, switching, Hot Line Orders, clearances, special
conditions, alarms and relay operations.
 All communications with Transmission Operators shall also be logged.
 Water elevations and releases and operational changes affecting water elevations and
releases.
 Status of auxiliary equipment.
 Testing of equipment or gate controls.
 Act of vandalism or other security incidents.
 Requests and occurrence to change from normal operation during an emergency or unusual
conditions.
 Communication network checks and emergency exercises conducted.
 The disabling and re‐enabling of facility alarms.
33
E302970 30 May 2021
 Unit start and stop times.
 Any equipment failures and malfunctions.
 Line outages.
 Breaker opening and closing.
 Callouts
 Any change in unit status (available, unavailable, etc.)
 Status of all major equipment.
 Listing of personnel (visitors) arrival and departure.
 All maintenance records
 Daily inflow, ppm level of silts
 Planned and forced outage details
 Equipment calibration records
 Expiry/validity records
The plant manager must review and initial the operating Log Book. Shift turnover is critical part of
the facility’s operation and provides oncoming operation staff with an accurate picture of the overall
status of the facility. Hence, the incoming operation staff must review logs, turnover checklist (if
used), SCADA displays, alarm displays, disabled alarms, protective devices, and computer pages, and
they must receive verbal briefing from the on‐duty operator prior to assuming responsibility for the
operation of the facility. A visual inspection of control boards including a test of the annunciator
windows will be completed to verify indication/annunciation light is operational. During a shift
turnover, at a minimum, the information on major equipment status, alarm status, work in progress,
hazardous energy control procedures, any abnormal plant conditions, water release, power
schedules and work schedule should be exchanged. The operation staff, then, will sign into the log
documenting that shift turnover has been completed.
7.4.2 Reporting
With the passing of time along with growth of demand in electricity and due to advancement in the
technical development the interconnected power system are becoming more and more complex.
This requires increased emphasis on the analysis of system performance to ensure achievement of
the best reliability. One of the most important requisites for such analysis is the availability of clear,
concise and the accurate reports on power system operation and maintenance (O & M) for review by
management at various levels. Specific details regarding preparation, issuance, and distribution of
the monthly O & M reports is described in the following paragraph.
A narrative report of power plant O & M activities shall be prepared and distributed monthly by the
power plant O & M office on each project that includes operating power facilities. The report shall
briefly describe all important non‐routine events of a power plant O&M nature that occurred during
the month, such as date, time, duration of major items of maintenance undertaken or accomplished
new equipment or service installation or connections, changes in system arrangement or
interconnections with adjacent utilities, major power interchanges between systems or water
movements scheduled or accomplished, new facilities added, important personnel activities, etc. The
report shall be distributed to the concerned as specified by the system operating authority/
regulating authority as applicable. The format for the report has been given in Appendix –A.
34
E302970 30 May 2021
In addition to the above indicated monthly O&M report the following reporting are required for
record keeping for future reference. The typical formats for the reports has been given in Appendix ‐
B.
 Annual Outage Program,
 Annual Availability Declaration,
 Monthly Generation Outage Program,
 Weekly Generation Outage Program,
 Scheduled Outage, Request Form,
 Forced/Maintenance Outage Request Form,
 Monthly Availability Declaration on Hour to Hour Basis,
 Monthly Availability Declaration on Hour to Hour Basis,
 Weekly Availability Declaration,
 Daily Availability Declaration,
 Verbal Dispatch Instruction Confirmation,
 Daily Generation Report Form,
 Daily Generation Log Sheet,
 Fault Registration Form,
 Monthly Generation Performance Report Form,
 Monthly Generation Report Form,
 Monthly Outage and Reduced Output Report,
 Maintenance Outage Report Form,
 Loading Status and Scheduled Outages,
 Forced Outages of Transmission Lines and System Failures, and
 Transmission Line Shutdown Implementation Form.
In case any accident occurs, the accident hazard notice needs to be given as earliest as possible to
the chief electricity inspector appointed by GoN.
7.5 Equipment labelling
In order to help ensure that the facility and the support personnel can identify, instrumentation,
controls and equipment, a well‐established and maintained program for labelling equipment is a
must. A good labelling program that is understood and maintained by O & M personnel enhances the
effectiveness of work activities. Such a program also helps to reduce errors by O & M personnel as
errors can result from incorrect identification of equipment and controls. Equipment labelling is
required also to comply with the safety regulations and for protecting from the health hazards.
As a minimum, the following items should be labelled:
 Emergency exits, fire alarms, fire protection, and fire extinguishers.
35
E302970 30 May 2021
 Rescue and first aid equipment.
 SCADA displays.
 Circuit breakers, disconnects, and power panels.
 Annunciator panels
 Grounding switches
 Valves
 Piping systems.
 Major plant equipment
 Control switches
 Protective devices, including relays.
 Metering.
The labels are placed on, or as near as practical to, the controls or equipment being labelled. Labels
are oriented so that they are easy to read. The operation manager should be responsible for ensuring
that missing or damaged labels, once identified, are promptly replaced and that newly installed
equipment or new modifications to existing equipment are properly labelled.
36
E302970 30 May 2021
8. References
 Guidelines for Operation and Maintenance of Hydropower Plants, Substations and
Transmission Lines by Department of Electricity Development, Kathmandu
 Guidelines for Maintenance of Civil Works (Including Hydro‐Mechanical) by AHEC, IIT Roorkee
 Guidelines for Sediment Management in Water resources & Hydropower projects, Feb 2019 by
CWC
 Indian standard code IS 6512
 Indian standard code IS 12633
 Standard Operating Procedure for management of silt in Hydro Electric project by CEA‐August
2018

37
E302970 30 May 2021


38
E302970 30 May 2021
Appendices
39
E302970 30 May 2021

40
E302970 30 May 2021
A Format for Monthly Report of Power Plant Operation
and Maintenance

E302970 30 May 2021

Name of Power Plant: ……………………………………. Installed Capacity:……………. Reporting Month:……………….
Gross Generation: ………………………… (kWh) Plant Use: ………………….. (kWh) Net Generation: ............................ (kWh)
Water for generation: ……………………….. m3 Downstream Release: ……………. m3 Elevations (m) at
Maximum hourly Generation: ............................ (kWh) Forebay/Reservoir Tailrace
Plant Factor ........................... (%)
Water Use factor:............................(%)
Unit Service Record
Operation Information Maintenance Information
Unit Gross Generation Time Operated Availability (hr) Availability Outage for Maintenance Actual Maintenance Time Description of
No. (hrs) factor (%) Day Time (hr: min) Duration Individual outage Total for Forced
(hr: min) month Outage
1
10
11

E302970 30 May 2021

E302970 30 May 2021
B Typical Format for Reporting

E302970 30 May 2021
ANNUAL OUTAGE PROGRAM

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

E302970 30 May 2021

Operation and Maintenance Manual: Dordi Khola Hydro Electric Project

Uploaded by

Copyright:

Available Formats

You might also like

Operation and Maintenance Manual: Dordi Khola Hydro Electric Project

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operation and Maintenance Manual: Dordi Khola Hydro Electric Project

Uploaded by

Copyright:

Available Formats

Distributed to Mr Guru Prasad Dhakal Himalayan Power Partners

4. Maintenance of Civil Structures 19

5. Maintenance of Hydro‐Mechanical Works 27

7. Requirements for Effective Operation and Maintenance 31

8. References 37

You might also like